Work Method Statement

xxx.xxx

Fuel Storage Tank Design, Fabrication and Erection

Project
Construction Project of Three (3) Petroleum
Depots in Chad
Client

SHTChad National Hydrocarbons Company

Contractor

Faber Insaat San. ve Tic. A.S. Istanbul, Turkiye

 WORK METHOD STATEMENT

FUEL STORAGE TANKS DESIGN, FABRICATION AND ERECTION

CONTENTS

SECTION TOPIC PAGE

1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 DEFINITIONS
5.0 RESPONSIBILITIES
6.0 RESOURCES
7.0 RISK ASSESMENT
8.0 HSE
9.0 QA/QC
10.0 WORK PROCEDURE
10.1 Detailed Engineering Design
10.2 Preparatory Works
10.3 Material Procurement
10.4 Fabrication
10.5 Packing and Shipment
10.6 Inspection of Tank Foundation
10.7 Erection
10.7.1 Annular Plates Laying
10.7.2 Bottom Plates Laying
10.7.3 Shell Course Erection
10.7.4 Stairway Erection
10.7.5 Appurtenances Installation
10.7.6 Roof Erection (Supported Fixed)
10.7.7 Roof Erection (Internal Floating)
10.8 Inspection and Testing
10.9 Calibration
10.10 Shot Blasting and Painting

WORK METHOD STATEMENT

FUEL STORAGE TANKS DESIGN, FABRICATION AND ERECTION

1.0 PURPOSE

The purpose of this Work Method Statement is to ensure a safe and

successful system of work has been identified and to communicate the
responsibilities, work methods, sequence of working, and safety
arrangements to all persons on, and off site during the activities listed
herein. This document was prepared for following proper methodology to
achieve the activities in a proper sequence for design, fabrication,
erection and testing of the fuel storage tanks.

2.0 SCOPE

xxx

xxx

for the Construction Project of Three (3) Petroleum Depots in Chad.

3.0 REFERENCES

3.1 International Reference Codes, Standards and Specifications

- API S 650 Welded Tanks for Oil Storage
- API RP 651 Cathodic Protection of Aboveground Petroleum Storage Tanks
- API RP 540 Electrical Installations in Petroleum Processing Plants
- API S 2000 Venting Atmospheric and Low-Pressure Storage Tanks
- API RP 2003 Protection Against Ignitions Arising Out of Static, Lightning, and Stray
Currents
- ASCE 7-10 Minimum Design Loads for Buildings and Other Structures
- ASME B31.1 Power Piping
- ASME B31.3 Process Piping
- ASME BPVC II C Welding Rods Electrodes and Filler Metals
- ASME BPVC V Non Destructive Testing
- ASME BPVC IX Welding and Brazing Qualifications
- ASTM A283 Standard Specification forLow and Intermediate Tensile Strength
Carbon Steel Plates
- ASTM A6 Standard Specification for General Requirements for Rolled Structural
Plates
- ASTM A620 Standard Specification for General Requirements for Steel Plates for
Pressure Vessels
- AWSSFA 5.1 Welding Consumables Classification
- NACE RP0193 External Cathodic Protection of On-Grade Metallic Storage Tank
Bottoms
- NACE SP0285 External Corrosion Control of Underground Storage Tank Systems by
Cathodic Protect.
- ISO 7507 Calibration of Vertical Cylindrical Tanks
- SIS 055900 SA 2 Surface Preparation for Under Side of Bottom Plate
- SIS 055900 SA 2 Surface Preparation for Shell, Roof, Deck, etc.
- NFPA 11 Standard for Low-, Medium-, and High-Expansion Foam
- NFPA 15 Standard for Water Spray Fixed Systems for Fire Protection

3.2 National Reference Codes, Standards and Specifications

- xxx
- xxx
- xxx
- xxx
- xxx
 - xxx

3.3 Contractors Reference Codes, Standards and Specifications

- HSE Plan
- QA/QC Plan
- Approved Drawings
- xxx
- xxx

4.0 DEFINITIONS

- CLIENT SHT - Chad National Hydrocarbons Company

- CONSULTANT Xxx
- CONTRACTOR Faber Insaat San. ve Tic. A.S.
- API American Petroleum Institute
- ASCE American Society of Civil Engineers
- ASME American Society of Mechanical Engineers
- ASTM American Society for Testing and Materials
- AWS American Welding Society
- BVPC Boiler and Pressure Vessel Code
- DFT Dry Film Thickness
- GSFCAW Gas Shielded Flux Cored Arc Welding
- HSE Health, Safety and Environment
- ITP Inspection and Test Plan
- LPT Liquid Penetrant Test
- MPI Magnetic Particle Inspection
- NACE National Association of Corrosion Engineers
- NDT Non Destructive Testing
- NFPA National Fire Protection Association
- PQR Performance and Qualification Record
- PWHT Post Weld Heat Treatment
- QA/QC Quality Assurance / Quality Control
- RFI Request for Inspection
- RT Radiographic Test
- SAW Submerged Arc Welding
- SMAW Shielded Metal Arc Welding
- WPQR Welder Performance and Qualification Record
- WPS Welding Procedure Specification

5.0 RESPONSIBILITIES

5.1 Project Manager

Project Manager; responsible in general coordination and ensuring that the

necessary resources to implement the approved method statement have
been allocated to the task also responsible in ensuring that all necessary
safety and protective equipment are provided along with properly trained
and qualified personnel.

