KOHASA ENGINEERING COMPANY LIMITED

COMPANY: MONIPULO NIGERIA LIMITED

PROPOSALTITLE: AGBANI FPF HULL CORROSION CONTROL

DOCUMENT TITLE

WORK METHOD STATEMENT

0 JULY 2019 Emiri E. Goodluck E. Proposal

Rev No Date Prepared by Approved by Purpose of Issue

CLIENT: MONI PULO NIG. LTD KOHASA ENGINEERING COMPANY LIMITED
TITLE: AGBANI FPF HULL COROSION CONTROL

TABLE OF CONTENT
1. INTRODUCTION.......................................................................................................................3

2. THE PROJECT SCOPE ...............................................................................................................3

3. ACRONYMS AND THEIR MEANINGS ........................................................................................3

4. PERSONNEL .............................................................................................................................3

5. METHOD STATEMENT ..............................................................................................................4

5.1 FABRICATION 4
5.1.1 MARKING OUT 4
5.1.2 CUTTING AND PROFILING 4
5.1.3 UNDER-WATER CUTTING TECHNIQUE (DRAG TECHNIQUES) 4
5.1.4 JOINT FIT-UP 5
5.1.5 WELDING 5
5.1.6 WELDING PROCESS 5
5.1.7 UNDER WATER WELDING PROCESS (Self-consuming Technique.) 6
5.1.8 ELECTRODES 6
5.1.9 SEQUENCE OF WELDING (CONTROL OF DISTORTION AND SHRINKAGE) 6
5.1.10 NDT 6
5.1.11 BLASTING AND COATING 7

JULY 2019. Page 2 of 7

CLIENT: MONI PULO NIG. LTD KOHASA ENGINEERING COMPANY LIMITED
TITLE: AGBANI FPF HULL COROSION CONTROL

1. INTRODUCTION
KOHASA intends to carry out a project of Re-plating and Painting of the Voids. This method statement details the various
activities required to achieved the project. The proposed location for this project is the Agbani FPF.

2. THE PROJECT SCOPE

The scope of this project shall include but not limited to the following :
 Removal of corroded plates
 Replacement of corroded plates
 Blasting and Coating of Plates

3. ACRONYMS AND THEIR MEANINGS

S/N ACRONYM MEANING
1 HSE Health, Safety And Environment
2 CAD Computer Aided Design
3 QAQC Quality Control And Quality Assurance
4 NDT Non Destructive Test
5 WPS Welding Procedure Specification
6 NDE Non Destructive Examination
7 PPE Personal Protective Equipment

4. PERSONNEL

S/N PERSONNEL FUNCTION

1 Project Manager He has the overall responsibility for the successful initiation, planning,
execution, monitoring, controlling and closure of a project.
2 Project Engineer Direct the operation as per procedure. Arrangement of workers and supervision
of the work order.
3 Construction Engineer A Construction Engineer liases with the Project team for successful
implementation of the project based on the Approved For Construction
drawings.
4 QAQC Engineer Carry out inspection as per procedure and ensures that quality jobs are
delivered.
5 Safety Officer Take care of all safety issues on site
6 Fitters Responsible for cutting and profiling, joint fit-up, alignment

7 Mates Assist the welders, fitters and Scaffolders in carrying out their assignment.

8 Welders Responsible for tack-welding and welding the various components that make
up the structure
9 Rigger He specializes on control of lifting and moving of extremely large or heavy
objects with the assistance of a crane, self-loader, and fork-lift operators.
10 Blasters He specializes on blasting of the structure.

11 Painters He specializes on spray painting of the structure.

12 NDT Technician He is responsible for all NDT related activities

13 Diver A Person who specialises in underwater activities

JULY 2019. Page 3 of 7

CLIENT: MONI PULO NIG. LTD KOHASA ENGINEERING COMPANY LIMITED
TITLE: AGBANI FPF HULL COROSION CONTROL

5. METHOD STATEMENT
The objective of the method statement is to carry out successful work implementation on site as to provide a timely and
accident free delivery of fabrication work and also give the best quality. The Re-plating and Painting of the Voids works
shall be carried out as per approved scope, drawings and specification provided by Client.

5.1 FABRICATION
The fabrication procedure adopted by KOHASA and the various processes are listed below.

5.1.1 MARKING OUT

 Prior to marking, the material shall be checked for its identification and defects.
 Marking shall be carried out as per the guide lines of the construction engineer and subsequent verification by the
QAQC Engineer prior to cutting.
 Transfer the dimensions using a measuring tape and steel chalk, for marking, on the materials to be used.
 Create a tolerance of +3mm to allow for proper cleaning.

