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MS-M-025 REV.1

METHOD STATEMENT

FOR

TANK MODIFICATION

DM WATER STORAGE TANK (K86-D-0405 A/B )

CONTRACT No. JI-194

SAUDI ARABIAN OIL COMPANY

KARAN UTILITY AND COGENERATION PROJECTKhursaniyah, Saudi Arabia

Signature

128 Feb 2011Print NameBinulalE.Z. MontejoR.A. DimatatacP. Ranzenbacher

Rev.DATEPrepared By MMGChecked By MMGApproved By MMGApproved By PSAL

TABLE OF CONTENTS

Page

1.0 PURPOSE3

2.0 SCOPE.3

3.0 REFERENCES3

4.0 RESPONSIBILITY..3-4

5.0 MANPOWER CATEGORY.................. 4

6.0 REQUIRED TOOLS.. 5

7.0 PROCEDURE........................................ 5-8

8.0 QUALITY CONTROL AND ASSURANCE 8

9.0 SAFETY PRECAUTIONS ............................9

10.0 ATTACHMENTS...............9

1. PURPOSE

To ensure that modification (installation of additional nozzles, pipe supports, restoration of paint and insulation) of De-mineralized Water Storage Tanks is carried out safely, and in accordance with good working practice, and as per PSAL/ARAMCO Job Specification. This procedure is intended to provide recommended practices, general application guidance and establish controls during preparation and execution of tank modification.

2. SCOPE

This Method Statement is applicable for the modification of De-mineralized Water Storage Tanks which will be carried out on the Karan Utility and Cogeneration Project, Khursaniyah Saudi Arabia. The scope of tank modification has been defined in Petrofac Engineering Data Sheet RD-770470, Rev. D .

3. REFERENCES

SAES-D-108 : Repair, Alteration, and Reconstruction of Storage TanksAPI STD 650 : Welded Steel Tanks for Oil Storage

API STD 653 : Tank Inspection, Repair, Alteration and ReconstructionSAES-W-017 : Welding Requirements of API Tanks

MS-P-012 : Method Statement for Repair/Touch-up Paint of Piping and Components, Equipment and Structural Steels

32-SAMSS-005 : Manufacture of atmospheric tanks

SAES-H-001 : Coating Selection & application requirements for industrial plant and equipments.

SAES-H-100 : Coating Materials & Application Requirements for Industrial Facilities

SAES-H-102 : Safety requirements for Coating Applications.

4. RESPONSIBILITY

1. 2. 3. 4. 4.1. Construction Supervisor: Ensure that all work is conducted in accordance with the applicable WPS and this Method Statement, that the welder is suitably qualified and that an RFI is issued to QC Department prior to commencing of work.

4.2. Quality Control Inspector:

On receipt of RFI from Construction Department, shall verify that all work is conducted in accordance with this method statement, applicable WPS, and that inspection activities are conducted in accordance with applicable SATIP. He shall complete all required QA/QC documentation and arrange for weld test in accordance with Saudi Aramco Specification when applicable.

4.3. Safety Supervisor:

4.3.1. Pre-mobilization Inspection & colour coding for all tools and equipment used on site. Ensure that all safety requirements have been adequately addressed and the work is carried out in accordance with PSAL/ARAMCO project safety procedures.

4.3.2. Ensure relevant documentation and certifications are submitted for welders, operators, drivers, scaffolders and riggers.

4.4. Engineer Supervisor:

Prepare and submit method statement for PSAL/ARAMCO review and approval. Provide technical support to MMG site operation group. Provide latest revision of AFC drawings, procedures, material specifications standards and technical specifications.

4.5. Rigging Supervisor:

To ensure that rigging and heavy lift activities are performed by ARAMCO CERTIFIED rigger in a safe and efficient manner. Rigging is engineered, performed and inspected to satisfy the Customer's requirements in accordance with the issued Project Drawings and Specifications.5. MANPOWER CATEGORY

5. 5.1. Foreman5.2. Millwright5.3. Mechanical Fitter5.4. Fabricator5.5. Helper5.6. Scaffolder5.7. Surveyor5.8. Rigger5.9. Permit Coordinator and other Involved Manpower

6. REQUIRED TOOLS

6.1 Appropriate Crane for Specified Lift

6.2 Slings/Non-Metallic Ropes/Soft Tag Lines

6.3 Shackles/Beam Clamps/Blocks/Wrenches

6.4 Spreader or Frame/Chain Hoist

6.5 Welding Machine

6.6 Wrenches/Levelling Tools/Feelers

6.7 Grinder

6.8 Lighting and Lighting Fixtures

6.9 Air Mover with Flexible hose and Couplings

7. PROCEDURE:

7.1 Preparation

7.1.1 Obtain AFC Drawings and procedures prior to modification works and ensure that all relevant documents have been approved by PSAL/SAUDI ARAMCO prior to commencement of the work and that those documents are disseminated to concerned personnel who will carry out the work.

7.1.2 Ensure that Permit to Work and documents necessary for access of personnel and equipment to site is in order, approved and issued.

7.1.3 Verify that tank is drained and isolated. Draining and isolation are responsibilities of ARAMCO.

7.1.4 Ensure that all equipment and materials to be transported to the work area from the warehouse / lay down area is in accordance with the project specifications and contract requirements.

7.1.5 Verify equipment and/or materials are undamaged prior to removal from the material receiving lay down area.

7.1.6 Segregate delicate parts and materials from major components in order to avoid the possibility of damage.

7.1.7 Only certified and approved lifting equipment / personnel will be used to move loose parts and materials.

7.1.8 Where required, proper protection shall be made to the existing structures around the handling route and working area to prevent damage. Temporary measures shall be promptly restored to their original condition after the works is completed.

