Method Statement For Tank Survey (MFL) and Repair
Method Statement For Tank Survey (MFL) and Repair
Document No.:01-072-00
CONTRACT 560-S28
CORROSION REPAIR AND PROTECTION
WORKS
TABLE OF CONTENTS
1.0 PURPOSE 03
2.0 SCOPE OF WORK 03
3.0 REFERENCES 03
4.0 PLANTS, EQUIPMENT AND MATERIALS 03
4.1 PLANT AND EQUIPMENTS 03
4.2 MATERIALS 03
5.0. SITE PLANNING AND PREPARATION 04
6.0 WORK PROCEDURE 04
6.1 PREPARATION 04
6.2 INSTALLATION 04
6.3 REMOVAL OF FORMS 05
6.4 SITE CLEAN-UP AND RESTORATION 06
6.5 SITE WELFARE 06
6.6 ORGANISATION, RESPONSIBILITY & SUPERVISION 06
6.7 WORK FORCE 07
7.0 HEALTH AND SAFETY 07
7.1. RISK ASSESSMENT 07
7.2 ENVIRONMENTAL SAFETY & HEALTH CONTRACTOR REQUIREMENTS 07
7.3. PROTECTIVE AND SAFETY EQUIPMENT 07
7.4. CONTRACTUAL REQUIREMENT 07
7.5. INFORMATION TO PERSONNEL 08
7.6. EMERGENCY PROCEDURE 08
7.7. PERMITS REQUIREMENT 08
8.0 ENVIRONMENTAL ISSUES 08
8.1. ENVIRONMENTAL IMPACT ASSESSMENT 08
9.0 QUALITY CONTROL 09
9.1. CONTRACTUAL REQUIREMENTS 09
9.2. CRITICAL WORKS 09
9.3. INSPECTION AND TESTING 09
9.4. REQUEST FOR INSPECTION (RFI) 09
9.5. FOLLOW UP AND EVALUATION 09
9.6 BEFORE CONCRETING 09
9.7 DURING AND AFTER CONCRETING 09
10.0 SAFETY ACTION PLAN 10
11.0 CONFIRMATION OF INSTRUCTIONS TO OPERATIVES 10
12.0 APPENDICES 10
1.0 PURPOSE
The intent of this document is to provide a complete Method Statement for the use of materials,
equipment, tools and plants; it includes the manpower and construction methodology in compliance
with RC requirements, drawings and technical specification with safety measures and quality control.
2.0 SCOPE OF WORK
The Royal Commission has identified 22 irrigation water tanks under said contract for repair and
coating which are located throughout the Jubail Industrial City. The Tanks are circular in section. Some
of them are made of complete steel while some are constructed of reinforced concrete floor and steel
shell. Due to aging, the internal surface of the tanks needs to be analyzed by magnetic flux leakage
technique followed by ultrasound technique for plate thickness. The patch repair of floor plates after
survey report is approved by RC and coating of internal surfaces of the tanks is also included in the
scope of work.
Refer Appendix-3 for the list of sites and Tanks details where the work is to be carried out.
3.0 REFERENCES
The following documents has mainly been used as reference in the preparation of this Method
Statement
CONTRACT DOCUMENT
APPROVED CONSTRUCTION EH&S PLAN (CODE-1)
METHOD STATEMENT FOR CONFINED SPACE (CODE-1)
RC IFC 560-801-20TY-CE-002
RC IFC 560-801-20TY-CE-029: LOCATION PLAN AND AS BUILD DETAILS OF STEEL TANKS
RC IFC 560-801-20TY-CE-030 : REPAIR DETAILS OF STEEL TANKS
RC GLS SEC. 09960 HIGH-PERFORMANCE COATINGS
RC GLS SEC 05120 STRUCTURAL STEEL
RC GLS SEC 05540 FLOOR PLATES
1. Encroachment Permit
2. Work Permit
3. Hot Works
4. Confined Space Permit
4.2 MATERIALS
Following materials will be used at the site
1. Scaffolding pipes
2. C-Clamps
3. Joint clamp
4. Levelling plump
5. Hand Level
6. Right angle
7. Warning Tape
8. U-Jacks
9. 2”x2” Timbers
10. 2”x4” Timbers
11. Ladders
12. Toe Boards
13. Welding accessories
14. RC approved coating Materials
15. Approved epoxy filler for filling pits on steel surfaces
Material handling and delivery on site
Materials will be delivered and received in the lay down area store room, in secured and controlled
room, or temporary lay down area at site. For the ready mix concrete it will be deliver on site by transit
mixer and it will be poured using a concrete pump.
and rescue procedures must be in attendance and continuously monitor the workers in the confined
space. At all times, the standby worker must be prepared and be appropriately equipped to carry out
rescue. Adequate provision should be made for the continuity of supervision at shift changeover or if
work continues outside normal hours.
A communication system must be provided:
From the worksite to outside rescue agencies.
In place between the worker in the confined space and the standby worker. This may be visual, two-
way radios, or hard line communications.
5.8 OTHER PRECAUTIONS.
Barricades shall be provided to keep vehicles and pedestrian traffic clear of the area, as required.
Adequate fire-fighting equipment shall be readily available. Special non-sparking (non-ferrous) tools
should be used where necessary. Lights and other electrical equipment must meet the requirements of
the RC Guideline and Specification. Ground fault circuit interrupters may be used as an additional
protection for operators of electrical equipment.