5.1.2 CUTTING AND PROFILING

 Cut the marked materials using oxy-acetylene, Cutting disc or the Plasma cutting set etc.
 Cut edges shall be visually examined for laminations and inclusions.
 Grind the various members to the dimension Marked-out. Tolerance of ±3mm is allowed.
 All corners shall be shaped so as to be notch free, sheared or cropped edges shall be dressed so that they are free
from distortion and burrs.

5.1.3 UNDER-WATER CUTTING TECHNIQUE (DRAG TECHNIQUES)

 Steel tubular electrodes shall be used for cutting out the corroded plates under-water
 Before cutting any section, a ground cable must be attached to the work piece
 Drag techniques shall be employed for cutting.
 Clean the spot for the ground clamp. The spot should be in a position in front of the diver and should be scraped
or wire brushed shiny clean. For diver safety, only C-type clamps should be used as grounding clamps for
underwater cutting
 Insert the electrode into the collet opening until it bottoms out against the washer. Tighten the collet nut. To start
the cut, hold the electrode perpendicular to the surface to be cut and hold the oxygen trigger down to get a
steady flow. Place the tip of the electrode against the work and call for SWITCH ON. If necessary, withdraw the
electrode slightly and tap it against the work to start the arc.
 As soon as the cut is started through the full thickness of the plate, drag the electrode along the desired line of
cut and keep it perpendicular to the work. Hold the electrode with the free hand as if holding a pool que,
approximately Four inches from the tip for a more stable cut. The tip of the electrode should be pressed against
the advancing lip of the cut. Pressure should be exerted in two directions: inward to compensate for electrode
burn-off and forward to advance the cut.
 Low oxygen pressure, high travel speed and uncontrolled manipulation are typical causes of back-flare that result
in incomplete cuts. In such cases, the area must be chipped and cleaned and the cut restarted
 When the electrode has burned down to within 3 inches of the collet nut, break the arc, release the oxygen
trigger and call for SWITCH OFF. When the phone talker has con-firmed SWITCH OFF, tap the electrode twice to
make sure the switch is off. Loosen the collet nut 1/2-turn and blow the cutting stub from the torch by squeezing
the trigger. Insert a new electrode and repeat the starting procedure.

JULY 2019. Page 4 of 7

CLIENT: MONI PULO NIG. LTD KOHASA ENGINEERING COMPANY LIMITED
TITLE: AGBANI FPF HULL COROSION CONTROL

5.1.4 JOINT FIT-UP

 The Members or Plates are aligned and retained in position to welding operations. The location of integral parts /
members to be assembled shall be checked dimensionally prior to full welding.
 Tack welds shall be used for secured alignment. Generally, the tack welds shall be subject to the same quality
requirement as the final welds unless otherwise specified.
 Tack welds containing any cracks shall be removed thoroughly and replaced with sound tack welds. Size and
location of tack welds will be based on the approved WPS.
 Ensure the dimensions are accurate before welding.

5.1.5 WELDING
 The edges or surfaces of parts to be joined by welding shall be uniform, smooth and cleaned from all foreign
materials such as moisture, slag, oil, grease, paint, scale or rust.
 Pre-heating must be done before welding during raining season.
 Check compliance with all other variables stated on the approved welding procedure.
 Carry out visual inspection of the welded joints before welding, during welding and after welding.

5.1.6 WELDING PROCESS

The following practices shall be used for welding.
 Prior to welding, the surface to be welded and filler material to be used shall be checked.
 Prior to welding root opening, the crucial dimensions shall be checked and groove face shall be free from oil,
water and dirt.
 Prior to welding, the welding current shall be measured the most appropriate welding condition (current &
voltage) shall be maintained with ammeter and voltmeter throughout welding work.
 All welding is to be carried out in an approved environment and, if necessary, additional protection may be
required. All joints are to be dried before welding in damp climatic condition.
 During welding work, the most appropriate arc length, angle and welding speed shall be maintained so that
welding defects shall be avoided and arc energy requirements are satisfied.
 All welds shall be 6mm continuous Fillet.
 In underwater fillet welding, it is important that there be no gap at the root of the fillet before welding. When the
gap cannot be eliminated entirely, it should be as small as the conditions will permit.
 Chipping and gouging shall be used, provided grinding follows them.
 In the case of multi-layer welding, slags and spatters on each completed bead shall be removed prior to the start
of welding for the following layer.
 All craters shall be filled to the full cross section of the welds.

