METHOD STATEMENT FOR

ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK

PROJECT.
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REVISION
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K1202107

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METHOD STATEMENT FOR ERECTION AND

INSTALLATION OF FIXED ROOF STORAGE TANK
T-51-09 A/B DM WATER TANK

12/11//2013

Hairol Zoll

Edy Melchor

Edy Melchor

Rev.

Date

Prepared By

Checked By

Approved By

METHOD STATEMENT FOR

ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK

PROJECT.
NO.
REVISION
NO.

METHOD STATEMENT FOR

ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK

PROJECT.
NO.
REVISION
NO.

PAGE NO.

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TABLE OF CONTENTS

SECTION

DESCRIPTION

PAGE

1.0

SCOPE

2.0

APPLICABLE CODES, STANDARDS AND REFERENCES

3.0

DEFINITIONS

4.0

LIST OF EQUIPMENT

5.0

MATERIAL STORAGE AND HANDLING

6.0

PREPARATORY WORKS

7.0

TANK ERECTION METHOD

7.1

ERECTION OF ANNULAR PLATES

7.2

ERECTION OF BOTTOM PLATES

7.3

ERECTION OF SHELL PLATES

7.4

INSTTALATION OF ROOF STRUCTURE

7.5

INSTALLATION OF ACCESSORIES &

7.6

TANK APPURTENANCES

10

ASSEMBLING OF STEEL STRUCTURES

10

& APPURTENANCES
8.0

WELDING SEQUENCE

11

9.0

INSPECTION

11

10.0

LEAKAGE TESTING

11

11.0

APPENDIX

12

METHOD STATEMENT FOR

ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK

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1.0 SCOPE
1.1 This procedure describes the sequence and methods to perform site erection and
fabrication of Fixed Roof Storage Tank for Knock Down (KD) Tank for Sabah
Ammonia Urea (SAMUR) Project2.0 APPLICABLE CODES, STANDARDS AND REFERENCES
2.1 API 650 Welded Steel Tank for Oil Service (revision 11, 2010)
2.2 PTS 34.51.01.31: Standard Vertical Tanks - Selection, Design & Fabrication
2.3 PTS 64.51.01.31: Standard Vertical Tanks - Field Erection & Testing
2.4 PTS 20.156A: Standard Tanks, Volume 1 - Part 1
2.5 PTS 20.156B: Standard Tanks, Volume 1 - Part 2
2.6 Approved Drawings
2.7 BS 2654 cross reference with EN1491

3.0 DEFINITIONS
3.1 KNM PETROSAB : Contractor
3.2 Consortium : AIT
3.3 PCSB : OWNER
4.0 LIST OF EQUIPMENT
4.1 FCAW/ SMAW / SAW welding machines
4.2 Hand Grinder
4.3 Hot Air Blower
4.4 Spreader Bar
4.5 Webbing Sling 6meter, 3000kg
4.6 Webbing Sling 12m, 4000kg
4.7 Robin water pump
4.8 Portable electrode rod dryer
4.9 Mobile Crane 25 & 45 ton
4.10 Diesel water pump
4.11 Welding rectifier
4.12 Electric cut-off machine
4.13 Horizontal lifting clamp
4.14 Lifting clamp
4.15 Gauging machine
4.16 Vacuum
4.17 SLR-0365 G210 Screw Pin Chain Shackle '7/8' (6.5T)
4.18 Electrode Baking & Holding Ovens
4.19 Flux Oven
4.20 Wind girder
4.21 Welder Buggy

METHOD STATEMENT FOR

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ROOF STORAGE TANK

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5.0 MATERIAL STORAGE AND HANDLING

5.1

Stainless steel plate materials, fitting, nozzle and material for structure, etc shall
be received, inspected and storage yard in separate bay and adequately protected
as specified in KPE-QAP-026 (Procedure for Handling)

5.2

The plates shall be stored with no deformation and ensure it is not dented and
supported with sufficient wooden blocks.

5.3

The stainless steel materials shall be protected against contamination from iron,
dust etc and shall not be stored at open yard which is direct contact with or within

12 inch (300mm) of the soil or in contact with porous or moisture retaining

supports such as raw wood.
5.4

Stainless steel materials shall be kept in the separate designated area and with
proper identification.

5.5

Walking on stainless steel material shall not be allowed during any stage of
storage and fabrication. A protection barrier such as wooden plank or plywood
shall be used.

5.6

Fabrication shall be carried out in separate demarcated area and completely

segregated from carbon steel and low alloy steels.

5.7

All contact surfaces of lifting and associated tools shall be protected with stainless
steel or non-ferrous coating/attachments.

5.8

Fabrication tools allocated for the fabrication of stainless steel shall be colour coded
with GREEN colour band.

