METHOD STATEMENT FOR ABOVE GROUND TANK ERECTION 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
REVISION HISTORY
 
 
 
Rev. Date Nr. of sheets Description
   
 

       
       
       
       
       

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Table of Contents
 
1. DESCRIPTION OF THE PROJECT ............................................................................................ 4
 
1.1. GENERAL............................................................................................................................... 4
1.2. ORGANIZATION.............................................................................................................................. 4
1.3. SCOPE OF WORK........................................................................................................................................................... 5
1.4. ENVIRONMENTAL CONSIDERATION ................................................................................ 5
1.5. ABBREVIATION ..................................................................................................................... 5
1.6. RESPONSIBILITIES ............................................................................................................... 6
1.6.1 Site Manager (SM) .......................................................................................................... 6
1.6.2 Construction Manager (CM).......................................................................................... 6
1.6.3 Site Project Controller (SPC) ........................................................................................ 6
1.6.4 QA/QC Manager (QA/QC) .............................................................................................. 6
1.6.5 Material Manager (MTM) ................................................................................................ 6
1.6.6 Mechanical Engineer (SME) .......................................................................................... 6
1.6.7 QC Inspectors (QCI)....................................................................................................... 7
1.6.8 Welding Engineer........................................................................................................... 7
1.6.9 HSE Manager .................................................................................................................. 7
1.6.10 HSE Supervisor .............................................................................................................. 7
2. MATERIALS................................................................................................................................. 8
 
3. ERECTION PROCEDURE ............................................................................................................8
3.1 Foundation……………………………………………………………………………………………...8
3.2 Bottom Plates…………………………………………………………………………………………...8
3.3 Shell Plates……………………………………………………………………………………………..10
3.4 Roof Structure & Roof Plate……………………………………………………………………….....14
3.5 Clean Up…………………………………………………………………………………...…………...16
 
4. WELDING.................................................................................................................................... 16
 
5. INSPECTION AND TESTING...................................................................................................... 17
 
5.1 Foundation Receiving Inspection ........................................................................................... 17
5.2 Orientation Check…………………………………………………………………………………...17
5.3 Dimension Inspection of Tank Shell……………………………………………………………….17
5.4 Local Deviation Check ……………..……………………………………………………………….18
5.5 Vacuum Box Test (VBT)…………………………………………………………………………….18
5.6 Air Leak Test………………………………………………………………………………………….18
5.7 Repair & Re-Examination…………………………………………………………………………...18
 
6. WELD INSPECTION ................................................................................................................... 18
 
6.1 Welder Qualification..............................................................................................................18
6.2 Visual Inspection of Welds ..................................................................................................... 19
 
7. NONDESTRUCTIVE EXAMINATION (NDE)............................................................................... 19
 
7.1 NDE Procedure ...................................................................................................................... 19
7.2 NDE Operator Qualification....................................................................................................... 19
7.3 Radiographic Examination (RT) ............................................................................................ 19
7.4 Magnetic Particle Examination (MT) / Liquid Pentrant Examination(PT).............................. 20

8. HYDROSTATIC TEST AND SETTLEMENT INSPECTION........................................................ 20

 
8.1 Hydrostatic Test.................................................................................................................... 20
8.2 Foundation Settlement .......................................................................................................... 21
 
9. BLASTING & PAINTING WORKS ............................................................................................. 21
 

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10. INSULATION WORKS........................................................................................................... 21

11. ERECTION SEQUENCE .......................................................................................................... 22

 
12. RIGGING PLAN ...................................................................................................................... 23
12.1 General……………………………………………………………………………………….…..23
12.2 Rigging Hardware…………………………………………………………………………….…23
12.3 Typical Lifting Arrangements…….………………………………………………………….…24
12.4 Rigging Material Selection……………………………………………………………………..27
12.5 Lifting & Handling Equipment Selection………………………………………………….…..29
12.6 Pre-Planning of Lifting……………………………………………………………………….…29
12.7 Set-Up of Lifting Equipment…………………………………………………………………...29
 
13. CONSTRUCTION EQUIPMENT .............................................................................................30
           13.1 Crane & Forklift ...............................................................................................................30
13.2 Electricity ........................................................................................................................30
13.3 Fire prevention ...............................................................................................................30
 

14. QUALITY CONTROL ............................................................................................................... 31

 
15. HSE PLAN ............................................................................................................................... 32
 
15.1 General .................................................................................................................................... 32
15.2 General requirement .............................................................................................................. 32
15.3 EMERGENCY PLAN ............................................................................................................... 33
15.4 EVACUATION PLAN............................................................................................................... 33
15.5 HSE CONSIDERATIONS ........................................................................................................ 34
 
16. RISK ASSESSMENT...............................................................................................................35
 
16.1 RISK MITIGATION AND CONTROL MESURES.....................................................................35

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1. DESCRIPTION OF THE PROJECT

 
1.1. GENERAL  
   
  PROJECT NAME :
CONTRACTOR :
COMPANY :

 
 
1.2. ORGANIZATION
 
Site Manager

 
 
 
 
Construction Manager  
 
   
  QA / QC HSE
 
 
MECH. ENGINEER
O
 
 
 
 
SUB-CON.

 
 
 
 
MECH. MANAGER MECH. MANAGER QA / QC HSE

4 
 
 
 

1.3. SCOPE OF WORK

 
This method statement covers the minimum requirements for Erection of above Ground
Steel tank. The CONTRACTOR shall be responsible for all of the erection works.
 
 
1.4 ENVIRONMENTAL CONSIDERATION
 
As per the Site Survey, The site is relatively flat and no slopes were detected, so slope
instability & landslides are unlikely to take place.
 
1.5 ABBREVIATION
 
CLIENT
  Contractor
  SM
  CM
  SPC
  QA\QC
  MTM
  SME
  QCI

5 
 
 
 

1.6 RESPONSIBILITIES
 
1.6.1 Site Manager (SM)
 
 
Site Manager is responsible for the overall erection activities to be carried out during
the project execution of scope of work and for implementation of this procedure.
He shall be responsible for ensuring that all recommendations from any incident,
Near misses are investigated and recommendations are implemented.
 