5.2 Construction Manager

 Construction Manager; responsible in ensuring the implement of construction
procedure and method statement, the Quality Control of work, supervise the
work and reporting the progress of work to Project Manager and must
observe any hold-points and notify the Engineer for inspection.

5.3 Safety and Environmental Officer

Safety and Environmental Officer; responsible in ensuring that all activities

are carried out safety patrol at the site, establishing the site safety plan,
conducting continuous safety inspection and stop any work deemed unsafe
and a risk to personal, taking action to rectified the unsafe condition and
report to project manager and preparing the notes of safety meeting.

5.4 QA/QC Engineer

QC/QA Engineer; responsible to monitor the execution and performance of

the works in relation to this method statement, approved drawings and
material specifications; detect and report nonconformance; ensure that all
nonconformance products or activities identified are reported; propose the
corrective and preventive action where possible and appropriate and record
the completion the nonconformance by report format.

5.5 Site Engineer & Foreman

Site Engineer & Foreman; responsible in ensuring that the site preparation
activities are conducted according to the approved method statement and all
activities on site are carried out in accordance with the schedule and the
construction drawing and take care all worker to be work with their
responsibilities and make a decision when some nonconformance occurring
their report to construction manager.

5.6 Worker

It is the workers duties to properly wear the protective equipment provided

and obey all safety rules. They must also perform the work as described in
the method statement procedure.

6.0 RESOURCES

6.1 Equipment and Tools

- Generators x
- Air Compressors x
- Mobile Cranes x
- Fork Lifts x
- Lifting Equipments x
- Plate Plasma Cutting Machines x
- Welding Groove Opening Machine x
- Automatic ClosedShotblasting Machine x
- Shop Primer Painting Machine x
 - Plate Bending Machine x
- SAW Welding Machines x
- Electric Welding Machines xx
- Electrode / FluxBakingOvens x
- Electrode / Flux Holding Ovens x
- Grinders xx
- Radiography Test Machine x
- Vacuum Test Equipment x
- Exhaust Fan x
- Paint Guns xx
- Trailers x
- Pick-ups x
-
- Total XXX

6.2 Man Power

- Project Manager (Mechanical Engineer) x

- Site Managers (Mechanical Engineer) x
- Safety & Environmental Officers x
- QA/QC Engineers x
- Site Engineers x
- Administration Chief x
- Accountant x
- Procurement Stuff x
- Chief Surveyors x
- Supervisor/Foreman x
- Welders / Assemblers xx
- Skilled Labors xx
- Electrician x
- Operators x
- Drivers x
-
- Total XXX

7.0 RISK ASSESSMENT

1. Hazards in the work area are identified, assessed and reported to

designated personnel.

2. Occupational Health and Safety issues and risks in the work area are
identified, assessed and reported to designated personnel.

3. Safe workplace procedures and safe work instructions are followed for
controlling risks.

4. Occupational Health and Safety, hazard, accident or incident reports

are completed according to workplace procedures and Chad
Government legislation.

8.0 HSE

8.1 Health and Safety

1. As per HSE Plan, the following system to be followed.

2. In general all recommendations and suggestions advised in HSE Plan

shall be strictly adhered by all personnel working at field and
fabrication yard premises.

3. All relevant elements of HSE Plan shall be followed.

4. Emergency and Response Plan shall be followed in case of any

emergency.

5. Road Transport Safety Procedure shall be strictly adhered while

transportation of manpower or formwork materials by vehicles.

6. Safety signs and symbols are identified and followed.

7. Tasks are performed in a safe manner and in accordance with

legislative requirements, company policies and procedures.

8. Organization of duties, tools, equipment and materials are performed

in accordance with company procedures.

9. Daily Tool Box talk shall be conducted prior to proceed for the work.

10.Prior to the commencement of any activities, the workforce will

receive an induction talk on the Project site safety requirements. This
induction talk will include both activity safety issues, as well as
general safety requirements.

11.Safety precautions should be followed during fabrication and erection.

12.Where work upon existing services may be required, the necessary

work permits and safety equipment should be obtained prior to the
activity commencement.

13.Personal protective equipment and clothing is worn, used and stored

according to company procedures.

