Académique Documents
Professionnel Documents
Culture Documents
A3
A2
A1
REV
For
approval
Issued for
Client
Review
08.03.1
3
Sandeep
Ajit
Amit
P.Natrajan
Supriyo
Mitra
Checked
by
Approved
by
05/02/1
3
Issued For
IDC
04/02/13
Arnab
Goswami
Purpose of
issue
Date of
issue
Prepared by
SL.NO
DESCRIPTION
PAGE NO
Purpose
Scope
Reference Documents
Definitions
Environmental
Process
8.1
General
8.2
8.3
8.4
Description of Equipment
8.5
Closeout
10
11
12
13
14
15
Personal
Tank erection Sequence
Scaffolding
QA/QC testing ( NDT) testing
Sand Blasting / Painting / Hydro Test
Calibration of Tanks
7
8
11
12
13
16
M201TPL-MPT-M-PRO-5029
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1. PURPOSE
The purpose of this method statement is to explain the various steps involved in lifting the Settling
Tank shells by Jack Lifting Method.
2. SCOPE
The scope of this method statement describes the method of lifting of Settling Tank using Jack
Lifting Method at Phase II-Mangala Process Terminal; associated facilities project EPC 1 Project
of CAIRN ENERGY INDIA Ltd.
3. REFERENCE DOCUMENTS
4. DEFINITIONS
CEIL - Cairn Energy India Pty. Limited(Client)
EIL
TPL
5.2
5.3
Emergency and response Plan shall be followed in case of any emergency. Road
Transport safety procedure shall be strictly adhered while transportation of manpower
or formwork materials by vehicles.
5.4
Daily Tool Box talk shall be conducted prior to proceed for the work.
5.5
6. ENVIRONMENTAL
6.1
6.2
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Daily Tool Box talk shall be conducted by job supervisor and weekly tool box
talk shall be conducted by respective area in-charge.
8. PROCESS
8.1 General
Prepare work permits, JSA and working procedure for CIL approval prior to
commencing work.
Organise a pre job safety meeting with all concerned to brief the planned
work activities and discuss their associated risks.
All lifting gears such as wire slings, web slings, shackles etc shall be inspected
and shall come with the valid load test certificate prior to lifting.
All personnel that will be involved with the works shall review the Job Safety
Analysis, Work procedure and conduct tool box meeting immediately before
commencement of work.
Ensure all personnel are equipped with appropriate PPE for the right job
especially for personnel working at height to wear safety harness, hand
gloves and vest.
Barricade the work area with red and white tape, sufficient warning sign
boards, work permit and JSA at Work site. Only authorized personnel are
allowed to be within the area during the lifting and erection works.
Erect Scaffolding/ install temporary support and platform to ensure works
accessibility.
8.2 ACTUAL LOAD CALCULATION
For Settling Tank D-234 & D-244 the Total Loads to be lifted shall be arrived
from the approved Drawings.
The Details as follows:
DESCRIPTION
WEIGHT IN TONNES
ROOF PLATES
81.00
ROOF STRUCTURE
51.00
SHELL APPURTENANCES
9.80
ROOF APPURTENANCES
1.50
11.20
SHELL COURSES
WIND GIRDER
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142.00
3.50
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TOTAL
300.00
12tonnes
100mm.
Weight
Approx. 25kg
12tonnes
2.5m or 3m
approx. 200kg
Largest component
Jack rod
M201TPL-MPT-M-PRO-5029
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Approx. 75kg
40 mm diameters
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9. CLOSE OUT:
All vehicles, tools & tackles shall be removed from the area after completion of
the job.
10.
PERSONNEL
II
Peoples Involved
Construction Manager.
QC Engineer.
Site Engineer.
HSE Engineer.
Site Foreman.
Roles and Responsibilities Refer Project Quality Plan M201TPL-MPT-Q-PLN0001 Responsibility and authority section.
M201TPL-MPT-M-PRO-5029
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11.
STOOL ERECTION
6th Shell Painting on outer surface one coat - and Bottom Plate along
with complete painting
Trusses And Cross Girder along with complete painting Lift Assly
Wind Girders / Foam Chambers/ Stair case along with one coat
painting /Roof Plat form / Roof Nozzles - LIFT
M201TPL-MPT-M-PRO-5029
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Wind Girders / Nozzles / Stair case along with one coat painting /Balance
Roof Plat form along with one coat painting, Nozzles LIFT( Partially)
On 4th Shell ( Only on 4th Shell) Oil through support bracket fabrication,
Oil through bottom plate fabrication with shell plate, Oil through vertical
plate fabrication with support bracket. Oil through plates shall be pre
fabricated as per Drg and Sand blasted. Sand blasted surfaces shall be
protected with the help of adhesion tape to protect the sand blasted
surfaces from rust. Bottom of the oil through surface shall be fully welded
with support bracket of oil through, balance structural work of Oil through
after erection of 1st Shell on nozzle portion.
3rd Shell
2nd Shell
1st Shell Plate erection with one coat painting external to the tank (Only following plate erection shall be taken preliminarily
1. One plate on Inlet nozzle N3 @ 180 area Plate S1A -25 mm
Thk
2. One Plate S1A 25 mm Thk
@ 90 to Nozzle N3
M201TPL-MPT-M-PRO-5029
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avoid dust to escape from the tank so that during the painting,
paint surfaces will not affected by dust contamination.
17.Now complete the copper blast of un erected shell plates at
bottom level ( level -1) and apply primer paint.
18.Erection of all shell plates now to be taken up and complete within
2 days of time.