 
1.6.2 Construction Manager (CM)
 
CM report to SM and is responsible for overall construction activities, controlling,
advising and supervision the erection crew to see the job on progress with proper
quality, safe work environment and completion on time.
 
1.6.3 Site Project Controller (SPC)
 
 
SPC, he report to SM and shall be responsible for planning, and scheduling of all
installation activities on a daily basis in co-ordination with Site Manager and
Construction Manager. He is also responsible for monitoring and preparation of
weekly progress reports.
 
1.6.4 QA/QC Manager (QA/QC)
 
QA/QC Manager report to SM and shall be responsible for all Quality activities related
to the Installation of equipment including the administration of non- conformance
management in close co-operation with various related departments. He is also
responsible for the supervision of all related records / Reports and Quality Control.
 
1.6.5 Material Manager (MTM)
 
 
MTM He report to SM and is responsible for receipt, storage, and issue of all project
materials according to the planning and scheduling of Installation activities.
 
1.6.6 Mechanical Engineer (SME)
 
SME He report to CM and is responsible for the preparation of all
drawings, resolving all technical problems arising during equipment erection activities.
He is also responsible for coordinating with Company engineers / Supervisors for
resolving Technical Queries.
 
1.6.7 QC Inspectors (QCI)
 
 
QC Inspectors They report to QA/QC Manager and are responsible for all quality
control activities on a daily basis including the inspection at various stages (before,
during and after the execution of activities), traceability maintenance, preparation of
quality records.

6 
 
 
 

1.6.8 Welding Engineer

 
 
Engineer the overall field welding works of water tanks, including coordination and
arrangement of inspection with the erection supervisor in accordance with this
procedures and job specification.
 
 
1.6.9 HSE Manager
 
 
HSE Manager report to SM and is responsible for Ensuring compliance of Health,
Safety and Environment during erection and including safety plan and direct safety
training.
 
He is responsible for ensuring that site management and supervisors correctly select
and maintain safety and protective equipment within the requirements of the project.
 
He is responsible for the investigation for all accidents and its causes and shall
recommend preventive measures.
 
1.6.10 HSE Supervisor
 
HSE supervisor, He report to HSE Manager and is responsible for but not limited to
the following:
 
*Safety Policy
 
(1) Personal Protective Equipment(PPE) shall be issued to all workers such as
safety shoes, helmets, working gloves, earplug, safety goggles(if required)
and safety harness for workers who will be assigned in elevated places 1.8
meter and above.
 
(2) All new recruits will undergo induction training and safety courses before they
are allowed to do work at Site
 
(3) All of work permit required for this working shall be applied and approved /
issued by Owner and all members of the work party shall have a Tool Box
Talk (TBT) outlining the requirements of the PTW and will sign their names on
said TBT form prior to commence the work
 
(4) The working area shall be cleared of non-essential personnel.
 
(5) High standards of housekeeping are understood to be indicative of a safe
workplace, during the course of all work activities workers shall continuously
clear away any waste materials from the task including general waste to a
designated place.
 
(6) CONTRACTOR understand that the environment is an important issue for
the project, and shall segregate the waste into the different waste streams
generated by the work scope of this procedure, in preparation.

7 
 
 
 

(7) Sand/concrete shall be moved to temporary disposal area defined by Owner

before move them to permanent disposal area.
 
(8) The working area shall be cleared to the satisfaction of company after work
completed.
 
2. MATERIALS
 
Material shall meet the requirement of the API 650 standards and drawings. Steel material
other than those listed in API 650 may be used, as permitted and approved by the Client.
 
3. ERECTION PROCEDURE
 
3.1. FOUNDATION
 
3.1.1 Check of foundation
 
Prior to commencing tank erection, the tank foundation shall be checked in
accordance with API 650 para. 7.5.5. And Inspection and Test Procedure.
 
3.1.2 During erection of the tank, the tank foundation settlement shall be checked under
the shell plate for keeping the tank within the allowable dimensional tolerances
specified code.
 
3.1.3 If there were some obstacles on foundation to erect of tanks, such foundation should
be reported immediately to Client.
 
3.2. BOTTOM PLATES
 
3.2.1 Arrangement of bottom plates
 
1) Preparation

a. P i a n o chords shall be stretched out on the X-X axis (0o – 180o) and the Y-Y (90°
– 270°) axis. The chords shall serve the datum lines in arrangement of the
bottom plates.
b. A bottom center plate shall be laid on the center point, which had been marked
by stretching piano wires crosswise above the foundation (Fig. 1)
 
2) Arrangement of bottom plates

a. For arranging the bottom plate, care shall be taken not to damage the foundation.
b. Bottom plates shall be arranged, starting from the tank center toward the
Circumference.
c. Before start of arrangement, each bottom plate shall be marked to show the line
for the required overlap.
d. After bottom plate has been arranged in place, it shall be tack-welded to such an
extent that the overlap line shall not move.
e. Tack welding at the time of arrangement shall be kept to minimum and shall be
removed prior to permanent welding.
 