5.9

A partition wall with corrugated sheet at sufficient height shall be prepared to prevent
contamination from carbon steel dust generated by grinding/cutting operation on
carbon and low alloy steel materials.

5.10

Dedicated bay shall be identified with

authorized personnel.

5.11

Rolling and bending machine surface shall be wire brushed, washed and blown
dry. A layer of protective coat eg; VCI 386, lime chalk, etc) shall be applied on
the roller surface prior to rolling or bending operation. Alternative methods such as
coating of roller or covering the roller with plastic/soft board sheet are also
acceptable.

'Caution Signage' for the entrance

METHOD STATEMENT FOR

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ROOF STORAGE TANK

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of

6.0 PREPARATORY WORKS

6.1

A 25 ton and 50 ton hydraulic Rough Terrain type crane will be positioned around the
tank foundation (100 ton and above crane only for erection of roof structure assembly).
If unfavourable soil conditions exist, pouring of gravel materials or laying out of thick
wooden planks or steel plates will used to support the ground and crane stability.

6.2

Before using the crane for lining operations, the inspection will be carried out for
proper functioning and verify all the safety devices (e.g. overload protection) are
operating satisfactorily. Test certificate should be available for inspection.

6.3

Scaffoldings and welding buggy will be used to facilitate erection and welding works.
Proper permit will be secured prior to erection of scaffoldings and welding buggy on
site.

6.4

All the erection aids such as clamps, wedges, shims, spacer plates and other devices for
aligning the welding joints will be provided on site including all lifting tackles.

6.5

AFC drawing checked and verified by CONSORTIUM shall be used.

6.6

Prior to erection, the centre slope shall be checked as per approved drawing. The
dimensions and elevations of the tank foundation as well as the correct orientation for
starting point shall be checked. Ensure that the foundation work has been formally
accepted by KNMPESB and CONSORTIUM before proceeding with the tank erection.
A release note shall be obtained from civil discipline on the handover of tank
foundation.

6.7

Prior to erection the centreline of the tank will be marked on the foundation as well as
the four points along the circumference at 0, 90, 180 and 270 degrees by
CONSORTIUM surveyor.

6.8

Elevation reference benchmark will be establish and set out on site. Plates and structural
materials intended for tank erection will be laid properly on the ground with proper
support and protection for not direct contact to the ground.

5.9

All the plate material shall be check for dimensional accuracy and reported in the
Applicable Inspection Report (Appendix I)

METHOD STATEMENT FOR

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ROOF STORAGE TANK

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Before tanks erection started, foundation shall be checked by the tank

builder with foundations contractor, and CLIENT to make sure that the
foundation are according to specification requirement. If there were some
obstacles on foundation to erecting of the tank, such foundation should be
repaired by foundation contractor. The foundation shall be marked on four
position (0, 90, 180 and 270) and will be done by foundation contractor or
CLIENT. The item to be inspection of foundation are Dimension, Flatness,
Levelness and sump location.

7.0 TANK ERECTION METHOD

All attached material for tank erection such like Blank Nut, U Bracket, and Shim Plate
material must be stainless steel but for Strong Back, Wedge, and Finger Pin just coated by
paint. (Refer Appendix 2)

7.1 Erection of Annular Plate

7.2

7.1.1

Backing strip shall be fitted and tack welded to the underside of each annular
plate on the same side as per approved drawings by qualified welder.

7.1.2

Annular plates, shall be laid in clock wise and fit-up as per approved drawings
with specified root gap, etc. Check shall be carried out to ensure the laid bottom
plate diameter is as specified in the respective tank approved drawing

7.1.3

Sequence of welding shall be performed in a correct manner. Necessary jigs

and fixture shall be provided to minimize the distortion due to weld shrinkage.

7.1.4

After completion of welding, all butt weld annular joint wherein shell plate will be
resting shall be ground smooth. The outer edge shall be radiographed and the
remaining potion of these joints shall be vacuum tested.

Erection of Bottom Plate

7.2.1

The bottom plate shall be arranged in accordance with Bottom Plate

METHOD STATEMENT FOR

ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK

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Drawing and Orientation Drawing.

7.2.2

First Lay down, the sketches plate, start from centre through to the
four direction angle (0, 90, 180 & 270).

7.2.3

The bottom centre plate shall be laid on the centre point which had
been
marked by stretching piano wires crosswise above the
foundation. Centre bottom plates which will be basis for laying
other plates.

