Mabruk Reinstatement EPF

Mabruk Oil Project

Operations

Method Statement for Repair of Bolted Crude Oil Storage Tanks

TK-03 & TK-04

Clien SLB Vendo Status Date Revision memo Issued by Reviewed by Approved by
t Rev Rev r Rev

Saleem Fathi Shravan Kumar Nadjib

27-Apr- Issued for Zouaoui
00 A - IFI Saleh Singh
2025 Information API Inspector Site Mechanical Lead
Construction
Manager

Company Document Number: LY-MRP-71-SLB-PRC-MEC-xxxxxx

Contractor
This document is property Document
of the COMPANY Number:
and it shall not be disclosed toPF0014-SLB-MX-6180-xxxx
third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management SLB- System. When it is printed, it shall be considered as “For information only”.
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Vendor Document Number: NA
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 2 of 12

Revision History List

Contents

1. INTRODUCTION....................................................................................................................
1.1. PROJECT DESCRIPTION.................................................................................................
1.2. SCOPE...............................................................................................................................
1.3. PURPOSE..........................................................................................................................

2. DEFINITIONS AND ABBREVIATIONS.................................................................................

2.1. DEFINITIONS....................................................................................................................
2.2. ABBREVIATIONS..............................................................................................................

3. REFERENCES.......................................................................................................................
3.1. APPLICABLE SPECIFICATIONS......................................................................................
3.2. APPLICABLE CODE AND STANDARD............................................................................
3.3. ORDER OF PRECEDENCE..............................................................................................

4. METHODOLOGY...................................................................................................................
4.1. MATERIAL RECEIVING CHECK.......................................................................................
4.2. PREPARATORY ACTIVITIES...........................................................................................
4.3. INSPECTION, DISMANTLING & REPAIR SEQUENCE....................................................
4.3.1. GENERAL INSPECTION...................................................................................................
4.3.2. SHELL & BOTTOM REPAIRS...........................................................................................
4.3.3. BOLTED SEAM LEAKS.....................................................................................................
4.3.4. SHELL TOLERANCES......................................................................................................
4.3.5. ROOF INSPECTION & REPLACEMENT..........................................................................
4.3.6. NOZZLE CHECKS.............................................................................................................
4.3.7. FOUNDATION CHECK......................................................................................................
4.3.8.NDT & FINAL INSPECTIONS..............................................................................................
4.3.12. NOZZLE CHECKS.............................................................................................................
4.3.13. FIRE FIGHTING LINE......................................................................................................
This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 3 of 12

5. HYDROSTATIC TEST PROCEDURE.............................................................................

6. PAINTING AND COATING APPLICATIONS...................................................................
7. MECHANICAL COMPLETION & FINAL ACTIVITIES.....................................................

1. INTRODUCTION
1.1. PROJECT DESCRIPTION
The aims of scope of SERVICES are to provide complete Early Production Facility (EPF) and power
generation sources (Diesel Generators), for the EPF and wells, allowing COMPANY to start production of
Mabruk Field through EPF Facilities. The capacity of the EPF has been identified as min 25,000 to
maximum 30,000 Net BOPD, and total liquid capacity of 50,000 BLPD. The PROJECT AND SERVICES shall
be performed to ensure that the facilities will be installable, safe, reliable, maintainable, operable, and
efficient throughout its expected guaranteed duration life. The required facilities should enable the
continued operation for a design lifetime of minimum 20 years with potential extension up to 30 years
from contract EFFECTIVE DATE on rent basis with option to buy in third year.
All project and services phase should be in line with COMPANY HSE requirements, considering
environmental minimum impact using zero flaring system to eliminate the routine flaring during
production.

This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 4 of 12

Figure 1: Mabruk field Location

1.2. SCOPE
The Repair Procedure pertains to the repair of Crude Oil Storage Bolted Tanks TK-03 and TK-04. It covers
the comprehensive methodology for inspection, dismantling, repair, testing, and final acceptance.
Activities include sweep blasting, defect identification, repair (patch plates or replacement), leak sealing,
on-destructive testing (NDT), hydrostatic testing, coating, mechanical completion, and documentation.
This procedure will ensure compliance with SLB policies and project-specific objectives.

