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PROJECT:

CC-CHP Licherfelde Project


Document Number:

Document Title:

Page:

Rev.:
Method Statement for
Fabrication and Erection of Date:
Demineralized Water Tanks

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Method Statement for Fabrication and


Erection of Demineralized Water Tanks

CC-CHP LICHTERFELDE
COMBINED CYCLE POWER PLANT - BERLIN
A1GHC DEMINERALIZED WATER TANKS 1&2

0
Rev.:

Description:

17.11.2014

Radakovic Z.

Date:

Prepared by:

Aproved by: Verified by:

Verified by
client:

PROJECT:
CC-CHP Licherfelde Project
Document Number:

Document Title:

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Method Statement for
Fabrication and Erection of Date:
Demineralized Water Tanks

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INDEX

1.

PURPOSE

2.

SCOPE

3.

REFERENCES

4.

DEFINITIONS / ABBREVIATIONS

5.

RESPONSIBILITIES

6.

PROCEDURE

7.

TESTING

8.

PAINTING

9.

DOCUMENTATION

PROJECT:
CC-CHP Licherfelde Project
Document Number:

Document Title:

Page:

Rev.:
Method Statement for
Fabrication and Erection of Date:
Demineralized Water Tanks

1.0

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PURPOSE
The purpose of this Method Statement is to define the general sequence of events, interfaces
and responsibilities relating to Fabrication and Erection works of De-mineralized water tank,
in order to meet the project specification, reference codes and standards.

2.0

SCOPE
This Method Statement describes the methods of identifying and executing the total
fabrication, erection, Inspection and Testing activities to enhance Safety, Quality, and
compliance to Project Specification.

3.0

REFERENCES

Codes, Standards & Specifications


Spec No.:
Description

1A5Y-A1-GHC-DP-MET-0001
1A5Y-A1-GHC-DP-MET-0002
1A5Y-A1-GHC-DP-MET-0003
1A5Y-A1-GHC-DP-MET-0004
1A5Y-A1-GHC-DP-MET-0005
1A5Y-A1-GHC-DP-MET-0006
1A5Y-A1-GHC-DP-MET-0007
1A5Y-A1-GHC-DP-MET-0008
1A5Y-A1-GHC-DP-MET-0009
1A5Y-A1-GHC-DP-MET-0010
1A5Y-A1-GHC-DP-MET-0011
1A5Y-A1-GHC-DP-MET-0012
1A5Y-A1-GHC-DP-MET-0013
1A5Y-A1-GHC-DP-MET-0014
1A5Y-A1-GHC-DP-MET-0015
1A5Y-A1-GHC-DP-MET-0016
1A5Y-A1-GHC-DP-MET-0017
1A5Y-A1-GHC-DP-MET-0018
1A5Y-A1-GHC-DP-MET-0019
1A5Y-A1-GHC-DP-MET-0020
1A5Y-A1-GHC-DP-MET-0021
1A5Y-A1-GHC-DP-MET-0022
1A5Y-A1-GHC-DP-MET-0023
1A5Y-A1-GHC-DP-MET-0024
1A5Y-A1-GHC-DP-MET-0025

Demineralized Water Tank 1 Tank General Arrangement


Demineralized Water Tank 2 Tank General Arrangement
Bottom Plates
Tank Shell
Roof
Roof Walkway - Demineralized Water Tank 1
Roof Walkway - Demineralized Water Tank 2
Caged Ladder
Nozzle For Outlet To Mix Bed Exchanger N1
Manhole N2
Manhole N2 - Details
Nozzle For Outlet To Demi Water Pumps N3
Nozzle For Demi Water Return N4
Nozzle For Level Indicator N5
Manhole N6
Nozzle For Level Indicator N7
Nozzle For Level Indicator N8
Nozzles For CO2 Filter And Emergency Venting N9
Nozzle For Demi Water Inlet N10
Nozzle For Overflow N11
Nozzle For Drain N12
Reserve Nozzle N16
Reserve Nozzle N17
Earthing Lug
Nameplate

PROJECT:
CC-CHP Licherfelde Project
Document Number:

Document Title:

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Rev.:
Method Statement for
Fabrication and Erection of Date:
Demineralized Water Tanks

4.0

1A5Y-A1-GHC-DP-MET-0026
1A5Y-A1-GHC-DP-MET-0027
1A5Y-A1-GHC-DP-MET-0028
EN 14015:2004

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Design Documentation
Operation and Maintance Manual
Instruction for Inspection and Testing
Specification for the desige and manufacture of site built,
vertical, cylindrical. Flat-bottomed, above ground, welded,
steel tanks for the storage of liquidsat ambiente temperature
and above.