14.Tools and equipment guards are used in accordance with

manufacturers specifications and regulations.

15.Tools and equipment will be provided with back-up alarms, lights, and
all other applicable safety devices.

16.Tested and certified lifting equipment should be used for lifting and
shifting purpose.

17.Welding cables and power cables to be laid properly as per

Occupational Health and Safety regulations.

18.Scaffolding shall conform to Occupational Health and Safety

regulations and shall be designed by a civil engineer.

19.Provisions of adequate cool drinking water, shade, and salt tablets

and or lemon will be in place.

20.Proper house keeping and clean condition shall be maintained in the

fabrication shop and site as per requirement.

21.First aid arrangements shall be followed as per procedure.

8.2 Environment

1. Refer to Environment Management instructions.

2. All activities shall comply with Environment Management Plan.

9.0 QA/QC

This shall be followed and maintained with the compliance / adherence to

the drawings, procedure and code specification. Records shall be kept in
the relevant check sheet and formats duly signed by all the concerned
departments.

9.1 Procedures / Reports

- Daily Progress Reports

- Weekly Progress Reports
- Monthly Progress Reports
- Document Transmittal Form
- Engineering Progress Report
- Accident Report
- Manpower Mobilization Schedule
- Equipment Mobilization Schedule
- Procedure Qualification Record
- Tank Erection Procedure - Conventional
- Material Identification Report
- Check Test Report
- Billing Status Report
- Welding Procedure Specification
- Sequence of Welding
- WPQR - Welder Performance and Qualification Record
- Inspection Report
- Radiography Procedure
- Radiography Inspection Report
- Vacuum Test / Air Test Procedure
- Liquid Penetrant Examination Procedure
- Post Weld Heat Treatment Procedure
- Magnetic Particle Exam Procedures
- Collapsible Test Procedure
- Hydrostatic Testing Procedure
- Flotation Test / Puncture Test Procedure
- Tank Calibration Procedure
- Blasting and Painting Procedure

10.0 WORK PROCEDURE

10.1 Detailed Engineering Design

 Design of the storage tanks are based on API 650 and other relevant
codes for construction of storage tanks.

Following designs will be made for tanks in the project.

- Topographic Survey Works

- Construction Control Survey Works
- Geotechnical Engineering Report
- Meteorological and Seismic Design Data
- Tank Shell Calculations and Drawings
- Fixed Roof Calculations and Drawings
- Internal Floating Roof Calculations
- Foundation Calculations, Design and Drawings
- Annular Plates Layout Details
- Bottom Plates Layout Details
- Shell Plates Erection Details
- Anchor Detail Drawings
- Shell Manhole Detail Drawings
- Shell Nozzles Detail Drawings
- Stairway Detail Drawings
- Roof Platform Detail Drawings
- Roof Manhole Detail Drawings
- Roof Nozzles Detail Drawings
- Nozzle Orientation
- Weld Map
- External Cathodic Protection Calculations
- Internal Cathodic Protection Calculations
- Tank Bottom External Cathodic Protection System Layout Details
- Internal Cathodic Protection System General Layout Details
- Earthing Calculations and Detail Drawings
- Lighting Calculations and Detail Drawings
- Cooling System Details
- Fire Fighting Calculations and Detail Drawings
- Fire Fighting General Layout
- Foam Chamber Montage Detail
- Safety Devices Calculations
- ITP - Inspection and Test Plan
- WPS - Welding Procedure Specification
- Painting and Procedure
- Mechanical Installation Manual
- Electrical Installation Manual
- Installation and Commissioning Manual
- List of Material (Steel Plate, Bolt, Pipe, Paint Materials)
- Cathodic Protection Materials
- Earthing and Lighting Materials
- All Procurement Documents (Material Requisitions & Technical
Specifications)
- Packaging and Shipment Details

10.2 Preparatory Works

1. Work instructions, including plans, specifications, quality

requirements and operational details are obtained, confirmed and
applied.
 2. Safety requirements are followed in accordance with safety plans and
policies.

3. Appropriate personal protective equipment selected, correctly fitted

and used.

4. Signage/barricade requirements are identified and implemented.

5. Plant, tools and equipment selected to carry out tasks are consistent
with the requirements of the job, checked for serviceability and any
faults are rectified or reported prior to commencement.

6. The equipment, which requires regular calibration, will be calibrated

prior to commencement as well.

7. Material quantity requirements are calculated in accordance with

shop drawings and specifications.

8. Materials appropriate to the work application are identified, obtained,

prepared, safely handled and located ready for use.

9. Environmental protection requirements are identified for the project in

accordance with environmental plans and regulatory obligations and
applied.

10.3 Material Procurement

1. Procurement will be made according to the approved project documents.

2. Specification and grades of all materials shall to bill of materials and

fabrication drawing requirements.