 

8 
 
 
 
 

 
 
 

 
3.2.2 Welding of bottom plate.
 
2) Welding of bottom plate to bottom plate,
 
a. The welding shall be started from the center of tank toward the circumference.
b. The first welding shall be done about 300 mm pitch and 50 mm long
c. In three-plate lapping Joint, the upper plate shall be cut off, and then
Hammered and welded 1n close contactw1th all lap Joints
welding sequence (back step welding method) as well as the distortion
Preventive jigs shall be used (Fig. 5 & 6)

 
 
 
 

9 
 
 
 

3.3 SHELL PLATES

3.3.1 Shell plate assembly

 
1) First course
 
a. Prior to the assembly of the shell plates, the shell circular line shall be marked on
the bottom plate and annular plate for erection. The radius marking should be
larger than the drawing considering the slope of foundation. After marking, locate
each shell plate joints on the shell circular line. At the same time, auxiliary reference
line shall be marked on 100 mm inside the shell circular line for later shell plate
roundness check. (Fig. 7)
 

 
 
b. The flush setting appliance (metal clips) shall be tack-welded along inside of the
circular line at pitch of approx. 1000 mm and the first shell plates shall be hung
up and set at the position by crane, etc. In parallel with the plate positioning, the
plate shall be flush-set and temporarily assembled.
 
c. Temporary assembly between the first course shell plates and the annular plate
shall be fixed by the wedges and the metal clip guide and spacer. No tack
welding of shell plate to annular plate shall be applied.
 
d. After the erection but before welding, first course shell plates roundness, level
and plumpness shall be checked and adjusted to within tolerance. (Fig. 9)

10 
 
 
 
 

 
 
2) Second course
 
a. When the traveling scaffolding is used, the scaffoldings shall be installed as
shown in Fig.10.
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
b. Vertical joints of the second course shall be assembled with the match mark
which had stamped on the top of the first course in accordance with the drawing.
 
c. Vertical joints shall be matched accurately and retained in position with spacers
and key plates. (Fig. 11)

11 
 
 
 
 

 
d. Horizontal joints between first and second course shall be matched to centerline of
each plates and retained in position with spacers and stiffeners. (Fig. 12)
 

 
3) Third and upper courses
 
Third and upper courses shall be assembled in a 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 courses to be assembled temporary shall be
third courses.
If required, the temporary wind girder shall be arranged with lugs and brackets at
appropriate height.
 
3.3.2 Welding of shell plate
 
1) Welding of vertical joints of first course
 
a. The vertical joint alignment shall be performed outside of shell. After the gap is
adjusted as per approved drawings and WPS, the upper base plate and shell
plate are fixed by using the strong back key plate and the ball pin.
 
b. Vertical manual welding shall be performed inside shell plate.
 
c. Remove Jig and upper base plate after vertical manual welding.
 
 
 
2) Welding of Vertical joints of fourth (4) to five (5) course

12 
 
 
 
 
a. After the gap is adjusted 3mm ranged by using strong back, the alignment shall
be performed by tag welding outside shell plate.
 
b. The vertical welding shall be done by the manual welding inside shell plate.
 
c. After remove the outside shell jig, it should be done the grinding from outside
shell plate.
d. Outside manual welding.
 
e. All welding joints shall be performed cleaning works.
 
3) The welding of horizontal joints between first and second course shall be made the
outside first and being the stiffeners removed. After that, the inside of shell plate
shall be welded.
 
4) Welding joints of third and other upper courses
 
a. The vertical joints of third course shall be welded before the welding of horizontal
joints between second and third course.
 
b. Assembling and welding of other upper courses shall be made as a same
manner as stated above. In principle, shell plates which are higher than 5th course
shall be assembled and welded one by one course.
 
5) Reference welding sequence for shell plates is shown on Fig. 13
 

6) The top curb angle shall be attached to the upper edge of the shell plate by
continuous welding according to the drawing. The back face of the top angle shall be
flush with inside shell plate.
 
7) Temporary Welding Platform/Welding Car.

13 
 
 
 
 
All steel fully bolted and welded construction C/W one top lifting point for lifting and
positioning and a pair of steel rollers for the manually sliding of the welding car on
the periphery of the tank.
 
The welding car is with non-slip steel floor board and bolted with L-Beam of 50 x 50 x
6 mm at a span of 500 mm for securing of wooden plank of 200 mm x 1180 mm for
welder in standing position.
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Beam 50x50x6 mm
 
 
 
 
 
 
Roller
 
Wooden 400x1180 mm
 
Flat plate
 
 
 
 
3.4 ROOF STRUCTURE AND ROOF PLATE.
 
3.4.1 Assembling of roof structure (Fig. 16)
 
1) Assembling method may be used with block system and one by one system at the
same time.
 
2) After arrangement shall be fastened firmly by bolts and each other's, and then will be
assembled in each position at every member, welding shall not be done for further
level correction. The demolished opening shell plate shall be kept safe condition
after that all assembling is completed, dimensions must be checked by drawing.

14 
 
 
 
 

 
 
 
(Fig 16)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
3.4.2 Assembling of Roof plates
 
1) Roof plates shall be assembled on the structure in the manner to avoid excessive
unsymmetrical loads working from the center.
 
2) Roof plates shall be hung up and carried on the roof structure by crane or other
suitable facilities.
 
3) Arrangement of the roof plates shall start from the tank center toward the
circumference.
 
4) Roof plates shall not be welded to the roof supporting structure.
 
3.4.3 Welding of roof plates
 
1) The roof plates shall be tack-welded with 50 mm pitch.
 
2) After completion of tack welding, it shall be skip-welded with 1000 mm pitch, and the
welding length is about 50 mm.
 
3) Welder shall be distributed evenly on the roof plates.
 
4) Thereafter permanent welding shall be performed.
 
5) In order to prevent distortion due to welding, proper Jig's as used for bottom plates
shall applied.

15 
 
 
 

3.5 CLEAN-UP
 
a) Remove all legs from the tank. Care must be taken not to create holes in the
tank bottom. Legs should be chipped or arced off – DO NOT KNOCK OFF.
b) Make all repairs and pickups on bottom.
c) Complete all overhead welding on the roof after complying with testing
requirements. Check the contract drawings for any special welding.
d) Plumb and weld the pipe support sleeve extensions (if required). The sleeve
extensions must be properly aligned with the sleeves when fitted and tacked into
place. Make sure and extension is not welded to a support.
e) Remove all burrs and grind flush on top surface of roof.
f) Remove all weld slag, weld spatter, arc strikes, loose scale, oil, dirt, sand debris
and rubbish.
 