DEFINITIONS / ABBREVIATIONS
Client
Contractor
Manufacturer
AFC
HSE
PPE
NDE
RT
UT
MT
PT
PWHT
WPS
RF Pad

VATTENFALL EUROPE WRME


IBERDROLA INGENIERIA Y CONSTRUCCION
MONTAVAR METALNA LOLA Belgrade, Serbia
Approved for Construction
Health, Safety and Environment
Personal Protective Equipment
Non-Destructive Examination
Radiographic Test
Ultrasonic Testing
Magnetic particle Testing
Penetrating Testing
Post Weld Heat Treatment
Welding Procedure Specification
Reinforcement Pad

5.0

RESPONSIBILITIES

5.1

Construction Supervisor shall be responsible for the implementation of this procedure who
shall pass on instructions down the line to maintain the required quality level at each stage
of construction.

5.2

Mechanical Foremen shall be responsible for the execution of correct working techniques
with strict adherence to this method statement and reference documents.

5.3

Site Superintendents / Foremen shall be directly responsible for the Quality produced by the
workers under them. They shall confirm that latest drawings, specifications, grades of

PROJECT:
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Method Statement for
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Demineralized Water Tanks

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materials, correct tools etc are used. They shall also guide the workers in the interpretation
of drawings/documents so that the work is carried out in correct sequential manner, meeting
the various in process inspection activities.
5.4

The Foremen shall be responsible for deploying qualified welders. They shall also be
responsible for ensuring that the welders withdraw electrodes as per WPS and that they
work within the welding parameters of approved WPS.

5.5

QC Inspectors / Welding Inspectors shall be responsible for carrying out the in process
Inspection of fabrication, arrangement for NDT and relevant tests as per ITPs. They shall
also be responsible for maintaining the documentation & records of inspection.

6.0

PROCEDURE

6.1

Quality Control
The QC Inspector shall:

Confirm that the approved procedure is being followed.


Confirm that documents / drawings (latest revisions) are used for fabrication.
Confirm the use of correct materials as per specifications, construction drawing & WPS.
Confirm Baking / Holding ovens And Welding machines have valid calibrations certificates.
Confirm that the welding is carried out using windshield cover during dusty and windy
periods, which would affect the quality of welds.
Confirm that the welders are qualified to relevant WPS.
Confirm that all NDT and Inspection points are carried out.

6.2

Safety

6.2.1

All equipments and accessories shall be verified and of adequate capacity according to HSE
requirements.

6.2.2

All personnel involved in fabrication / erection works shall be informed of hazards and will
adopt preventive measure while using said substances.

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Method Statement for
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Demineralized Water Tanks

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6.2.3

All electrical equipments shall be properly earthed.

6.2.4

All the welders must use their safety equipments such as welder helmets, hand gloves and
personal protective equipments.

6.2.5

All necessary safety precautions to be followed while carrying out NDTs such as RT, PT,
MT, and UT as mentioned in the relevant procedures.

6.3

Sequence of Operation

6.3.1

Receipt of Material and Storage


All related materials, which are received, shall be stored in the lay down area. They shall be
stacked properly without touching the ground, placed on wooden rafters. Care shall be taken
to stack materials properly segregated.
Special precautions must be taken to minimize the risk of damage to the corrosion resistance
properties of stainless steel. Stainless steel shall be handled so as to minimize contact with
iron or other types of steel during all phases of fabrication and construction.

6.3.2 Receipt Inspection of Materials


On receipt of materials, Mechanical Supervisor / Foremen shall check the material class,
size schedule and heat nos. discrepancies shall be reported to QA/QC department. Due to
Instructions shall be given to workers to transfer all necessary information before using for
construction.

6.3.3

Edge Preparation
Weld edge preparation shall be made as per joint design given in drawing / WPS. All paint,
rust, grease etc. shall be cleaned for a distance of 25mm from the weld edge from inside and
outside of the welding components.

6.4.4

Brief Description of Detailed Work


The tanks are made of flat bottom, cylindrical shell, cone roof, nozzles and accessories.