3. Prior to procurement, Clients specific requirements shall be

conformed to.

4. Conformance shall be checked at pre-order, receipt, inspection and in-

process stages.

5. All materials shall be bear manufacturers markings and shall

correlate with Mill Test Certificates.

10.4 Fabrication

10.4.1 Cutting Plates

1. Plate material shall be straight and/or flattened by pressing or rolling,

before the material is processed in any way.

2. All shell plates shall be profiled to tolerance of 2 mm in length and

1 mm in width.

3. Plates shall be measured diagonally to ensure rectangularity.

4. Curved edges of roof, bottom sketch plates and annular plates shall
be cut to shape by the machine operated gas torch.

5. Various radius templates will be used for marking and cutting.

 6. Templates shall be approved by Consultant before using.

7. The resulting surface shall be uniform, smooth and free from scale or
slag accumulations.

10.4.2 Marking

1. All plates and structural members, fittings or any other component

shall be clearly identified by marking heat number on the parts using
hard punching for traceability.

2. Heat numbers shall be stamped on these materials in the corner

approximately 6'' from either edge.

3. Each weld joint shall be marked with joint number and welder
number.

4. Heat numbers on each plates shall be highlighted for ease of

correlation with mill certificates and shall be located on outside of the
finished tank.
10.4.3 Plate Edge Beveling

1. The edge of the tank plates shall be sheared, machine cut or beveled
with a machine operated gas-cutting torch.

2. Shearing shall be limited to plates less than or equal to 10 mm thick

used for butt-welded joints and to plates less than or equal to 16 mm
thick used for lap-welded joints.

3. According to the drawings, single or double welding groove will be

opened to the proper corners of the plates using welding groove
opening machine

4. The beveled edges shall be ground to remove all the above

accumulations.

Horizontal joint beveling Vertical joint beveling

10.4.4 Shot Blasting and Shop Primer Coating

1. All plate material shall be shot blasted and shop primed for temporary
protection during storage and construction.

2. Any corrosions / mill scale shall be removed from the steel plates.

3. Plate surfaces should be blasted by the automatic closed blasting

machine as per SIS 05 5900 SA SA2.

4. Post shot blasting, the material passes to the shop primer coating.

5. First shop primer coating will be applied according to the painting

procedure.

6. Drying of the paint will be ensured, and being ready, it will be placed
on the carrying table.
10.4.5 Rolling of Shell Plate

1. Plate dimensions shall be verified prior to the start of edge

preparation or rolling operations.

2. Shell plates shall be shaped to the correct curvature of the tank.

3. Rolling will be developed in place, in a fabrication shop designed and

built for this purpose.

4. Plate shall be rolled within permissible localized variations as

specified in ASTM A6 and ASTM A20 and shall be free from buckling,
dents, excessive drawing, distortion or obvious imperfections.

5. Templates shall be used to measure the rolled plates curvature.

6. Rolling of shell plate giving required load stage by stage on rolling

direction.

7. Check radius using the above template stage by stage until the
required radius is obtained.

8. Rolled shell plates shall be stacked on radius cradles, which is same

to roll for further process.
10.4.6 Shop Fabrication of Annular, Bottom and Roof Plates

1. Plate surfaces should be blasted by the automatic closed blasting

machine as per SIS 05 5900 SA 2 and SA 2.

2. Plates will be marked for each drawing.

3. Treated corners will be wrapped with masking tape.

4. First coat paint will be applied to both surfaces of plates according to

the specifications.

5. Packaging of the items which are accepted by Consultant Examiner

will be finished.

10.4.7 Shop Fabrication of Shell Plates

1. Plate surfaces should be blasted by the automatic closed blasting

machine as per SIS 05 5900 SA 2 and SA 2.

2. Dimensions of plates will be checked against the dimensions in the

drawings, and they will be cut accordingly.

3. Plate surfaces and corners will be cleared of burrs.

4. Plates will be marked for each drawing.

5. According to the drawings, single or double welding groove will be

opened to the proper corners of the plates using welding groove
opening machine.

6. Shell plates will be bent at the bending machine (roller) with the help
of temporary tools prepared for bending.

7. Surfaces of shell plates will be cleared of any oil or dirt and the
treated corners will be wrapped with masking tape.

8. First coat paint will be applied according to the painting procedure.

9. Drying of the paint will be ensured, and being ready, it will be placed
on the carrying table.

10.Packaging of the delivery items which are accepted by Consultant

examiner will be finished.

11.The packages will the separated according to the destination stations

and the package lists will be prepared.

10.4.8 Shop Fabrication of Roof Supporting Steel Structure

12.Middle section ceiling steel will be produced according to the

drawings.
 13.The ceiling beam will be cut and holes will be drilled on it according to
the drawings.