7.2.4 The arrangement of bottom plates shall be laid out from centre to
outward and tack-welded in surface to be straight as shown attached

figure. Tack welds shall be 1.18 inch long or more on 1ft - 7.68 inch
pitch.
7.2.5 For three laps joint, after finished first layer welding, checked welding
line using Dye Penetrate Test or Vacuum Box Test (Section V, article 6,
of the ASME Code). Bottom plates shall be assembled and tack-welded
using special jigs for anti-distortion if necessary. Weld sketches plates
which shell plate will be laid long of weld 7.87 inch (min.) from out
to inward.
7.2.6 At the proper welding, the Vertical joints of 'V' blocks shall be welded
first. Lapped plates shall be in close contact during welding. After the
Vertical joints of 'V' blocks are welded, the Horizontal joints 'H' blocks
shall be made.
7.2.7 Care shall be exercised during welding of bottom plates to assure
minimum distortion and uniform lapping with as possible, plates
shall be held in close construction at all lap joint.
7.2.8 After completion of welding works of bottom, tested using Vacuum
Box and Soap suds to all welding line with a vacuum of 5 to 7 psi.
7.3

Erection of Shell Plate

7.3.1 First Course The shell circle line for erection shall be drawn on the
bottom plates and punched equally by number of shell plates.

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7.3.2 When the assembling of the first ring have completed, the vertical
joints shall be tack-welded from inside to outside.
7.3.3 After completion of the tack-welded on the vertical joints, the level of
top edge and plumbness shall be inspected with an instrument theodolite.
7.3.4 Check the item horizontal measuring
Temporary Assembling of 1st Course.

position

should

be After

7.3.5 The first continuous welding shall be made from the outside for
vertical joints and back weld from inside. The Welding from down
to up .The strong back or key plates shall be installed at right angle
with the weld line to prevent plate distortion during welding.
7.3.6

Prior to application of the first bead to the inside welding, the strong
back or key plates shall be removed and welded joints shall be
cleaned thoroughly in a manner that will leave the exposed surface
satisfactory for fusion the weld metal to be added. This cleaning shall
be made from inside by arc-air gouging and/ or grinding to evenly
and smoothly.

METHOD STATEMENT FOR

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ROOF STORAGE TANK

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7.3.7

Second Course, the scaffolding board shall be arranged with lugs and
brackets on both side of the first course. When the traveling
scaffolding is used the scaffolding shall be installed.

7.3.8

Vertical joints of the second course shall be assembled with the

match mark, which had stamped on the first course. Vertical joints
shall be matched accurately and retained in position with spacers

and stiffeners. Horizontal joints between first and second course shall
be matched to inside of each plates and retained in position with
spacers and stiffeners.
7.3.9

After completion of second course installed, start welding of vertical

joints of second course in the same manner as the first course.

7.3.10 The welding of horizontal joints between first course and second
course shall be made the outside first, and being the stiffeners
removed. If there were some defect at first layer which shall be
hindrance to welding from inside, after that the reverse side of
horizontal joints shall be welded.
7.3.11

The fillet weld joint between shell plate and bottom plate shall be
welded after second or third course shell plate is assembled.

7.3.12

Third and Upper Course, third and upper course shall be assembled
in the same manner as the second course. The temporary assembling
of each course shall be completed in the day, and the maximum
allowable numbers of shell course to be assembled temporarily
shall be 3 (three) courses in case of the plate used 8 (eight) feet
width and 4 (four) courses in case of the plates used 6 (six) feet
width.

7.3.13

The vertical joints of third course shall be welded before the

welding of horizontal joints between second and third course.
Owing to circumstances of erection schedule, welding of vertical
joints of 2 (two) or 3 (three) courses may be proceeded prior to
welding of horizontal joints.

7.3.14

Assembling and welding of other upper courses shall be made as the

same manner as stated before. In principle, shell plates which is
higher than 5th courses shall be assembled and welded one by one
course. If there were some undesirable phenomenon like a settlement
of foundation during the shell assembling and welding, the level
should be measured.

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7.3.15

Provision for Wind Load, whenever the strong winds is foreknow

to blow during temporary assembling, following provisions shall
be made.

7.3.16

When the typhoon is anticipated to approaching during the

assembling of the shell plates higher than 4th course, the plates
higher than 4th course to be assembled temporarily shall be taken
down to the ground.

7.3.17

7.3.18

7.4

If the shell plate have been assembled up to 4th course, the channel
stiffener ring shall be installed by clamping on the top periphery. The
plate shall also be tied to supports on grounds by wire ropes.
Top Angle, top angle shall be assembled and tack-welded after the
welding of vertical joints of the shell finally and grind smoothly
of vertical weld to pass through top angle. The horizontal joints
between top angle and shell shall be welded finally.

INSTALLATION ROOF STRUCTURE

7.4.1

Installation of Cone Roof Installation of Rafter Lug: Mark the

position of rafter lug on internal surface of top course shell
plate and then welded there to.

7.4.2

Roof Plates, roof plates shall be installed in accordance with

drawing after all roof structure bolted and welded completely.

7.4.3

Roof plates shall be laid out and tack-welded using special jigs
for anti- distortion if necessary. Tack-welds shall be made not
less than 1 inch long on 20 inch center.