4. WELDING
 
4.1 The production welding shall be performed in accordance with the approved Welding
Procedure Specification.
 
4.2 The welder and welding operator shall be qualified in accordance with welder and
welding operator performance qualification procedure.
 
4.3 Welding consumable control shall be as per approved Welding Consumable Control
Procedure.
 
4.4 Welding defects shall be removed and repaired in accordance with welding repair
procedure.
 
4.5 The reinforcement of all butt joint welds on each side of the plate shall not be
exceeding the following thickness.
 
Plate Thickness, mm Maximum reinforcement Thickness, mm (inches)
( inches ) Vertical Joints Horizontal Joints
< 13 (1/2) 2.5 (3/32) 3.0 (1/8)
> 13 (1/2) to 25 (1) 3.0 (1/8) 5.0 (3/16)
> 25 (1) 5.0 (3/16) 6.0 (1/4)
 
4.6 The reinforcement need not be removed except to the extent that it exceeds the
maximum acceptable thickness, unless its removal is required.
 
 
 
4.7 All temporary welds for jigs and fixtures and construction platform erection shall be
engineered and the welding sequence, welding requirements shall be confirmed to
applicable standards and Client requirements.
                                                                                                                                                                                                                             

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5. INSPECTION AND TESTING

 
5.1 Foundation Receiving Inspection
 
 
QC personnel shall review the foundation inspection report provided from Construction
team. The actual foundation dimension (i.e., diameter, levelness, etc.) and benchmark
(i.e., tank center, 0, 90, 180, 270 degree mark) shall be checked against the inspection
report. The foundation surface shall be visually inspected to be free of any dent or bulging
and no scrap steel, concrete block or other obstacle shall be left on the surface of the
foundation.
 
Where a concrete ring wall is provided under the shell, the top of the ring wall shall be
level within +/-3mm in any 9m of the circumstance and within +/-6mm in the total
circumstance measured from the average elevation.
 
5.2 Orientation Check
 
 
At the time of primary laying-down or erection of main components such as shell, bottom
annular, sketch plate, bottom plate, QC personnel shall check those locations meet the
orientation drawings. Prior to the opening of shell plate for installation of nozzle/manholes,
their location and opening size shall be checked.
 
 
5.3 Dimension Inspection of Tank Shell
 
 
5.3.1 Level, Roundness and Plumpness Check of Lower Shell
 
After erection of the lowest shell course, and before starting welds of vertical joints, level,
roundness and verticality shall be checked to ensure that the tank will be completed
within the specified dimensional tolerances.
 
The top level shall be checked when the erection of each 1, 3, 5 course shell of
Foundation with Crushed Stone Ring wall and settlement shall be monitored.
 
5.3.2 Shell Roundness
 
On completion of shell to bottom annular (Sketch) weld, tank internal radius shall be
measured at 300 mm above the bottom corner weld.

The measurement shall not exceed the following tolerance as per API 650 paragraph
7.5.3.
 Radius Tolerance ± 13 mm for tank diameter range < 12 m.
 Radius Tolerance ± 19 mm for tank diameter range 12 to < 45 m
 Radius Tolerance ± 25 mm for tank diameter range 45 to < 75 m
 
5.3.3 Shell Plumpness
 
Plumpness of tank shell shall be inspected after completion of all shell welds. Out of
plumpness in each shell course is max.3mm.
The out of plumpness measured for shell top to bottom shall not exceed H/200 with a
maximum of 50mm.(“ H” means the total height of the tank)

17 
 
 
 

5.4 Local Deviation Check

 
Local deviation check shall be made, if there is any noticeable distortion after completion
of shell weld.
1) Peaking of the tank shell:
Deviation at vertical weld joint shall not exceed 13mm. Peaking at vertical weld joints
shall be determined using a horizontal sweep board 900mm long.
 
2) Banding of tank shell:
Deviation at horizontal weld joint shall not exceed 13mm. Banding at horizontal weld
joints shall be determined using a straight edge vertical sweep board 900mm long.
 
5.5 Vacuum Box Test (VBT) (As per API 650, para. 8.6)
 
1) Upon completion of welding of the tank bottom, the bottom weld and plate shall be
examined visually for any potential defects and leaks.
 
2) Vacuum testing is performed by means of a box with glass window in the top. The
open bottom is sealed against the tank surface by a sponge-rubber overlapping from
all four sides
 
3) The seam under test is coated with soapy water. The vacuum box is placed over the
coated part of the seam, and a vacuum is applied to the box.
 
4) VBT shall be performed for the required welds at vacuum pressure specified in the
applicable specification and/or drawings with minimum 5 second holding time.
 
5.6 Air Leak Test
 
After completion of construction, all nozzles and manholes reinforcement pad shall be
tested by applying up to 100 kPa (15 lbf/in.2) gauge pneumatic pressure between the tank
shell and the reinforcement pad, using soapsuds or other suitable means suitable for the
detection of leaks shall be applied. Air leak test will be carried out before Hydrostatic Test
M.T /P.T examination.
 
Any leakage observed shall be unacceptable.
- Each Reinforcing pad of nozzle and manhole
- Lap joint of cone roof
 
5.7 Repair and Re-examination
 
When any weld imperfection is judged to be repaired by welding, repair welding shall be
made in accordance with the applicable welding procedure specification. Repaired area
shall be re-examined by the same method originally taken.
 
 
6. WELD INSPECTION
 
6.1 Welder Qualification
 
 
All site welding shall be carried out by the qualified welders in accordance with ASME
Sec. IX and API Standard 650- 9.3.