6.0 WORK PROCEDURE
Following major activities / steps are involved for complete repair of the Tanks.
6.1 TANK SURVEY USING MFL AND ULTRASOUND TECHNIQUE
INTRODUCTION TO MFLTECHNIQUE
A ferromagnetic specimen is magnetised and depending upon the level of induced flux density,
magnetic flux leakage due to both near- and far-surface flaws is detected by the voltage induced in
a detector coil or a Hall effect element, which is traversed over the surface of the specimen. This
method is not limited to surface-breaking or near-surface flaws, but actually becomes increasingly
sensitive to far-surface flaws with increasing levels of magnetisation. Also, the output from the
detector can be amplified, filtered, digitised, etc and stored to produce automated inspection
systems.
INTRODUCTION TO ULTRASONIC TECHNIQUE
Ultrasonic methods of NDT use beams of mechanical waves (vibrations) of short wavelength and
high-frequency, transmitted from a small probe and detected by the same or other probes. Such
mechanical waves can travel large distances in fine-grain metal, in the form of a divergent wave
with progressive attenuation.
The frequency is in the range 0.1 to 20 MHz and the wavelength in the range 1 to 10 mm. The
velocity depends on the material and is in the range 1000-6000 m/s.
The technique detects internal, hidden discontinuities that may be deep below the surface.
Transducers and coupling wedges are available to generate waves of several types, including
longitudinal, shear and surface waves. This applications is very common for internal testing of thin
plate thickness of steel tank
PROCEDURE
The bottom plate of steel tank will be inspected by this technique. The flaw models for pitting and
local corrosion in tank floors may be a series of flat-bottomed cylindrical holes and rectangular
grooves having various widths and depths. The magnetization characteristic curve for the steel
plates will be examined and the value of saturated magnetic flux density (Bs) will be estimated (T)
for the plain carbon steel.
The experimental setup consisting of an electrically magnetizing yoke, a magnetic sensor, a
controllable sensor positioned and test specimen is shown in Fig.1.
The measurements of magnetic leakage flux density distribution will be done using a Gaussmeter and the
sensor head for which consist of an axial type Hall probe which has an active area of 0.1 mm ´ 0.1 mm and
a thickness of 0.1 mm. The specimens will be magnetized by direct current at a constant average magnetic
flux density. This can be checked by using a search coil and a flux meter. The Hall probe scans across the
center of flaws by taking small precise step using a computer controllable positioning motor. At each step,
the horizontal (Bx) and vertical (By) components of magnetic leakage flux density in the upper spatial
domain can be accurately measured. Then, the acquired data of Bx and By are stored into a personal
computer, for the correction of background noise due to stray field arising immediately from the
magnetizing yoke. In this experiment, the lift off value, which is defined as a distance from the upper-
surface of test specimen to the central position of Hall probe, is set to be constant. This "lift off" is denoted
by "y" mm in this paper.
Measurements of the magnetic flux density (Bx and By) at the lift off value y=1.0 mm in the upper spatial
domain can be done by scanning with the Hall probe across the center of flaws. After the corrections of
background noise, the distribution profiles of Bx and By vs sensor's position were obtained. Some examples
of the results on the horizontal component of magnetic leakage field (Bx) are shown in Fig.2 and Fig.3 for
various sizes of flaws.
INVESTIGATION RESULTS
The Coloured continuous scanning of the floor showing remaining the thickness corresponding to
20%, 40%, 60%m 80% thickness loss due to corrosion will be submitted to Royal Commission.
The area of less than 4mm thickness remaining on the floor of the tank is recommended for patch
repair.
6.3.1 Remove the internal coating by light grit blasting.(SSPC-SP5, White metal blast cleaning)
6.3.2 Grid blasting on concrete surface will be avoided
6.3.3 Test the prepared surface to anchor profile which shall be in the range of 35-75 micron
Welfare facilities on site shall be provided like rest areas, toilet or washrooms, shaded area, chilled
water dispensing area, smoking area, prayer area.
8.0 HEALTH AND SAFETY
8.1 RISK ASSESSMENT
Detailed Risk assessment for all activities is provided in the Appendix-2
Police — 999
Ambulance — 997
Industrial security — (03) 341 7777
Fire brigade — 998
Waste water — (03) 341 0109
SCECO — (03) 341 7341
Potable water — (03) 341 6095
5. Read and understand the instructions attached to the air bottle trolley.
Those names listed below confirm receipt of the method statement and have had the contents
explained to them/understand it and are aware of the site ES&H requirements.
Note to contractor supervisor – Any significant change from this method statement requires it to be
revised and resubmitted to OBI before work can commence.
13.0 APPENDICES
APPENDIX-1 RISK ASSESSMENTS
APPENDIX-2 CONFINED SPACE ENTRY PERMIT
APPENDIX-4 CONFINED SPACE ENTRY LOG SHEET
(MANHOLE/TANKS)
APPENDIX-5 CONFINED SPACE MONITORING SHEET
APPENDIX-6 COLD WORK PERMIT
APPENDIX-7 HOT WORK PERMIT
APPENDIX-7 CONFINED SPACE AWARENESS TRAINING