14.The wind beam will be bent at the bending machine.

15.The arms of the ceiling support system will be manufactured

according to the drawings.

16.Following surface preparation, the first paint coat will be applied in

compliance with the painting procedure.

17.Its dimensions and DFT (dry film thickness) will be measured for
ready-made package lists for each stage of the production and
transportation to the work site.

18.Packaging of the items which are accepted by Consultant examiner

will be finished.

19.It will be transported to the work site for assembly.

10.4.9 Shop Fabrication of Internal Floating Roof

1. The cutting of plates according to the approved fabrication drawings.

2. Cleaning of the surfaces for production.

3. Preparation for welding for floating roof, verification of external panel

dimensions for all in accordance with approved fabrication drawings.

4. Preparation of the central section of the floor in accordance with

approved drawings, separation from its corners, welding at the work
site with approved WPS of qualified welders.

5. Marking of floating roof panels, cleaning of burrs and applying

masking tape.

6. Repeating the same operations for the central section and performing
the cleaning activities.

7. Application of the first paint coat to the finished and cleaned parts
according to the painting procedure.

8. All produced parts will be examined according to Consultant approval.

9. The visual inspection dimensional check and package lists of the

produced parts should accompany the delivery.

10.The preparation and production of the permeation of support pads of

the floating roof will be performed as per approved drawings and
approved by Consultant.

11.The production of these parts will be completed and following the

examination, the burrs will be cleared off.

12.It will be ensured that surface preparation is performed and first coat
of paint is applied according to the procedure.

13.Packaging of the items which are accepted by Consultant Examiner

will be finished.
 14.Examination reports for package lists and compliance of
transportation boxes for transportation will be prepared.

15.Delivery to the work site for construction

10.4.10 Shop Fabrication of Stairs and Handrails

1. Components of the tank (controlled plates, pipes, guardrails and steel

constructions) will be placed to their positions according to the
approved shop flow fabrication drawings.

2. All the structural items shall be straightened before marking and

cutting.

3. Mark the components as per drawing.

4. All the cutting operation, as per requirement shall be carried out after
getting the clearance from inspection authority.

5. Components of the structure will be processed using the cutting and

bending machines.

6. All the cutting operation shall be carried out by gas cutting method.

7. Grind the cut edges smooth to remove burrs and slag.

8. Fabrication such as fitting, welding, drilling, etc. shall be carried out

as per drawing and after the clearance from inspection authority.

9. Dimensions of the parts which are cut of welded with approved WPS
will be verified.

10.Welded areas will be cleared of burrs.

11.After fabrication all these structural items shall be blasted as

requirement.

12.Components will be delivered to the galvanizing unit.

13.Hot dip galvanizing will be performed according to the procedure.

14.All stages of the plant production for each tank inspection shall be
performed in accordance with Consultants Procedure and the
company records will be completed without error.

15.Preparation of package lists for all parts and the placed layers.

16.Packaging of the parties which are accepted by ConsultantExaminer

will be finished.

17.They will be delivered to the work site for construction.

10.4.11 Shop Fabrication of Manholes, Nozzles and Other Appurtenances

18.A protective shelter shall be used.

19.All manholes, nozzles and other appurtenances shall be fabricated
and PWHT in the shop, in accordance with the approved construction
drawings.

20.The produced components will be cut at full scale when they are
placed into their locations, for instance, flanges and metal parts, and
they will be prepared and joined according to the drawings.

21.Before joining, welding burrs will be cleaned by grinding and with a

brush and these parts will be transported to the painting area for
surface preparation.

22.Each weld shall be started (root pass) and finished while the preheat
temperature is maintained without interruption.

23.The prepared parts will be joined according to the fabrication

drawings using a tack welding.

24.After dimensions are verified, the actual welding will be performed

according to the approved fabrication drawings.

25.Pipes shall be pre-heated around its circumference and maintained on

12'' sections on either side of the weld.

26.Pipes shall be covered immediately after welding and be permitted to

cool at uniform rate.

27.Primer and final paint coats will be applied.

28.Examination reports will be provided; packaging lists and packages

suitable for transportation will be prepared.

29.Packaging of the items which are accepted by Consultant Examiner

will be finished.
10.5 Packing and Shipment

1. Packing of the goods will be done according to professional standards

and in a safe manner in order to prevent damage during
transportation.

2. Materials will be packed by engineering ID number system.

3. Bolts, nuts, nipples, and other small parts shall be boxed or put in
kegs or bags for shipment.

4. All flange faces and other machined surfaces shall be protected

against corrosion and from physical damage.

5. The packages will the separated according to the destination stations.

6. Examination reports will be provided; packaging lists and packages

suitable for transportation will be prepared.

7. Plates and tank material shall be loaded in a manner that ensures

delivery without damage.