1.3. PURPOSE

The purpose of this document is to define the procedure, methodology, tools, safety measures, and
quality requirements to ensure the safe, professional, and environmentally compliant repair of crude oil
storage bolted tanks during the EPF Project. It provides guidelines for material handling, inspection,
coating, hydrotest, mechanical completion, and quality control documentation.

This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 5 of 12

2. DEFINITIONS AND ABBREVIATIONS

2.1. DEFINITIONS
 MOO COMPANY: Mabruk Oil Operations

 CONTRACT: Agreement between MOO and SLB

 CONTRACTOR: SLB

 SUB-CONTRACTOR: An organization performing specific services under the CONTRACTOR.

 MANUFACTURER/VENDOR/SUPPLIER: Supplier of materials, products, or services to the CONTRACTOR

2.2. ABBREVIATIONS
Abbreviation Definition
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ANSI American National Standards Institute
EDMS Electronic Document Management System “SharePoint”
MDR Master Document Register
MOO Mabruk Oil Operations.
ITP Inspection and Test Plan
ITR Inspection Test Record
IFC Issued For Construction
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ANSI American National Standards Institute
EDMS Electronic Document Management System “SharePoint”
MDR Master Document Register
NACE National Association of Corrosion Engineers
ASTM American Society for Testing and Materials
ASNT American non-destructive testing

This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 6 of 12

3. REFERENCES
3.1. APPLICABLE SPECIFICATIONS
Document Number Document Title
PF0014-SLB-MP-7737-0003 Painting and Coating Specification

3.2. APPLICABLE CODE AND STANDARD

Document Number Document Title
API 12B 16th Edition Specification for Bolted Tanks for Storage of Production
Liquids
API 12R1 6th Edition Installation, Operation, Maintenance, Inspection, and
Repair of Tanks in Production Service
API 653 5th Edition Tank Inspection, Repair, Alteration, and Reconstruction
Project ITPs, Approved Drawings & Procedures

3.3. ORDER OF PRECEDENCE

1. Relevant national laws and regulations

2. Project technical documents and drawings.
3. Project specifications and standards
4. International codes and standards
5. Contractor/Supplier/Manufacturer’s practices

4. METHODOLOGY
4.1. MATERIAL RECEIVING CHECK
 Inspect and verify all received materials (plates, bolts, gaskets, coatings) against
approved Material Submittals and Purchase Orders.
 Ensure valid certification, batch traceability, and proper storage before usage.

4.2. PREPARATORY ACTIVITIES

 Ensure all approved Work Permits (Confined Space, Working at Height, Hot Work, etc.)
are obtained.
This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 7 of 12

 Conduct toolbox talks and pre-lift meetings with all involved personnel are always
performed before starting activities.
 The Worker can access to the work area only after Client has issued dedicated permit to
work, that means all the required test and check to be performed by SLB, if need, have
been successfully completed.
 Verify availability of all tools, equipment, PPE for all workers must comply with safety
project requirement, and project-approved drawings.
 Rigging study and lifting plan shall be in place. Before any lifting activities
commencement, the lifting circle area must be barricaded to prevent unauthorized
workers or bystanders from entering a danger zone.
 No lift will be performed if Supervisor appointed will be not present full time at site.
 Install required safety equipment (explosion-proof lighting, gas testers, ventilation fans).

Plant Required Resources Required

- Generator - Tank Supervisor
- Paint & Sandblast machine - Fitters
- Compressor - Painters
- Portable Mixer - Civil Supervisor
- Concrete vibrator - Mason
- Electrical/Manual Tools - Carpenter
- Compactor (if needed) - Helpers
- Crane - Crane operator
- Rigger

4.3. INSPECTION, DISMANTLING & REPAIR SEQUENCE

4.3.1. GENERAL INSPECTION

 Painting and inspection on interior and exterior of the both tanks as per SLB
specification and code.
 API 653, Painting Inspectors & UT technician to assess and document defects.
 Prepare and submit Inspection Reports & Repair Procedures for approval.