7.1.9 Locate installation points for additional nozzles as per drawing.

7.1.10 Install scaffolding where necessary.

7.2 Open manholes and vent the tank.

7.3 Welding shall be as per approved WPS.

7.4 Restore painting where affected as per drawing specifications and MS-P-012, Method Statement for Repair/Touch-up Paint of Piping and Components, Equipment and Structural Steels.

7.5 Coating shall be APCS-2A /APCS-4 /APCS-3 (Epoxy Lining) as per note 9 of Drawing RD-770470. Coating & painting shall be executed in accordance with Aramco Specifications SAES-H-001.

7.6 Install additional nozzles with reinforcement pads and pipe supports as per drawing.

7.6.1 Cut hole and form bevel as per drawing specification. Cut hole smooth and true. Unless specified otherwise, the actual hole diameter shall be +3.2 mm of the nominal specified diameter.

7.6.2 Ensure that the reinforcing plates telltale hole is threaded prior to installation.

7.6.3 Use adequate shielding when preparing weld joints and during welding.

7.6.4 Grind up to sound metal the periphery around weld joints at least 75mm from centreline of the welds.

7.6.5 Welding shall be as per approved WPS.

7.6.5.1 All structural supports and pipe supports shall be continuously welded.

7.6.6 Restore affected paint and insulation after Testing and Inspection.

7.6.6.1 Restore painting where affected as per drawing specifications and MS-P-012, Method Statement for Repair/Touch-up Paint of Piping and Components, Equipment and Structural Steels.

7.6.6.2 Restore insulation as per drawing specification and MS-P-006, Method Statement for Hot Insulation and Weatherproofing Application for Piping and Equipment.

7.7 Installation of Tie-in Spools including valves and temporary supports are included in Tie-in Procedure.

7.8 Inspection and Testing

7.8.1 Temporary and permanent attachments to shell plates.

7.8.1.1 Conduct visual examination.

As per API STD 650 Visual Examination

A weld shall be acceptable by visual inspection if the inspection shows the following:

a. There are no crater cracks, other surface cracks or arc strikes in or adjacent to the welded joints.b. Undercutting does not exceed the limits given in 5.2.1.4 for vertical and horizontal butt joints. For welds that attach nozzles, manholes, cleanout openings, and permanent attachments, undercutting shall not exceed 0.4 (1/64 in.)mm.c. The frequency of surface porosity in the weld does not exceed one cluster (one or more pores) in any 100 mm (4 in.) of length, and the diameter of each cluster does not exceed 2.5 mm (3/32 in)

7.8.1.2 Inspection of Reinforcing Plate Welds

API STD 650 5.3.4 After fabrication is completed, but before the tank is filled with test water, test the reinforcing pad by applying up to 100 Kpa (15 Lbf/in) gauge pneumatic pressure between the tank shell and the reinforcement plate on each opening using the telltale hole specified in 3.7.5.1. While each space is subjected to such pressure, a soap film, linseed oil, or another material suitable for the detection of leaks shall be applied to all attachment welding around the reinforcement, both inside and outside the tank.

7.8.1.3 Examination and test requirement of Paragraph 12 of SAES-D-108 shall be used.

7.8.2 As per API STD 653 12.1.2.3 Completed welds attaching nozzle neck to shell, and reinforcing plate to shell and to nozzle neck, shall be examined by the magnetic particle or liquid penetrant method.

7.8.2.1 Conduct Examination by Liquid Penetrant Method as per Sec. V, Article 06 of ASME Code.

7.8.3 Conduct a full 24 hour Hydrostatic Test.

7.8.3.1 As per API STD 653 & 32-SAMSS-005 A full hydrostatic test, held for 24 hours, shall be performed on:

b. Any tank that has undergone major repairs or major alterations unless exempted by 12.3.2 for the applicable combination of materials, design, and construction features.

7.9 Hydrostatic testing

7.9.1 Isolation of Tank prior to modification works is responsibility of ARAMCO.

7.9.2 Ensure that modifications are accepted and released.

7.9.3 Remove all debris, foreign materials inside the tank.

7.9.4 Install blinds on abandoned and additional nozzles, and seal all manholes.

7.9.5 Fill with potable water up to design level of liquid and hold for 24 hours.

7.9.6 Conduct survey on modification welds.

7.9.7 Drain tank after acceptance by PSAL / ARAMCO.

7.10 Upon completion of testing and inspection and acceptance by PSAL / ARAMCO, conduct housekeeping properly.

8. QUALITY CONTROL AND ASSURANCE

Inspection shall be conducted and recorded in accordance with the Job Specific Inspection and Test Plan.

9. SAFETY PRECAUTIONS

Make sure that all necessary work permits are issued. Check all lifting equipment prior to commencing lifting activities. Stay away from any suspended load / falling bodies. Wear full body harness when working at elevated platform. Ensure that barricade tapes and warning signs are properly installed. Ensure that there are no hazardous or combustible gases present in the work area. Install flashing light to traffic. Copy of approved JSA to be maintained at work site by work supervisor, requirements discussed in daily TBT.

10. ATTACHMENT

10.1 K86-A-RA-566035-014 P&ID DEMIN WATER STORAGE TANKS10.2 MECHANICAL DATA SHEET, RD-770470 Rev. D MODIFICATION TO DEMIN WATER STORAGE TANKS K86-D-0405 A/B .

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