Packing for bottom, roof and shell steel plates will be done in following
forms;
10.6 Inspection of Foundation

1. Before erecting the bottom plate the tank foundation shall be

inspected visually for evidence of cracks, damage etc.

2. Before proceeding to the assembly, ensure that necessary survey of

topographic measurements and labeling of the ground on the tank
will be mounted have been performed, and that the elevation and
axle settings of the assembled anchorages have been correctly fixed.

3. Spot level of the foundations shell be verified and tolerances shall be

as per the limits specified in API 650 Section 7.5.5.2.

4. A check of the dimension, level and reference point shall be carried

out prior to takeover of the foundation and all QA/QC required
documents should be signed by Consultant.

5. Level and direction of the foundation shall be confirmed and accepted

by Consultant.

6. Camber and flatness of foundation surface shall be confirmed and

accepted by Consultant prior to erection of the tanks.

7. Exact center point shall be marked.

8. The tank should be oriented on the tank circle whose 0, 90, 180 and
270 degree points are drawn on the concrete ground.

10.7 Erection (Conventional Method and Internal Floating Roof)

Erection sequences of tanks will be as follows:

- Laying of Annular Plates

- Laying of Bottom Plates
- Erection of Shell Plates, Wind Girder and Top Curb-angle
- Erection of Stairway
- Assembly and Installation of Internal Floating Roof
 - Erection of Structural and Appurtenances
- Installation of Tank Internal Piping
- Assembly and Installation of Roof
- Tank Hydrostatic Test
- Shot Blasting and Painting
- Installation of Seal
- Box-up
- Handing-over

10.7.1 Annular Plates Laying

1. Welding map must be checked before starting welding.

2. Check the dimension of anchor bolt diameter, if its not enough, cut
around the slots of the bolt.

3. A backing plate shall be fixed to each annular plate.

4. Start annular plate erect form clean out door. (If any)

5. Each annular plate shall be placed in accordance with the approved

project drawings in correct orientation.

6. The radius of each annular plate outer edge shall be measured.

7. Fit-up between annular plates shall be adjusted as required.

8. Upon completion of erection and prior to welding of annular plates, a

final check of the joint fit-up welding gaps and radius shall be made.

9. The lapping line of the bottom plates shall be scribed.

10.The shell plate assembling line shall be marked.

11.The weld area (8'') upon which the shell plates to be erected shall be
ground flush.

12.All welds shall be inspected by vacuum and NDT techniques.

10.7.2 Bottom Plates Laying

1. Welding map must be checked before starting welding.

2. All plate cutting at site shall be with gas torch.

3. The bottom plates, starting from the center plate shall be laid
progressively towards the annular plates in accordance with the
project drawings.

4. Root pass welding will be done by back step method with 30 cm

intervals parallel from inside to outside.

5. Laps shall be maintained while the fit-up of short seam and long seam as
per drawing.
 6. Temporary tack weld to be carry out on the long seam to avoid
uneven movements and distortion while the fit-up and welding of
short seam.

7. Short seam welding will be carried out alternatively to avoid distortion.

8. To prevent welding distortion, restraint jigs or reinforcing beams shall be

used.

9. After the completion of short seam welding, remove the temporary

tacks on the long seam by grinding to facilitate the long seam fit up.

10.Long seam welding will be carried out alternatively to avoid distortion.

11.Suitable fixtures shall be used to prevent warp age or buckling of the

bottom plates when welding the longer side of each plate.

12.Minimum laps shall be maintained while the fit-up of long seam as per
approved drawing.

13.Joggling shall be carried out by hammering wherever it necessary.

(Three plate joining junction)

14.On completion of the welding of the bottom plates, welding of the

tank bottom to the annular plates shall be completed.

15.Sketch to annular plate joint shall be welded only after shell to bottom
joint welding.

16.After completion of the welding works, the gauges are removed and
point welding places are cleaned thoroughly by wire brushing and
grinding.

17.Water draw-off sump shall be insulated (installed olmas

gerekmiyormu izolasyon deil) and welded according to approved
drawing.

18.The first shell plate start point shall be scribed.

19.The center point of the tank bottom shall be scribed.

20.All the bottom plate's joints vacuum box test shall be carried out as
per approved process and code specification.

21.If any defect found the defect weld shall be removed by grinding and
re-weld and conduct the vacuum box test. Repeat the sequence until
the defect cleared.
 Bottom plates welding sequence

10.7.3 Shell Course Erection

1. Welding map must be checked before starting welding.

2. The shell plates shall be placed around the tank foundation.

3. All required fixtures shall be installed on the inside of the shell plates.

4. All required fixtures shall be installed on the inside and outside of the
annular plates to ensure that the shell plates are aligned with the
scribed line.