18 
 
 
 

6.2 Visual Inspection of Welds

 
 
Regardless of any other method of examination used, the welds shall be subjected to
visual examination and be free from injurious defects and shall meet the followings.
1) Crack Not permitted, remove if any
2) Overlap Not to exceed 1.5mm
3) Undercut Not to exceed 0.4mm for vertical butt joints
Not to exceed 0.8mm for horizontal joints
4) Bead width un-uniformity Ap per Approved WPS
5) Bead height un-uniformity Not to exceed 3-5mm
6) Incomplete penetration and lack of fusion Not permitted
7) Insufficient toe length of fillet weld Add welding
8) Crater Remove
9) Spatter Remove
10) Thickness of reinforcement
 
Plate Thickness Vertical joints Horizontal joints
Up to 12.7mm 2.5mm 3.0mm
Over 12.7mm to 25.4mm 3.0mm 5.0mm
Over 25.4mm 5.0mm 6.0mm
 
 
7 NONDESTRUCTIVE EXAMINATION (NDE)
 
7.1 NDE Procedure
 
 
NDE shall be performed in accordance with ASME Sec Ⅴ, API 650 Section 8.1~8.4
and ASME Section VIII Div. 1
 
7.2 NDE Operator Qualification
 
 
NDE examiner shall be qualified in accordance with ASNT SNT-TC-1A or equivalent
internationally recognized qualification scheme and interpreted by ASNT SNT-TC-1A
Level II or Level Ⅲ.
NDE will be carried out by Sub-contractor.
 
7.3 Radiographic Examination (RT)
 
 
Radiographs shall be judged in accordance with ASME Section VIII Div. 1 paragraph
UW-51(b). The number and location of Radiographs shall be taken as specified in
8.1.2 of API 650.
 
1) Vertical joint;
One spot radiograph shall be taken in the first 3m of completed vertical joint of each
type and thickness, and one in each 30m thereafter, 25% of which shall be at
intersection.
2) Horizontal joint; one in the first 3m and one in each 60m thereafter.

19 
 
 
 

3) Vertical spot radiograph in each vertical seam in the lowest course shall be done,
and satisfy the requirements of above 1)
 
7.4 Magnetic Particle Examination (MT) / Liquid Penetrant Examination(PT)
 
MT or PT shall be applied upon the following the component welds.
- Nozzle/Manhole to Shell welds
- Annular plate
- Bottom plate
- Roof plate,
.
The acceptance standard of MT indications shall be in accordance with ASME
Section VIII Div. 1 Appendix 6, paragraph 6-3 and 6-4.
 
The acceptance standard of PT indications shall be in accordance with ASME
Section VIII Division 1 Appendix 8, paragraph 8-3, 8-4 and 8-5.
 
8 HYDROSTATIC TEST AND SETTLEMENT INSPECTION
 
8.1 Hydrostatic Test
 
 
Prior to the tank hydrostatic test, QC personnel shall ensure that all inspection and test
required by the inspection and test plan have been successfully completed. Hydrostatic
test shall be performed by filling water up to the maximum liquid level.
Care shall be taken the metal weather seal does not come out from the shell top angle
for tank.
 
During hydrostatic test of tank, roof drain valve of the tank shall be kept open and observe
for the leakage of test water into the drain system.
 
Tank settlement monitoring shall be performed throughout the water filling and
discharging.
The measurement frequency shall be as below.
 
a) Tank empty
b) Tank 25% full
c) Tank 50% full
d) Tank 75% full
e) Tank full
 
At least 24 hours after the tank has been filled to the maximum test height.

Test water shall be supplied by diesel engine pump from water tank lorry.

Water to be discharged from tank after hydrostatic test shall be throw away to suitable
oil field area.

20 
 
 
 

8.2 Foundation Settlement

 
During the hydrostatic (water) test, the foundation settlement shall be observed and
recorded by Contractor. For the purpose of elevation, with reference to a fixed bench
mark of permanent reference points on the tank shall be taken by the fabricator and
recorded before and during hydrostatic test.
 
9 BLASTING & PAINTING WORKS
 
 
Tank external and internal surface shall be painted in accordance with the painting
specification and surface of tank shall be cleaned with power tool before painting at
sites.
 
All tank plate surfaces shall be shop primed and/or painted in accordance with the
Painting specification at shop.
 
10 INSULATION WORKS
 
 
Tank external surfaces shall be insulated in accordance with the insulation
specification after hydrostatic test.
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

21 
 
 
 
 
 
11 ERECTION SEQUENCE
 
 
-
 
 
 
Grouting
 
 
 
Check of Foundation
 
 
 
Install and welding of Annular Plates
 
RT or UT
 
Install and welding of Bottom plates
 
Vacuum Test
 
Erection & Welding of 1st - last course
shell
 
NDE
 
Assembling of Roof Structure
 
 
 
Erection & Welding of Roof plate
 
Vacuum Test
 
Installation of Appurtenances
 
 
 
Installation of Heating Coil Support
for Tank Inside
 
 
 
Hydrostatic Test
 
 
 
Internal Painting
 
 
 
External Painting
 
 
 
Insulation  
   
  Calibration & Tank Inside Cathodic
  Protection System Power On
 
Final Inspection

22 
 
 
 

12. RIGGING PLAN

 
12.1 General
 
This rigging plan shall considers methods of eliminating hazards and controlling risks
that arise from the use of lifting gear on any project site and does not cover manual
handling.
 
Lifting gear selected for a lifting operation will be suitable for the activity it is to carryout,
free from defect and comply with current best standards. Lifting gear will be clearly
marked to indicate the Safe Working Loads (S.W.L.).
 
An initial thorough examination and test certificate of all lifting gear will be carried out
and supplied by the manufacturer. These certificates of conformity will be retained in a
register and copies will be kept with the lifting gear for inspection purposes.
 
Only qualified, knowledgeable employees are to be allowed to perform rigging tasks.
 
 
The competent person shall inspect all rigging before each use and remove any
defective equipment from service.
 
12.2 Rigging hardware
 
Rigging hardware shall be certified and rated for capacity, based on load and tested to
appropriate standards. The hardware must not be used to make lifts in excess of that
capacity.
 