JULY 2019. Page 5 of 7

CLIENT: MONI PULO NIG. LTD KOHASA ENGINEERING COMPANY LIMITED
TITLE: AGBANI FPF HULL COROSION CONTROL

5.1.7 UNDER WATER WELDING PROCESS (Self-Consuming Technique.)

 Before entering the water, set the amperage and run several beads on a plate.
 Use the tong test ammeter to check the amperage.
 After the diver enters the water, the first task is to clean a spot for the ground clamp. The spot should be in a
position in front of the diver, as close as practical to the weld joint and should be scraped or wire brushed shiny
clean. For diver safety, only C-type clamps should be used as grounding clamps. The clamp must be firmly
secured to the work piece and the cable should have sufficient slack to prevent it from being pulled loose. The
diver may elect to lightly tack weld the clamp in place when there is a possibility of it working loose. The ground
should always be kept in the diver’s forward line of vision

 The diver should make a test weld to check the “heat” at working depth.

 Via the communications system, the diver can instruct the tender to fine tune the welding machine, that is;
increase or decrease the amperage as needed. The open circuit voltage may also require adjustment.

 After the optimum settings are determined, welding can begin the diving tender should always maintain a written
record of the following: The welding amperage as read from the tong meter, Both open and closed-circuit voltage
as read from the volt meter, Electrode diameter, type, manufacturer and waterproofing material, Electrical
polarity, Length of welding cable and Depth of work site.

5.1.8 ELECTRODES

 The electrodes used for welding shall be of suitable type and size depending upon specifications of the parent
materials, the method of welding, the position of welding and quality of welds desired. However, only low
hydrogen electrodes (E 7018) shall be used for plates and sections above water welding. While (E 7014)
electrodes shall be employed for under water welding.
 All low hydrogen electrodes shall be baked and stored before use as per manufacturer’s recommendation.
 The electrodes shall be re-baked at specific temperature for one hour and later on cooled in the same oven to
100°C or as per process required.
 From baking oven the electrode shall be transferred to a holding oven maintained at specific temperature.
 The electrodes shall be drawn from this oven to the electrode quiver for use.

5.1.9 SEQUENCE OF WELDING (CONTROL OF DISTORTION AND SHRINKAGE)

 The sequence of welding shall be selected to ensure that the components assembled by welding are free from
distortion and large residual stresses are not developed
 In assembling and joining parts of a structure or of built–up members and in welding reinforcing parts to
members, the procedure and sequence shall be such as will minimize distortion and shrinkage.
 In so far as practicable, all welds shall be deposited in symmetrical sequence so that shrinkage on both sides of
the structure will be equalized.
 Joints expected to have significant shrinkage shall be welded before joints expected to have lesser shrinkage and
with as little restraint as possible.
 All welding shall be carried out continuously to completion or to a point that will ensure freedom from cracking
before the joint is allowed to cool below the minimum specified preheat and inter-pass temperature.

5.1.10 NDT
 All non-destructive testing shall be performed as per approved agency, as per the contract in accordance with the
requirements of the applicable standards and project specifications.
 Carry out NDT on visually certify welded joint.
JULY 2019. Page 6 of 7
CLIENT: MONI PULO NIG. LTD KOHASA ENGINEERING COMPANY LIMITED
TITLE: AGBANI FPF HULL COROSION CONTROL

 Identify repairs from assessment of visual and NDT reports.

 Carry out welding repairs on defective joint and carry out NDT again to certify the integrity of that joint.
 A third-party Inspection agency shall be engaged as independent and approved testing and inspection agency to
carry out 100% MPI on Weldments

5.1.11 BLASTING AND COATING

 Abrasives for blast cleaning shall be clean, dry and free of any constituent.
 Plates shall be properly cleaned before blasting.
 The structure will be blasted according to KOHASA blasting/painting procedure as approved by the client.
 Paint shall be applied to dry, clean prepared surfaces under controlled favorable weather conditions and in
accordance with manufacturer data sheet.
 Painting shall be applied as per the project specification.
 Preparation generally shall comply with requirements SSPC, client specification and printed instructions of the
manufacturer.
 Check that all coating materials to be used are recommended by the manufacturers for the particular surface and
condition of exposure.
 Painting shall be carried out with skilled workers.
 Three coating system shall be used, the primer, intermediate and the final coat.
 All coating materials shall be applied evenly in a continuous full coat free from over-spray, dry-spray, wrinkling,
sagging, curtaining, holidays, thin spot, pinholes and other film defects.

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