5. Bracket hooks shall be fitted inside and outside each shell plate
before it is lifted into position.

6. Each shell plate shall be secured on the annular plate and aligned by
using guides and wedges.

7. The first shell plate with its edge on the start mark shall be erected
upright using a 100 mm channel support.

8. Strong back plates shall be employed to secure adjacent shell plates.

An alignment and width check of joint gaps shall be carried out before
tack welding the vertical seams.

9. The alignment fixtures shall be removed, all tacks cleaned and all
vertical joints of the first shell course welded.

10.The shell course dimensions shall be checked for roundness at the

bottom and top levels, vertically at a minimum of two points and for
level at the shell plate top-level line.

11.When checking is completed the second course of plates shall be

placed into position together with the first shell course.

12.For the erection of the second and subsequent courses, scaffold

brackets and plates shall be attached to the shell plates and secured
with rope. The shell plates shall then be lifted into position.

13.On completion of assembling the shell plates handrail shall be

installed on the inside of the scaffold.

14.Wall ladders shall be attached on the inside wall of the tank.

 15.The second course vertical joints shall be aligned and welded.

16.Aligning horizontal seam between 1st and 2nd courses, and fit up
check shall be carried out after tack welding.

17.The alignment fixtures shall be removed, all tacks cleaned and

horizontal joints shall be welded.

18.After completing welding of horizontal joint, 3rd. shell course shall be

erected.

19.The same sequence shall be followed to complete the assembly of the

remaining shell courses.

10.7.4 Stairway Erection

1. Pad location for the stair case support shall be marked on the shell
plates.

2. Pad shall be welded and appropriate QC check to be done. Weep hole

shall be provided on all pads.

3. All stair-treads, handrails must be bolted to stringer in segments up to

the intermediate landing platforms.

4. Assembled lower segment of spiral stairway shall be lifted and

installed. Following the lower segment, first intermediate platform
shall be erected.

5. After welding of the lower segment, further portion shall be erected in

similar way.

6. MPI shall be carried out on all temporary attachment removal areas.

10.7.5 Appurtenances Installation

1. After completion of bottom shell course welding shell manholes and

nozzles shall be marked as per drawing.

2. Orientation, elevation and projection shall be maintained as per

drawing and offer for the inspection clearance.

3. Cut the openings by gas cutting after proper inspection by Inspection

Authority.

4. Install the reinforcing pads wherever required as per drawing before

erection.

5. Erect the prefabricated manholes or nozzles as per the orientation

and the elevation shown in the drawing.

6. Suitable jigs and fixtures shall be provided to prevent the distortion

during the welding.

7. Welding shall be as per WPS and to be welded by the qualified welder.

8. Manhole neck shall be fabricated and the longitudinal joint shall be

radiographed.
 9. All RF pad weld shall be pneumatically tested at an pressure of 1.05
kg/cm2.

10.Reinforcing pad pneumatic test shall be carried out to the satisfaction

of the Consultant.

11.All the shell manholes or nozzles final weld from both sides and
reinforcing pads welds shall be inspected by visually and by LPT, to
the satisfaction of the Consultant.

12.Flanges to pipe joint shall be prefabricated and required NDT shall be

completed before erection.

10.7.6 Roof Erection (Fixed Supported)

1. Shell plate and roof structures shall be protected by heavy wind

during the erection using guy wire rope method.

2. A detailed execution procedure and/ or plan including the detailed

dimensions of the device shall be prepared and submitted to
Consultantfor approval, prior to commencement of shell construction
work.

3. Roof structure shall be assemble on the ground in section or

completed depending on size and weight.

4. Assembled roof structure shall be erected inside the tank after

completion of bottom plate and annular plate.

5. Roof of outer rafter shall be assemble on the ground in section or

completed depending on size and weight.

6. Assemble the roof plate on the temporary support.

7. Assemble and welding the center ring and center plate complete with
stiffener and rib plate.

8. Fit the ring on the roof plate.

9. Install the rafter and girder on the roof plate.

10.Erect the outer rafter on the temporary support after completion of

bottom plate and annular plate.

10.7.6 Floating Roof Erection (Internal)

1. When half portion of the bottom plates are welded, including annular
plates segment plus the internal welding between 1st shell course
and annular plates, vacuum box test shall be conducted and cleared
for internal float roof assembly.

2. Internal floating roof lower deck plates shall be laid and welded in
same sequence of bottom plates.
 3. Mark up on the lower deck plates, the location of outer rim,
Intermediate rim, compartment plates, structures, leg supports and
accessories.

4. Positioning, fit up and welding of outer rim, intermediate rim plate,

center rim plate and rafter.

5. Complete welding of vertical and all joints to the lower deck plates

6. Welding of the compartment of the floating deck shall be done

starting from the opposite side of the entry ramp.

7. When total assembly and welding of the floating roof without roof
plates is completed, including sleeves supporting legs, all manholes
and nozzles of 1st shell course shall be closed.