Makeshift hooks, links or fasteners made from bolts, steel plate, rods etc., or other
such attachments shall not be used. Lifting fixtures must be constructed in accordance
with government requirements.
 
Rigging hardware may not be modified from its original design, unless certified as
identified above.

Rigging capacity charts shall conform to the appropriate standard capacity ratings.

Spreader Bars – are required to be certified and rated for capacity at working spans
and shall be clearly marked with their weight. This weight shall be added to the total lift
calculation.
 
 
The load must be attached to the hook by means of slings or other appropriate devices,
which shall be of sufficient size and condition.

23 
 
 
 

12.3 Typical Lifting Arrangements

 
Definition : the term “Sling” includes a wide safety variety of configurations for all fibre
ropes, chains and webs.
 
1) Single Vertical Hitch
 

 
The single vertical hitch can be used to support a load by a single vertical part or leg
of the sling. The total weight of the load is carried by a single leg ; the angle of the
left is 90 ° and the weight of load can equal the maximum safe working load of the
sling and fittings. The single vertical hitch provides absolutely no control over the
load because it permits rotation.
 
2) Multiple Vertical Hitches
 
Two, three of four single hitches can be used together to form a bridle hitch for hoisting
an object that has the necessary lifting lugs or attachments. A bridle hitch can be
used with a wide assortment of end fittings. It provides excellent load stability when the
load is distributed equally among the legs, the hook is directly over the center of
gravity of the load, and the load is raised lever. To distribute the load equally, It
may be necessary to adjust the leg lengths with turnbuckles. The sling angles must
be carefully determined to ensure that the individual legs are not overload.
 
 
 

24 
 
 
 

Unless the load is flexible, It cannot be assumed that a three –or four – leg hitch will
safety lift a load equal to the safe load on one leg multiplied by the number of legs.
Each leg may not be carrying its share of the load ; with slings having more than two
legs and a rigid load, two of the legs may be taking most of the load while the others
are only balancing it.
 

 
3) Single Basket Hitch
 
A single basket hitch can be used to support a load by attaching one end of a sling
to a hook, wrapping the sling around the load, and securing the other end to the
hook. It cannot be used on a load that is difficult to balance because the load can tilt
and slip out of the sling. Ensure that the load does not turn or slide along the rope
during a lift, because both the load and rope will be damaged.
 

 
 
 
 
 
 
 
 
 
 
 
 
 

25 
 
 
 
4) Double Basket Hitch
 
A double basket hitch consists of two single basket hitches passed under the load in
such a way that it properly balanced. The angle between the load and the sling should
be approximately 60 ° or greater to avoid slippage. Lower angles, not below
40 °, can be adopted providing an anti-slippage device is installed.
 
 
 

 
 
5) Single Choker Hitch
 
A single choker hitch forms a noose in the rope that tightens as the load is lifted.
Because it does not provide full 360° contact with the load, it should not be used to
lift loose bundles form which material can fall or loads that are difficult to balance.
The single chocker can also be doubled up as shown, to provide twice the capacity
or to turn a load.
 
 
 
 
 

 
 
 
 

26 
 
 
 
6) Double Choker Hitch
 
A double choker hitch consists of two single chocker attached to the load and spread
to provide load stability. Like the single choker, they do not grip the load completely,
but because the load is less likely to tip, they are better suited for handling bundles,
pipes, rods, etc.
 

 
 
 
12.4 Rigging Material Selection
 
 Fibre Rope Slings
 
Fibre rope slings are preferred for some applications because they are pliant, they
grip the load well, and they do not mar the surface of the load, they should only be
used on light loads, however, and must not be used on object that have sharp
edges capable of cutting the rope, or in applications where will be exposed to high
temperatures, severe abrasion or acids.
 
 Synthetic Webbing Slings
 

 
Synthetic webbing slings have a number of advantages for rigging purpose;
 
Their relative softness and width, as compared to fibre rope, wire rope or chain
sling, mean they have much less tendency to mar or scratch finely machined,
highly polished or painted surface, or to crush fragile objects.
Because of their flexibility, they tend to mold themselves to the shape of the
load.
They are not affected by moisture and certain chemicals.
Synthetic webbing slings are non-sparking and can be used safety in
explosive atmospheres.

27 
 
 
 
 

They minimize twisting and spinning during lifting

Their lightweight permits ease of rigging ; their softness precludes hand cuts
and minimizes the danger of harm from a bump by free-swinging sling.
They are elastic and stretch under load more than either wire rope or chain, and
are thus to absorb heavy shocks and cushion the load, Where sling stretching
must be minimized, a sling of larger load capacity or a polyester sling should
be used.
 
The capacities are also based on a 2 : 1 factor of safety, assuming that the end
fittings are of adequate strength.
 
 Chain Slings
 

 
Chain slings find application in those areas where the primary requirements are
ruggedness and resistance to abrasion and high temperatures.
 
The only chain suitable for overhead lifting is fabricated from alloy steel and identified
by a letter, usually A or 8, marked on each link.
 
 Wire Rope Slings
 
Steel wire rope slings have several advantages for lifting materials
 
Great strength and a minimum of weight are combined with flexibility. The breaking
of outer wires of impending failure. Reserve strength is provided because the inner
wires are protected by the outer wires and possess sufficient strength to carry the
load if a reasonable factor of safety is allowed for the sling.
 
Wire rope slings must be carefully selected for the application and service in which
they are to be placed. Refer to the learning package on wire rope for the appropriate
procedures and precautions.

28 
 
 
 
 

All wire rope slings should be made of improved plow steel and should have independent wire
rope cores to reduce the possibility of the rope being crushed in service.
 
12.5 Lifting and Handling Equipment Selection
 
Ensure that the crane and other lifting equipment have a minimum Safety Working
Load (SWL) in excess of the equipment weight.

All handling activities must be performed with extreme care and by qualified personnel. Basically,

cranes and, in general, each lifting equipment, shall be selected according to

the above lifting load data and to the distance of the areas (i.e. ; distance from receiving
area to the final assembly area)
 
As crane capacity (SWL) is depending on the crane outreach, a detailed study shall be done to
determine the site lifting plan.
 