7.4.4

At the continuous welding, transverse joints shall be welded first.

The welding shall be started at the center of plate width and
proceeded outwards symmetrically. When all transverse joints are
welded, welding of the longitudinal joints shall be made from
center to outward in a same manner as the transverse joints,
circumferential joints between roof plates and top angle shall be
welded finally.
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INSTALLATION OF ACCESSORIES & TANK APPURTENANCES

Each tank accessories and appurtenances shall be assembled and installed

in accordance with the applicable construction drawings which it have an
Approval for Construction status.
6.4.1

Nozzles & Manhole

Lay out position of Nozzles/Manhole on the shell plate and roof

plate. Check orientation, elevation and radius/diameter every
nozzles. After approved by inspector, cut the marked area and set
up reinforcing plate for each nozzles Fit up Nozzles and use
temporary support for neck nozzles and also check projection
flange from shell plate. Weld joint neck nozzles to shell from
inside and outside tank and weld reinforcing plate to shell plate
6.4.2

Roof Handrail
Lay out position of all post handrail at around top roof plate,
set up and weld each post handrail to roof plate, set up and weld pipe
handrail (already bended) on the top post handrail. Set up and weld
pipe handrail as middle handrail on the middle of the post handrail.
Set up and weld flat bar as bottom handrail with distance 100 mm
from roof plate on the bottom post handrail.

6.5

ASSEMBLING OF STEEL STRUCTURES AND APPURTENANCES

6.5.1

All appurtenances will be assembled and installed in according with AFC

drawing within tolerance specified in PTS 64.51.01.31 (Standard Vertical
Tanks Field Erection & Testing).

6.5.2 The shell manhole opening will be made after adjustment of the level,
verticality and roundness are completed, prior to the installation of 2nd course
shell plates.
6.5.3

Cutting of holes for nozzles will be made upon completion of the welding of
bottom to shell plate and upon approval by AIT representative after
inspection.

6.5.4 When welding the manhole and nozzles, the shell plate will be
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reinforced with strong back to avoid possible distortion and deformation.

7.0 WELDING SEQUENCE

7.1

Welding sequence of bottom plates, shell plates and roof plates shall be as per
AFC drawing (see appendix)

7.2

Manual Welding

Each welding procedure shall be qualified in accordance with the latest

practice as given in applicable rule of ASME Section IX Welding and
Brazing Qualification, or if other pre-qualified welding procedure that meets
the project requirements is available shall be submitted to Owner for
approval.
7.3

Temporary Welding
Holes in plate works to assist erection are not permitted. Lugs, nuts clamps
and other devices required only for the erection purposes may be attached to
the tank plates by welding. All these attachments must be removed, and
any noticeable projection of weld metal remains shall be carefully grind
and chipped away. Plates must not be gouged or torn in the process of
removing attachments. Any indentation caused thereby must be filled with
weld metal and grind flush with the plate surface.

7.4

Weather Control
Welding shall not be carried out when the surfaces to be welded are wet,
nor when rain or high winds are blowing, unless the welder or welding
operator and the work are properly shielded

7.5 Tack Welds Control

All the tack welding directly involved in permanent components of tanks
shall be done by the qualified welder in accordance with approved
WPS/PQR. The tack welds used in the vertical joints between shell plates
and in the horizontal joint between the bottom course of shell plates and the
bottom plates during the assembly of the tank, shall be removed and shall
not remain in the finished joints.

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7.6 Electrodes and Welding Materials

Electrodes, flux and wire shall be stored in their original packets or cartoon
in a dry place adequately protected from weather effects. If the electrodes
become damp but are not otherwise damaged they may be used only after
being dried out in a manner approved by the electrode manufacturers. Any
electrodes which have areas of the coating broken away or damaged shall be

discarded. An oven shall be available to ensure the use of dry electrodes in

accordance with the recommendation of the electrode manufacturer

8.0 INSPECTION
8.1

Inspection shall be carried as per Inspection and Test Plan and other applicable
Procedures.

9.0 LEAK TEST

9.1
Leak test shall be carried out as per approved Full Water Test Procedure
(KPE1011020- Q-P-006).

METHOD STATEMENT FOR

ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK

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APPENDIX I
(APPLICABLE INSPECTION FORMS)

KNM Petrosab Engineering Sdn Bhd

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METHOD STATEMENT FOR

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APPENDIX II
(SKETCHES ATTACHMENT)

KNM Petrosab Engineering Sdn Bhd

K1202107

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METHOD STATEMENT FOR

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INSTALLATION OF FIXED
ROOF STORAGE TANK

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REVISION
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APPENDIX III
(STRUCTURAL CACULATION FOR GONDOLA CAGE)

KNM Petrosab Engineering Sdn Bhd

KNM Petrosab Engineering Sdn Bhd