8. Temporary ladder positioned in two locations of the 2nd or 3rd shell

course shall be provided to enter in the tank.

9. Closing of the 1st, 2nd and, in case, 3rd shell course will be done in
steps, in order to complete at the same time the assembly of the
floating roof (still without roof plates).

10.Water shall be pumped inside the tank trough one nozzle and slowly
float roof will be lifted up.

11.Water shall be pumped until the float reaches the height allowing the
insertion of the pins into the legs.

12.Check the orientation of the floating roof, as per floating roof layout
drawing.

13.Water shall be drained.

14.Tank shall be cleaned with high pressure water jet.

15.Floating deck roof plates shall be installed.

16.Foam dam shall be installed.

17.Manholes, drainage, internal piping, etc. shall be installed.

18.Roller ladder shall be installed.

19.Primary shoe and seal shall be installed after final hydrotest and
internal painting, as per supplier instruction.

10.8 Inspection and Testing

Also see Field Inspection and Test Procedure xxx.xxx

10.8.1 Welded Joints

1. If any tack welds are to be incorporated into horizontal shell seams

these shall be dressed to the satisfaction of the Consultant
Representative.

2. Fillet welds that cross horizontal or vertical shell seams shall be

subjected to 100% MPI.
 3. One spot radiograph shall be taken of each radial joint.

4. The shell to bottom weld shall be inspected by wet MPI on the inside
and outside after the 1st pass each side and after hydro test on the
completed welds.

5. When roof truss main supporting members are made up from two
shorter length, the penetration of these welds shall be examined by
radiography.

10.8.2 Tank Bottom and Roof Plates

1. All tank bottom and roof plate welds shall be tested, before hydro-test
& painting, using vacuum box soapy water shall be applied to all
joints.

2. Test shall be done after at least 4 days of welding.

3. Roof plate shall be tested applying internal air pressure not exceeding
the weight of the roof plates and applying to the weld joint a soap
solution for the detection of leaks.

4. Annular plate joints shall be tested by RT and MPI according to API

650 Section8.

10.8.3 Tank Shell

1. Applying NDT on shell joints shall be according to approved ITP of

tank and API 650 Sec. 6.

2. On completion of the tank construction, inspection of all welded

seams and dimensional check according to API 650 Section 8 and
acceptance by the Consultant, a hydrostatic test shall be conducted
in accordance with the approved procedure to demonstrate welding
quality and foundation stability.

3. Hydro test shall be carried out according toapproved Hydrostatic

Testing Procedure. See Field Inspection and Test Procedure xxx.xxx

10.8.4 Nozzle Reinforcement Pad Test

1. Nozzle reinforcement pad will be pneumatically tested at 1.05 kg/cm 2

with soap solution.
 2. This test shall be carried out before filling the tank for hydrostatic
testing.

10.8.5 Fixed Roof Test

1. After filling the tank up to curb angle, all openings in the roof shall be
closed and internal pressure shall be applied equivalent to the weight
of roof plates, all welded joints in roof shall be checked with soap-suds
for detection of leaks.

2. For tanks with small internal pressure, the test pressure shall be equal
to 1.25 design pressure.

10.8.6 Dimensional Control

1. Dimensional check including peaking, banding, plumpness and

roundness shall be according to API 650 Section 8 and approved ITP of
tank.

10.9 Calibration

See Tank Calibration Procedure xxx.xxx

10.10 Shot Blasting and Painting

1. Before application of paint, the surface shall be cleaned of dust etc.

by wire brushing / sand blasting by SA 2 for under side for bottom
plate and SA 2 for shell, roof, deck etc.

2. All paints shall be stirred up not be carried out if the atmospheric

temperature is less than 5 C, above dew or if the temperature
exceeds 40C, in the shadow or if relative humidity exceeds 85% or
any other adverse weather conditions such as rain, fog, dust storm
etc.

3. Coating media shall be applied in uniform thickness.

4. All slots, recesses, grooves, corners, angles and interstices shall be

distributed or removed and new paint shall be applied uniformly.

5. All paint containers shall only be opened prior to utilization and shall
be carefully closed immediately after withdrawal of material.

6. Material, which become unserviceable during storage shall not be

applied.

7. All painting material shall be kept in weatherproof barracks and shall

be kept cool and dry.

8. Paint shall be applied by brush or by spray.

9. During spraying the paint shall be maintained thoroughly mixed in the

spray gun.

10.The paint shall be sprayed uniformly.

11.Surface impossible to be coated by spraying shall be painted by
brush.

12.Painting work shall be done in day time only.

13.Check dry film thickness (DFT) with standard paint thickness

measurement instrument such as Elcometer.

14.Tank number and capacity shall be painted on each tank with suitable
size letters and numbers.