12.6 Pre–planning of Lifting
 
The installer shall be responsible for obtaining the following as a minimum:
 
 Shipping and net weights of each separate component of the tank and accessories.
Refer to below load table on which are considered Critical Lift with the assigned location of
each box with reference to the tank packaging list prepared by the CONTRACTOR. Also
refer to Layout for the location of each items mentioned on the table.
 
 Providing all the information required for the installation of the Crane. Below is the the table
for the expected load at each point, and the center of gravity of a
50-ton and 30 ton Hydraulic Truck Crane.

12.7 Set-Up of Lifting Equipment

 
The crane shall be levelled on a firm supporting surface. Depending on the nature of the supporting
surface, it may be necessary to have structural supports under the outrigger pontoons or tires to
spread the load to a larger bearing surface. Refer to layout for the location of the Crane.
 
When making lifts on outriggers, all tires must be free of supporting surface. All outrigger
beams must be extended to the same length; fully retracted, intermediate extended, or fully
extended. The front bumper outrigger must be properly extended.
 
When operating on fully retracted outriggers, do not exceed 78° maximum boom angle with
counterweight. Loss of backward stability will occur causing a backward tipping condition.
 
 
Before swinging boom to over side position on tires, or on fully retracted outriggers where
capacities are not published, boom must be fully retracted and 45° boom angle maintained.
 
 
When installing or removing counterweights, crane must be on fully extended outriggers and boom
fully retracted.

Before setting up on intermediate outriggers, retracted outriggers, or tires, refer to Working

Range Diagrams and rated lifting capacities to determine allowable crane configurations

13.CONSTRUCTION EQUIPMENT

13.1 Crane & Forklift

 

 
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Crane & Fork-lifts are very useful on construction sites for material lifting and handling.
However Crane & Forklifts can be a leading cause of accidents when they are used improperly or
operated by unqualified personnel. Close attention must be given to operator training, routine
inception and maintenance of Equipment.
 
General requirements
 
a) Only qualified and trained persons holding a valid Iraqi operator’s license for the item of
equipment will be assigned to operate said equipment.
b) Equipment will be inspected and tested by an approved 3rd party inspection company
c) The lift capacity will be clearly marked on each equipment.
d) Each equipment will be equipped with a safety cage or bars as required to protect the
operator from falling objects.
e) Each equipment will be equipped with a limit switch to prevent over-travel of the hoist and
relief valve to prevent overloading conditions.
f) Each equipment will be equipped with automatic reversing alarm.
g) Each equipment will be equipped with a horn and front and reversing lights.
h) The use of fork extensions is prohibited unless the extensions are approved by and
designed as recommended by the manufacturer and inspected by an authorised 3rd party
inspection company.
i) Equipment will be properly maintained. Equipment with mechanical defects will be
removed from service until repaired and records kept of all said repairs.
 
13.2 Electricity

Electrical energy is used extensively to assist in the construction process. Electrical shock is a
regular cause of death on construction sites.
Fatalities occur on both high and low voltage electrical supplies, the common causes are:
Unauthorized/untrained people.
Damaged/faulty equipment, Poor insulation
Inadequate earthing methods,
Not following procedures for isolation, Excavation
works,
Persons working too close to 'Live' services
Only designated electricians will be permitted to energize/isolate electrical supplies
 
13.3 Fire prevention
 
Fire prevention means taking necessary action to prevent fire and explosion. One of the most
important parts of any job plan action is to eliminate the potential of accidental fire and explosion.
 
When the potential of fire and explosion is removed from the work or activity, a major hazard is
eliminated. This prevents injury to workmen, damage or loss to property.
 
Normally, portable fire extinguishers are adequate on construction sites. Other fire fighting services,
such as use of fire-water mains/hoses or fire trucks will also be needed.
 
13.3.1 FIRE EXTINGUISHERS
 
a) A multi-purpose class dry powder fire extinguisher will be provided for each and every work area,
they will be checked by Supervisory and Safety personnel everyday if used as equipment for a fire
watch and in other cases no less than weekly.
b) Fire extinguisher will be well maintained. Used or empty extinguisher will be immediately reserved and
replaced.
c) Fire extinguishers will not be used as doorstoppers.
 
14 QUALITY CONTROL
 
 
Contractor has a responsibility to establish Field QA/QC procedures including Site Welder control
in conjunction with the detailed construction plan, control all activities related to quality matter during
installation of fiscal metering.

 
Page 30 of 34 
 
 
 
The dedicated Contractor QC inspectors shall inspect and record the inspection during installation
of works
 
Quality Control activities will be performed during installation of equipment in accordance
with any specific procedure as minimum;
 
1) WPS/PQR
2) Welder Qualification Procedure
3) Piping Pressure Test Procedure
4) Visual Inspection Procedure for Piping
5) Non-conformance Procedure
6) Notification Of Inspection
7) General Weld Procedure
8) Weld Repair Procedure
9) Storage, Control & Distribution of Welding Material at Site
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
15 HSE PLAN
 
15.1 General
 
It is the Contractor’s responsibility to ensure that all its personnel, adhere to these requirements and
continuously strive to meet the highest HSE standards. The COMPANY HSE Integrated
Management System focuses on the delivery of excellent health, safety and environmental
performance during the design, procurement, construction, commissioning, maintenance and
operation of the projects. Specific attention will be given to those management processes for
identifying and managing Safety, Health, Environment and Operational risks. These will include
but not be limited to the management of:

 
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 Safety and accident prevention
 Plant and equipment integrity
Pollution prevention and environmental protection
Energy efficiency
Personal health and occupational
Physical security
Sustainable development
Accrued Dust
Contaminated Soil & Industrial waste
Exist pipeline Leakage
 
15.2 General requirement
 
The CONTRACTOR shall have an HSE Method Statement which satisfies the following
general requirements:
 
CONTRACTOR shall have an HSE Policy in place, reviewed and authorized by company and be
actively using a formal HSE Method Statement which demonstrate commitment to continuous
improvement and excellence in HSE issues and which satisfies all the appropriate elements of ISO
standards.
 