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Method Statement for
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Demineralized Water Tanks

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The tank has been supplied in rolled plates to be assembly and welded on site as following
descriptions:
a) For the erection set up please refer to the attached drawings.
b) The bottom will be supplied in plates to be position and fit upped on the tank foundation
using a suitable crane . Lifting holder will be welded on each plate to be use for the
lifting in to final positioning of the same. After the position the fit up will start and as
soon completed welding has to be perform.
c) The plates will be positioned on a leveled concrete foundation where the circumference
of the shell plates (fabricated shell plates) has been identified by guide plates tack
welded on the bottom. As soon all the plates composing the shell plates are on position a
plate fit up will be execute. In order to avoid the bending of the plates along the welding
area, steel devices will be fixed and the bending will be controlled and adjusted during
the welding with pins. Completed the welding the devices will be removed and the used
tack welding will be cleaned with grinder. Time by time the shell plates will be
supported by profiles in order to avoid any collapsing and any misalignment. To erect
the tank shell scaffolding will be erected. The above operation will be repeated three
times in order to complete the tank shell.
d) The welding of the shell to the bottom shall be practically completed before the welding
of bottom joints that may have been left open to compensate for shrinkage of any welds
previously made is completed.
Shell plates may be aligned by metal clips attached to the bottom plates, and the shell may be
tack welded to the bottom before continuous welding is started between the bottom edge of
the plate and the bottom plates.
e) Secondly, Tank roof shall be assembled as follow:

Tracing, positioning and welding of the roof plate on the shell;


Erection of roof supports scaffolding on the tank middle;
Dismounting of the support scaffolding.

Erection of the service platforms and ladder will be performed using a suitable crane.
The platform and ladder anchor plates will be welded on the tank shell. After this operation
the erection activities will start.

PROJECT:
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Method Statement for
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Demineralized Water Tanks

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f) The three shell including tank roof should be lifted with suitable capacity crane.Second
shell is now aligned and welded (all welds) to the bottom side of third shell according to
drawing. Similarly, all the shell plates are erected (second, first) accordance with the
drawing.

g) Welding shall be done between bottom shell and bottom annular plates (fillet welded)
from both sides.
The initial weld pass inside the shell shall have all slag and non-metals removed from
the surface of the weld and then examined for its entire circumference prior to welding
the first pass outside the shell. (temporary weld fit up tacks excepted), both visually and
by any one of the following methods to be agreed to by purchaser and manufacturer;
a. Magnetic particle.
b. Applying a solvent liquid penetrant to the weld and then applying a developer to the
gap between the shell and the bottom and examining for leaks after s minimum dwell
time of one hour.
c. Applying a water-soluble liquid penetrant to either side of the joint and then
applying a developer to the other side of the joint and examining for leaks after a
minimum dwell time of one hour

6.3.5 Fit up of Assembly


Before fit up, the components and fittings shall be visually checked for inside cleanliness.
The fit up shall be carried out as per the requirements of WPS & drawing. Fit up shall be
carried out by using bridge tacking within the grooves using a qualified welder. Arc shall
be stuck inside the groove and not on the inside or outside surfaces of shell plates.
6.3.6 Inspection of Assembly
Inspection of fit up assemblies including dimensional check shall be carried out prior to
release for welding.

PROJECT:
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Method Statement for
Fabrication and Erection of Date:
Demineralized Water Tanks

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6.3.7 Welding Joints


All welding procedures and welder qualifications shall be according with EN 15614-1

Requirements of the WPS, specification of piping and HSE practices shall be followed.
Weld joint number shall be written near the joint by solid paint marker. Only qualified welders shall
be used for Tacking & Welding. All temporary Tacks/ bridge shall be removed one by one (by
grinding) as the welding progresses. Continuous welds shall be used for all horizontal top side joints
and for vertical joints. Horizontal bottom-side joints shall be seal-welded if specified by the
purchaser. Seal welding should be considered to minimize the potential for entrapped moisture,
which may cause corrosion.
Full penetration butt-welds shall be used for joining ring section. Tanks and their structural
attachments shall be welded by the shielded metal arc, gas metal-arc, gas tungsten-arc or flux-cored
arc Process using suitable equipment. All tank welding shall be performed in accordance with the
requirements of related drawings and welding procedure specifications. Welding shall be performed
in a manner that ensures complete fusion with the base metal. Each layer of weld metal or multi
layer welding shall be cleaned of slag and other deposits before the next level is applied.
The edges of all welds shall merge with the surface of the plate without a sharp angle. For
vertical butt joints, the maximum acceptable under cutting is 0.4mm of the base metal. For
horizontal butt joints, undercutting not exceeding 0.8mm in depth is acceptable.
During the operation, plates shall be held in close contact at all lap joints.
Note:
o Break all sharp edges, remove all burrs, and spatters
o Base plate fillet welds shall be continuous
o All Nozzle above 2 NB shall be provided with reinforcement pads and all RF pads shall be
provided with M6 Tap hole.
o All structural attachments to Tank or roof shall be continuous seal welded
o Nozzle pipe shall be seamless.
6.3.8 Visual Inspection of Joints Before, During and after Welding

QC / Welding Inspectors shall perform in-process visual inspection before, during and after
completion of welding of the joints.
The identification tag will be tied up or marked on each welded joints.

