METHOD STATEMENT FOR STORAGE TANKS

1500 MTPD Phosphoric Acid plant 4500 MTPD Sulphuric Acid plant METHOD STATEMENT Erection, Alignment of Tank course shells by jockeying method.. 1500 MTPD Phosphoric Acid plant 4500 MTPD

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1500 MTPD Phosphoric Acid plant

4500 MTPD Sulphuric Acid plant METHOD STATEMENT

Prepared by Reviewed by Safety Release QA/QC

Approval Approved by

Date

Name

Section Engineer Construction Manager Safety manager QA / QC Manager Project Manager

Date

Name

Site Manager

4500 MTPD Sulphuric Acid plant

Method Statement No

CIVIL ELECTRICAL MECHANICAL INSTRUMENTATION

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1 INTRODUCTION

The following is the method statement for the erection of Carbon Steel storage tanks with roof

by Jacking method and covers the following tanks

a) Fulisilic acid storage Tanks-2nos (234-R-01A/B)

b) Sulphuric acid product storage tanks-3nos

c) Potable water tank-1nos (245-R-01)

d) Diesel storage tank-1nos (246-R-01)

e) Molten sulphur tank -1nos

It comes under Sulphuric & Phosphoric acid plant

2 Function and location, General Description, Scope of Work

a) Function and Location

The function of the storage tank is to store the Concentrated acid / Weak acid / Effluent for Maturation/Storage purposes, and it was located in phosphoric acid plant area

Erection of I-Beams on the civil foundation and leveling

Erection, Alignment, Fit up and welding of bottom base plate

Inspecting welding with required NDT procedures like DP Test, Radiography, and Vacuum

box UT etc (refer-ITP)

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Erection, Alignment of Tank course shells by jockeying method

Erection of roof

Erection of Internal Baffle plates, Dip tube etc

Erection of Walk ways, staircase, Agitator support, Hand railing

Erection of Ladders, Flat forms and Hand rails

3 Related Documents

a) Technical specifications

b) Approved construction drawings

c) Weld map

d) Release of material for construction form SNC Lavalin

e) Release certificate starting of erection over civil foundation from MID

f) Vendor’s instruction/manual required

g) I.T.P (Inspection Test Plan)

h) All last revisions of Drawings, WPS, PQR, Welder certificated, etc

4 Required Material Testing, during and before work

Material grade to be confirmed for WPS/PQR/WELD Qualification

Batch number, Heat number punched on the plate to be compared with Mill certificate

5 Environmental and Safety

All the lifting tools gear like slings, belts, D-Shackles etc are of Tested & Certified by the TPI

Cranes involved in Erection are certified by TPI

All the PPE used for the work is of approved quality

All the Workers, Staff, Engineers involved in work are geared with full basic PERSONAL

PROTECTION EQUIPMENT

TOOL BOX TALK will be conducted on daily basis at the starting of the job

When working at height above 1.5mts from the ground every person to be wearing a safety belt When working at height proper scaffolding will be provided for accessing, testing, inspection for the client

Scaffolding work will be done by properly trained and certified workers only under the

supervision of Engineer

Entry Permit system for usage of scaffolding will be practiced

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While starting of welding, gas cutting, grinding, gouging operations HOT WORK permit system

will be practiced

All the gas cutting torches are installed with approved Flash back arrestors

All the welders are with proper hand gloves, Apron, Face shield and other additional required

safety gears

While working in confined space CONFINED SAPCE ENTRY PERMIT system will be practiced

All the power tools are of certified and tagged properly

All the power, welding cables are of certified and tagged properly

For handling Plates special lifting tools like horizontal and vertical plate lifting tools are used

Good housekeeping will be practices at all the time

Fire extinguishers are kept near the work for any fire incidents

Gas cylinders are stationed during work so that they maintain required distance from the heat source

Best engineering will be practiced to avoid accidents

6 Detail of work supported with sketches and with special highlight for details

• Extension of I Beams to the required length (Refer to QI(QUALITY INTERNATIONAL)

procedures)

• Inspection of welding

• Erection of I-Beams on slab

• Aligning & Leveling of I-Beams

• Anchoring of I-Beams of to the concrete foundation.(Hold)

• Erection of Bottom base Plate on the I-Beams

• Fit-up and Welding of Bottom base plate

• Inspection of welding By Penetration, RT, and Vacuum test

• Erection of Shell-5 plate on the bottom base plate and alignment with fit up

• Vertical welding of shell-5

• Inspection of vertical & Horizontal by RT through 10% of the total length of the welding

• Erection of shell-6 on the top of shell-5 and followed by alignment, fit up and welding of vertical

& horizontal welding

• Inspection of vertical & Horizontal by RT through 10% of the total length of the welding and

100% RT of the T-Joints

• Erection and fabrication of Roof

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• Installation and fabrication of available Baffle plates

• Erection of Hydraulic jacks inside the tank and distribute symmetrically such that every jack per

3 meter of the circumference

• Installation, erection of walk ways and hand railings if advised

• Lifting of the shell-5 by 2450mm height by hydraulic jacks

• Erection, alignment and fit up of shell-4

• Welding of horizontal and vertical welds

• Welding of Bottom shell -1to the Bottom base plate

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• Installation of Nozzle, pipe supports, flat forms, ladders, agitator supports and handrails