 4.3.2. DISMANTLING OF ROOF, RAFTERS, SHELL, AND BOTTOM PLATES

 Erect internal and external scaffolding for safe access.
 Ensure the work area is clear of trip hazards and fully accessible.
 Place the crane in a suitable position for safe lifting and transportation to the laydown
area.
This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 8 of 12

 Crane Safety:
o All lifting operations must be carried out under an approved Rigging Plan and
lifting permit.
o Pre-use inspection of crane and lifting tackles must be conducted daily.
o The crane operator must be certified and authorized.
o Barricade the lifting area to restrict unauthorized access.
o A signalman must be assigned for each lifting operation.
o No lifting shall occur without the supervisor's full-time presence.

4.3.2. SHELL & BOTTOM REPAIRS

 Erect scaffolding inside tank for access.

 Replace or patch damaged plates as per API 653 and API 12B.
 PQR, WPS, and repair procedures must be pre-approved by SLB Quality Team.
 Welder qualification test shall be conducted after approved WPS & PQR.
 Consider non-metallic composite repairs for corroded or holed areas and material shall
be submitted to SLB for approval before use.
 Consider welding patching by gas tungsten arc welding process (GTAW) in case of
leakage or corroded over acceptance criteria (API 12R1 6th Edition) on critical area
between first shell plate and bottom plate.

4.3.3. BOLTED SEAM LEAKS

 Sweep blast affected external shell areas for UT inspection, inspect bolts and gaskets.
 Remove bolts, apply silicone sealant, and reinstall as recommended and silicone sealant
shall be approved by API 653 Inspector.
 Replace nuts/bolts and strip gaskets where necessary.

4.3.4. SHELL TOLERANCES

Check and adjust:

 Shell Plumbness
 Shell Roundness
 Shell levelness
 Peaking and banding (after each new plate erection)

This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 9 of 12

4.3.5. ROOF INSPECTION & REPLACEMENT

 Roof plate visual inspection and replacement.

 Inspect/replacement or repair roof rafters, bracings, and hangers.
 Perform vacuum testing of roof seams.

4.3.6. NOZZLE CHECKS

 Verify orientation, elevation, Modification & Addition of Nozzle if required and
projection of all nozzles.

4.3.7. FOUNDATION CHECK

 Excavate the sides of the ring wall concrete foundation up to a depth of 300mm below
ground level.
 Chip off the concrete cover top and sides and wherever loose concrete surfaces and
expose the reinforcement
 Provide formwork on all sides and pour epoxy grouting material for a thickness of 75mm
on top and side.
 Appy external protection paint light grey epoxy. - two coats. (2 x 125=250 microns total
thickness DFT)

4.3.8.NDT & FINAL INSPECTIONS

 Conduct NDT (VT, UT, MT, PT or vacuum test as applicable) on all welds and leak-repair
areas.
 Document findings and ensure compliance.

4.3.9. ROOF PLATE REMOVAL AND INSTALLATION

 Remove all roof plates using a crane, maintaining full HSE compliance.
 Remove plates systematically to prevent uncontrolled collapse.
 Install new roof plates with proper nut bolts and gaskets as per approved drawings.
 Install new rafters and shell course connections as required.
 Full internal scaffolding installation before roof rafters’ removal to ensure tank stability.
 Remove all rafters one by one to maintain structural safety of the tank.

4.3.10. SHELL COURSE REMOVAL & REPAIR

 Remove 3rd Shell Course as per Inspection Report findings.