PROJECT:
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Method Statement for
Fabrication and Erection of Date:
Demineralized Water Tanks

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

There are no other cracks, other surface cracks or arc strikes in or adjacent to the welded
Joints.

b)

Under cutting does not exceed the limits given for vertical and horizontal butt joints. For
welds that attach nozzles, manholes, cleanout openings, and permanent attachments, under
cutting shall not exceed 0.4mm.

c)

The frequency of surface porosity in the weld does not exceed one cluster (one or more
pores) in any 100mm of length, and the diameter of each cluster does not exceed 2.5mm.

6.3.9

Identification of Joints and execution of NDE


The QC / Welding Inspector shall identify the joints to be offered fort NDE as per
requirement & the applicable piping specifications.
As welding progresses, control shall be taken as soon as it is practicable. The contractors
inspector may determine the location where the control are to be taken.

o QC Inspector shall organize for NDE as per the requirements . HE shall also organize for
NDTs repairs. The QC inspector shall be responsible for interpretation and reporting of
NDEs and also for coordination of NDE with Contractors representatives.
o The initial weld pass inside the shell shall have all slag and non-metals removed from the
surface of the weld and then examined for its entire circumference prior to welding the first
weld pass outside the shell (temporary weld fit-up tacks excepted), both visually and by the
following method to be agreed to by purchaser and manufacturer.
a. Liquid Dye penetrant
All defects found in welds shall be called to the attention of the contractors inspector,
and the inspectors approval shall be obtained before the defects are repaired. All
completed repairs shall e subject to the approval of the contractors inspector.

PROJECT:
CC-CHP Licherfelde Project
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Document Title:

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Rev.:
Method Statement for
Fabrication and Erection of Date:
Demineralized Water Tanks

7.0

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TESTING

Following checks to be carried out agter completion of all Fabrication and Erection works.

Out of roundness

Peaking Check

Verticality / Plum Check

Radius of the Bottom

Orientation of the Nozzles with Tank

Examination and Testing of the Tank Bottom


Upon completion of welding of the tank bottom, the bottom welds and plates shall be
examined visually for any potential defects and leaks. Particular attention shall apply to areas such
as sumps, dents, gouges, three-plate laps, bottom plate breakdowns. Arc strikes, temporary
attachments removal areas, and welding lead arc burns. Visual examination acceptance and repair
criteria are specified in 6.5. In addition, all welds shall be tested by the penetrant test. (Or MT)
Hydro testing
After the entire tank is completed but before any permanent external piping is connected to the tank,
the shell (except for the shell of tanks designed in accordance with accordance Appendix F) shall be
tested by one of the following methods

a. If water is available for testing, the tank shall be filled with water as follows:
(1) To the maximum design liquid level, H;
(2) For a tank with a tight roof , to 50mm (2in.) above the weld connecting the roof plate or
compression bar to the top angle or shell; or
(3) To a level lower than that specific in sub item one or two when restricted by over flows, an
internal floating roof, or other freeboard by agreement between the purchaser and manufacturer.
The tank shall be inspected frequently during the filling operation, and any welded joints above the
test-water level shall be examined in accordance with item b.
b. If sufficient water to fill the tank is not available, the tank may be tested by
(1) painting all of the joints on the inside with highly penetrating oil, such as auto mobile spring oil,
and carefully examining the outside of the joints for leakage;

PROJECT:
CC-CHP Licherfelde Project
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Method Statement for
Fabrication and Erection of Date:
Demineralized Water Tanks

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(2)Applying vacuum to either side of the joints or applying internal air pressure as specified for the
roof test in 5.3.6 and carefully examining the joints for leakage; or
(3) using any combination of the methods stipulated in 5.3.5.b sub items 1 and 2.
8.0 Painting