7 Curing and Weather Protection

All the plate will be supplied with sand blasted and primer coated by QI

All the welding edges will be protected by tape while painting

Any additional welding made on painted are will be power brushed and coated again

For locations with scratches, burns on painting etc during erection will be painted again.(rev-1)

8 Show hold points for internal and external required inspection including specified tests on

products

Fit up inspection for levels, weld gaps, etc

Vacuum test of welding of the bottom base plate

While welding Test of root pass with penetration test

Horizontal and vertical welds 10 % of the total length by RT

RT test for the T-Joints by 100%

9 Construction Equipment to be used , including standby Arrangement for breakage

While the shells are erected by Jacking of the top shells with Hydraulic Lifting Jacks which are

activated by a power pack A standby power pack is available for breakage And numbers of

spare hydraulic hoses are available for breakage

10 Lifting equipment, involved (where applicable, crash, tower crane…test and location)

For handling of plates cranes will be used for shifting, lifting, erection and purposes

11 Tools and associated other contractors Apparatus involved in this

The following tools are involved in work

• Welding Rectifiers machine

• Gas cutting torch

• Grinding machines of different sizes (100mm, 125mm and 150mm)

• Owen for baking of electrodes

12 Manpower involved and Trades, who does what and when

Supervisor for Tanks: - He takes care of all the activities associated in erection and fabrication of tanks and he involved in all the activities from staring to the finishing

Riggers: - These will involve in handling the plates for erection, alignment etc

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Fabricator/ Fitter: - He is responsible for fit ups, alignments, verticality and tolerances of the

total tank

Lifting Forman/ Jacking Specialist: - He takes the takes the lead role in alignment and

positioning of Hydraulic lifting Jacks, He takes the leading role in lifting of the tank shells at every step

Pipe Fitter: - He takes the fit up of nozzles and other pipe supports and structural items

Welders: - These will do all the welding operations

Grinders: - These will do grinding operation for the tank

Helpers: - These are the general helpers to skilled workers involving in job

Crane operator: - These will operate the crane

QA/QC Team: - These will guide the job for required QA/QC levels

13 Work Schedule Requirements’ and Timing for This work

For this job the daily regular work hours will be 10 hrs excluding lunch time

From 7-00Am to 6-00PM

On weekly half’s required core skilled workers like welders will be engaged if necessary

14 Training and Orientation for the Team

For all the team members TOOL BOX TALK will be conducted at the beginning of activity on daily

basis

The scaffolding team will be of trained and certified

The crane operator will be of trained and certified

The riggers involved will be of trained and certified

Regular monitor of welders and if necessary training will be given regularly

15 Tests on Systems (QA /QC )

Radiographic Test of all T-Joints by 100%

Vertical & Horizontal welding RT by 10 % of the total length of the welding

Vacuum test for the Base plate

Dye Penetrate Test for all Root pass and Final

In case Repair is needed, extension shots (penalty) to be match with API650

To be advised for any other test is needed

16 Logistics involved if work is expected to extend beyond normal working hours

Lighting while working at night

Shade protection while the wind velocity is very high

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17 Annexes and sketches lists

WEIGHTS OF THE INDIVIDUAL MATERIALS for crane, lifting gear selection purpose

1 IPE 270 TANK BOTTOM BEAMS

2 CS Plate of 2400mm Width X 12000mm Length mm X 16mm Thick = 3.617 Tones

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Isometric view of foundation after erection of I beams

Close up view of foundation, I Beams and bottom plate

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Erection, fit up and welding of bottom plate segments

Erection of 1 st shell plate on bottom plate

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Complete erection, fit up & vertical welding of 5 th shell

Erection of 6 th shell plate on 5 th shell by conventional method

Keeping vertical joints plates adjoining courses a minimum of 600mm apart

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Complete erection, fit up, vertical & horizontal welds of 6 th shell

Erection, fit up, welding of spiral stair case for the shells completed

Erection, fit up, welding of Baffles and stair case subjected to availability of material for 5 th & 6 th

shells

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Erection fabrication of Tank Roof before jacking

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Lifting of 5 th & 6 th shells by hydraulic jacks

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4 th shell 1 st plate erection, alignment on bottom plate

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4 th shell 2 nd plate fit up

Complete erection, fit up and vertical welding of 4 th shell

Jockeying down the 5 th shell to align with the 4 th shell, fit up and completion of horizontal welding

Erection, fit up, welding of Baffles plates, staircase etc subjected to availability of material and

approval for 4 th shell

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Lifting of 4 th shell for 3 rd shell erection

Erection of 3 rd shell first plate

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Erection fit up of 3 rd shell 2 nd plate

Complete erection, fit up and vertical welding of 3 rd shell plates

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Jockeying down to align top shells with 3 rd shell, horizontal welding of 4 th & 3 rd shells

approval for 3 rd shell

Lifting the 3 rd shell for 2 nd shell erection

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Erection of 2 nd shell first plate

Complete erection, fit up and vertical welding of 2 nd shell

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Jockeying down for alignment, fit up & horizontal welding between 2 nd shell & 3 rd shell

approval for 2 nd shell

Lifting 2 nd shell for 1shell erection and fit up

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1 st shell first plate erection, fit up

1 st shell complete erection, fit up & vertical welding of shell

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Jockeying down 2 nd shell to align, fit up and horizontal welding of 2 nd shell and 1 st shell

approval

Fillet welding of bottom plate to 1 st shell

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