CONTRACTOR shall have a system to manage hazards in the workplace, which are associated
with the execution of the contracted activities, inclusive of SUB- CONTRACTOR activities.
 
CONTRACTOR shall have a system to manage environmental and health impacts of the activities
to be undertaken within the contract framework.
 
CONTRACTOR shall have controls implemented against the above hazards/impacts and, when
working at COMPANY controlled sites, those controls which are requested against hazards/impacts
identified already by the COMPANY and duly passed on to the CONTRACTOR.

CONTRACTOR shall ensure the use of trained personnel including HSE matters. CONTRACTOR

shall advise COMPANY of any revision or amendment to CONTRACTOR’s HSE MS

issued during the term of the contract.

 
CONTRACTOR shall review its HSE Method Statement at least annually and update it as necessary.
 

15.3 EMERGENCY PLAN

 
This process establishes the procedures to follow for a fast and effective response in dealing with
any emergency situations.
 
Emergency responsible person : HSE Deputy Manager :
Emergency Contact number : Firefighting contact number :
  : Police station contact number :
  : Security contact number :
  : Doctor Haydar Dhiaa?? :
  : Nurse :
1) Any emergency occurring on construction sites or at accommodation camps would have
serious consequences: people would be injured or even killed,
buildings/structures would be destroyed; plant and equipment would be damaged; production
would be held up and construction completion dates may not be met.
 

 
Page 32 of 34 
 
 
2) Such situations demand adequate protection, with rescue and relief measures to handle
emergency events safely, quickly and efficiently.
 
3) It is therefore necessary to ensure that all persons on site and at camps are aware of what they
have to do in the event of an emergency and response procedure the responsibilities and duties
of key personnel must be made.
 
4) Analysis of the emergency response procedure must be carried out by practical training
complete with a program of regular drills and exercised.
 
5) The procedure, in addition to the duties and responsibilities of key personnel and individuals
shall also describe the system of evacuation, firefighting, rescuing, searching and tackling other
types of emergencies. It shall also indicate the availability of facilities such as location of
firefighting equipment, assembly points, exits and access routes and the procedure to
arrange assistance if necessary from any outside agency.
 
 
15.4 EVACUATION PLAN
 
In the event of a fire, explosion, bomb threat or the need to evacuate the plant, the actions listed
below should be followed:
 
1. On sound of the alarm, stop all activities and vacate the building or area without delay, by the
nearest exit to the muster point or as directed by client representatives.
 
2. Move quickly, but do not run.
 
3. Do not return to a work area to collect belongings.
 
4. Do not overtake others along the route.
 
5. Assemble in the designated Assembly Point.
 
6. Do not enter the building or work area under any circumstances until the all clear is given.
 

15.5 HSE CONSIDERATIONS

 
The general scope of work includes supply, fabrication, construction, supervision, installation, Pre-
commissioning, Commissioning, assist to start-up and conduct performance tests of the work,
including all interface activities with CONTRACTOR, with the aim of assuring the efficient progress of
the work.
Throughout the phases of the work, the Contractor shall implement an HSE System to manage the
Health, Safety and Environmental activities and to ensure that the relevant targets are met in
accordance with the contract. The objectives of the HSE System are the following:
 
Comply with all applicable Health, Safety and Environmental Regulations; Coordinate
all safety related activities;
Adopt a positive, proactive, committed safety culture throughout all phases of the work.
 
Minimize the possible accidents and damage during all phases of the work and guarantee a
safe working environment for the workers;
Identify all potential hazards associated with the work and develop prevention, control and mitigation
measures to eliminate or minimize harm to people, damage to plant or equipment or adverse
environmental damage and implement a suitable plan to manage possible emergency situations.
SAFETY NOTES

 
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SAFETY HELMETS will be worn at all times.
 
Waterproof, oil resistant gloves and safety spectacles/goggles will be provided and worn by the
operatives as necessary.
 
SAFETY FOOTWEAR will be worn on site at all times that provides protection to toes and soles.
 
HIGH VISIBILITY garments will be worn at all times.
 
SAFETY HARNESS AND RESTRAINTS will be used for all work at height where the operative’s
feet are 1.5 meters or more above ground and the working platform is not secured with safety
barriers on ALL sides.
All heavy plant movement will be directed by an appointed and suitably trained banks man who will
be readily identifiable.
 
All reversing of HGV’s and concrete wagons will be directed by a banks man.
 
No substance will be used without COSHH assessment and the user(s) being made aware of the
requirements by the piling foreman, the MSDS shall be kept at the work location and at the
emergency first aid/clinic point. (See attached C O S H H assessments for information).
 
Machine drivers will accept only EMERGENCY STOP SIGNALS from persons other than the Banks
man for the particular operation.
 
Spill kits are situated in the container in the event of any diesel or hydraulic oil spills.
 
At the end of each day, the piling rig is to be either packed away ready for transport, or drilled into
the ground (as per the operating manual) in the event of high winds during none.

16 RISK ASSESSMENT

16.1 RISK MITIGATION AND CONTROL MESURES

 
The Project Risk Management approach adopted by the project is summarized below:
Determine how likely it is to occur
Evaluate the risks against assessment criteria
Document the findings
Implement suitable risk reduction measures
Ensure that the recommended measures are implemented and effective.
Reduce the probability of occurrence
Reduce the consequences
Plan for recovery in the event of a loss of control
The design considers all aspect of Health and safety on site especially during construction works
and integrated such requirements into the design, if associated risk and hazards cannot be eliminated
by design, mitigation procedures are invoking to reduce the severity and likelihood of the risks and
hazards to occur.  

 
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