Painting specification 1A5Y-A1-GHC-IP-MET-0026


Internal Painting system : Painting system S-3
External Painting system : Painting system S-S
Stairs and Railing should be galvanized or used Painting system S-S

If blast cleaning is necessary, it shall be done with sharp acicular grains of sand or grit containing
not more than 2% by weight iron as free iron or iron oxide. Steel shot or sand used previously to
clean non-stainless steel is not permitted
Control of Non-conforming Product
During construction activities, care shall be taken to produce any non-conforming product.
9.0

DOCUMENTATION
Following documents should be prepared as minimum

o
o
o
o

10.0

Daily Weld Inspection Report


Painting Inspection Report
Alignment and Verticality Check Report
Non-Destructive Examination Report

Attachments
1. Inspection Test Plan
2. Risk Assessment

10

Mark line of tank wall.

20

R30

100
50

150

700

350
Temporary connection plate
700x150x10 S235JR 8x

n5000

50

Temporary plate
100x50x5..........60x

n5012

DETAJL B
Detail B

( 1 : 10 )

12

1. Check measure protocol of concrete fundament.


2. Alignment of bottom plates.
3. Welding of bottom plates. Use temporary connection plates to prevent distortion.
4. Control of welding.
5. Mark on flat bottom plate position of first cylindrical shell.
6. Put around marking line plates for temporary fixing first cylindrical shell.

PREREZ C-C
Section C-C
(1:5)

50

Polizdelek:

t. sestavne risbe:

WATER TANKS

Phase I

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev. 0

1. Put first plate of first cylindrical shell on bottom plate.


2. Temporary fix plate with L profiles.

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase II

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.

DETAJL A
Detail A

( 1 : 10 )

1. Put second and third plate of first cylindrical layer on flat bottom plate.
2. Adjustment make with 'Chicago' connection plates.
3. Third plate have over length of 100mm.

40
8,5

200
80
2
53

250

8,0

R1
0

R1
0

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase III

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.

DETAJL A
Detail A
( 1 : 10 )

1. Weld vertical welds between first and second plate.


2. Weld vertical weld between second and third plate.
3. Control dimension and straightness.
4. Measure perimeter, and cut over length.
5. Weld last vertical weld on first layer.
6. Put temporary plates for connection first layer and plates of next layer.

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase 4

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.

DETAJL A
Detail A
( 1 : 20 )

Connection between plates


make with 'Chicago' plates.

DETAJL B
Detail B
( 1 : 10 )

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase V

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.

METALVAR d.o.o.
Vse avtorske pravice, ki niso s
pogodbo izrecno preneene na
naronika, so pridrane.
METALVAR d.o.o.
All rights whitch are not explicitly
transferred to the employer by
contract are reserved.
B

tolerance
`2

30-120
`2

`3

`4

`6

2000-4000
`8

4000-8000
`10

`12

` 14

`16

8000-12000 12000-16000 16000-20000 20000-

Pri jeklenih konstrukcijah veljajo tolerance odprtih mer po DIN 8570 razred B.

120-315 315-1000 1000-2000

TOLERANCE ODPRTIH MER

10

10

11

11

12

12

13

13

14

Polizdelek:
t. sestavne risbe:
Izdelal:

CHICAGO SPOJKA
METALVAR
Z.Radakovi

Dimenzije:
KD t.:
Podpis:

Material:

14

15

530x150 mm
15

16

A
A

DETAJL A
Detail A
B

(1:5)

a4
C

a4

D
D

E
E

F
F

G
G

H
H

I
I

J
J

K
K

Signacija/Poz.:

Koliina:
Rev.:

16

kom 0
ISO A1

DETAJL A
Detail A
( 1 : 10 )

1. Put all plates in second layer.


2. Weld vertical weld between first and second and third plates in second layer.
3. Make control and final measurement of perimeter.
4. Cut over length on third plate.
5. Weld last vertical weld. on second layer.

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase VI

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.

DETAJL A
Detail A
( 1 : 10 )

Same procedure as for second layer.

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase VII

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.

DETAJL A
Detail A
( 1 : 10 )

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase VIII

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.

After welding both radial welds between layers,


weld radial weld between first layer and bottom plate.

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase 9

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase X

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.

A
DETAJL A
Detail A
(1:5)

Polizdelek:

t. sestavne risbe:

WATER TANK

Phase 11

Dimenzije:

KD t.:

100m3 mm

Material:

IBERDROLA

Signacija/Poz.:

Koliina:

Rev.:

kom Rev.