This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 10 of 12

 After removing the 3rd shell course, install minimum 8 wire slings clockwise to maintain
tank integrity and safety.
 Install external scaffolding up to the 2nd shell course.
 Perform sweep blasting on corroded areas at 2nd and 1st shell courses.
 UT Inspection to be conducted after sweep blasting.
 Based on UT results:
o Remove damaged 2nd shell course and 1st shell course, if required.
o Start installation from the 1st shell course, maintaining erection sequence.
o Maintain nut bolt torquing sequence strictly to ensure uniform tightening.

 Install seal or chocking material at all joints as necessary.

4.3.11. BOTTOM PLATE REPAIR

 Follow Inspection Reports and clean the bottom plates thoroughly.
 Identify holes or pitting:
o Small holes: fill with non-metallic epoxy based on API Inspector
recommendation.
o Big holes: weld patch plates using same parent material after obtaining
approved WPS & PQR from QC.
 In critical zone areas, welding of patch plates shall be performed using parent material
under strict quality control.
 Install seal or chocking material at all joints as necessary.
 Replace damaged bolts and nuts completely as per specifications.

4.3.12. NOZZLE CHECKS

 Verify orientation, elevation, Modification & Addition of Nozzle if required and
projection of all nozzles.
 Visually check for internal corrosion.
 Check the attaching flanges gasket face for any damage or corrosion

4.3.13. FIRE FIGHTING LINE

 Piping shall be inspected visually for any leaks. Upon satisfactory completion of the
visual inspection and any repairs conducted, the rings shall be tested hydrostatically
as per the piping line list or project specifications.

4.3.14. FINAL INSPECTIONS

This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 11 of 12

 Conduct final inspection by the QC Team in accordance with the approved ITP
sequence.
 Final visual inspections, dimensional checks, and mechanical completion activities
will be completed before dossier submission.
5. HYDROSTATIC TEST PROCEDURE
Release for Hydrotest:
 Based on clearance from QA/QC, Engineering & Client.
 Proper venting to avoid air pockets.

Test Execution:
 Fill tank with fresh water as per API 650 and project requirements.
 Conduct leak checks and settlement monitoring during and after test.
 Leak observation for 24 hours minimum.
 Hydrostatic tests shall be witnessed and documented.
 After hydrotest, water shall be drained, tank flushed and dried.

6. PAINTING AND COATING APPLICATIONS

 Surface preparation and blasting as per SLB Painting and Coating Specification.
 Ensure all coatings comply with approved specification PF0014-SLB-MP-7737-0003.
 Record environmental conditions (dew point, humidity) before coating applications.

Apply:
 Primary coat
 Intermediate coats (if require)
 Final coat
 Painting inspection to verify DFT, surface cleanliness, and adhesion.
 Comply with document PF0014-SLB-MP-7737-0003.

7. MECHANICAL COMPLETION & FINAL ACTIVITIES

 Final Inspection and Punch List generation.
 Visual and dimensional control checks as per approved drawings.
 Match-marking, nameplate check, and quantity verification.
 Release for Grouting.
 Dismantling scaffolding and demobilization.
 All punch list items must be closed prior to final acceptance.

This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private
 Document number
Method Statement for Repair of Bolted MRP Ref.: LY-MRP-71-SLB-PRC-MEC-xxxxxx
Crude Oil Storage Tanks TK-03 & TK-04
Revision: 00 Status: IFI
Document Type: PRC System / Subsystem: 71 Discipline: MEC Rev Date: 22-Apr-2025
Contractor document number: PF0014-SLB-MX-6180-xxxx Page 12 of 12

8. FINAL INSPECTION & DOCUMENTATION

Submit a Mechanical Completion Dossier including:
ITPs & ITRs
 Final Inspection Reports
 Quality Dossier Index
 Material Certifications
 NDT Reports
 Hydrotest Results
 Painting & Coating Reports
 Approved WPS/PQRs and Welder Qualifications
 Crane lift plan and certificates
 Wire sling tensioning reports (for tank integrity maintenance)

This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document has been generated by Electronic Document Management System. When it is printed, it shall be considered as “For information only”.
SLB-
The controlled copy is the screen version, and thus, it is the document holder’s responsibility to make sure that the latest version is in use.
Private