19.Primer painting shall be done on weld joint,( shell course No1 and
2) after manual cleaning
20.After copper blast and primer painting, now the tank is ready for
final paint coating of VEGF (Vinyl Easter Glass Flake).
21.Apply VEGF (Vinyl Easter Glass Flake) on the internal surface of
shell and release for Holiday test as required by FQP.
12.
Scaffolding
Scaffolding the is safety requirement is a temporary structure used to support people and material
in the construction or repair of buildings and other structures. It is usually a modular system of
metal pipes or tubes.
After the assembly of all internals OR if possible during the assembly of Internals to the possible
extent Scaffolding is being constructed inside the tank along the periphery of the tank for
activities related to copper blasting and painting activities.
Scaffolding for roof welding and touch up paint for roof under side, shall be carried out with the
help of hanging plat form constructed with girder clamps on roof structures and cross girder.
Detailed calculations for Quantity requirement is enclosed along with sketches of Scaffolding
construction.
M201TPL-MPT-M-PRO-5029
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13.
Following are the testing methods for fabrication works are followed for quality controls.
Areas and type to be tested.
a. All butt welds horizontal joints -
10% Radiography
b. All T- Joints-
100% radiography.
Pneumatic test.
However other than tests mentioned above, as per standards, following additional test are also
taken up for higher quality standards.
M201TPL-MPT-M-PRO-5029
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All fillet Welds and Butt welds Shall be provided with 100% DP test to find the quality of the
weld.
SCOPE
1. This test procedure shall be carried out to detect the leak in shell weld joints
and to observe the load stabilization of liquid in interval level height.
PURPOSE
1. The purpose of this procedure is providing the guideline and sequential steps
for the hydro test / water fill up test for the tank.
CHECK LIST
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1
2
3
4
5
6
After completion of the erection, welding and NDT the following points shall
be checked before testing.
All the mechanical activities completion in respect of the drawing.
Radiography completion including repairs.
The entire NDT test like chalk-diesel test, LPT (DP) , RF .Pad pneumatic test,
vacuum box test completion.
During the hydro test of the tank all Instruments shall be isolated to avoid the
damage during the hydro test
Since the is to be carried out by Tumbli Water / Injection water, ensure all
hook ups of required pipes with tank nozzles, so that Tumbli Water / Injection
water from operating plant can be fed to settling tanks.
Line Size ( Line Number)Isometric Drg No
Vent and M/w Open to be checked while filling the water to ensure air
release.
Finally mechanical clearance from the CAIRN/EIL shall be taken before
commence of hydro test in approved format
TEST MEDIA
Test media shall be Produced Water from MPT.
PROCEDURE
1
Required pipe shall be identified to allow the produced water to feed into the
settling tank. Ensure the hook up to be completed to settling tank nozzles as
per approved Drg.
2. Markers shall be provided on the shell, 500 mm from the bottom to check
tank settlement. Size shall be 50 X 50 X 6mm angle and 100 mm long. The
nos. of setting marker shall be minimum 4 Nos
3 Setting marker shall be welded and initial level reading shall be taken with
respect
to the permanent benchmark using dumpy level / Total station
4 Shell settlement measurements shall be made after tank erection, prior to
Hydro testing
5 and during water filling at 1000 mm intervals up to maximum filling height of
tank.
6 The levels taken before water filling called as initial level of the tank and shall
be recorded in an approved format.
7. The water filling height shall be restricted to the max. Liquid Level or up to
the curb record.
8. The water filling shall be carried out in four stages (25%, 50%, 75% & 100%
of the
max liquid level of the tank)
9. Any leaks observed in the shell joint during the hydro test shall be noted and
repaired with the water level min. of 300mm below the leak spot.
10.The repaired shall be carried out as per the procedure and tank test shall be
recommended.
11.After each stage of filling, a load stabilization period shall be
observed as
minimum
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Mobile: 09821063498
5. Summary of Tanks
Sr. No. Tank No.
Dimensions
Type
Qty.
1
2
CR
CR
02
02
MPT-D-234/244
MPT-D-250E/F
6. Location of Tanks
Cairn Energy India Pty. Ltd.,
Barmer Mangala Process Terminal,
Barmer (Rajasthan)
7. Condition for Measurements
a. All details about tank including drawings shall be provided to the Calibration
agency before carrying out calibration.
b. Calibration of Shell and bottom up to datum point shall be
carried out only after hydrostatic test of the tank. The tank shall be
completely empty and clean.
c. The measurement works shall be carried out after ensuring the
tank is totally available for measuring work in safety condition.
8. Calibration Equipment
Following equipments provided by calibration agency will be used for
Sr. No.
Equipment
Size
Make
1.
2.
3.
4.
5.
6.
Strapping Tape
100 M
measuring.
M201TPL-MPT-M-PRO-5029
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Calibration Method
a). Vertical Calibration
For use of Optical calibration a reference circumference is required.
This is obtained by taking the average circumference of the
bottom plate course, which is measured by strapping either
continuously or for larger tanks in series of areas by the use of
calibrated master tape. Reference strapping is taken at 80% from
the bottom of the course.
On the reference circumference stations are marked at equal
intervals around the tank wall, the number of optical perpendicular
stations. This is obtained by the following formula.
Stations = Circumference in meter
6
(Rounded the nearest even number of stations with the minimum
of 8 stations and maximum of 24 stations)
The horizontal stations shall be chosen to insure that the vertical
transverse of the trolley along the shell at any given station shall
be at least 300mm from the vertical weld seam and their should
be no interference in its line of travel.
For any given horizontal station, a minimum of two vertical
stations is established for each course at 20% and 80%.
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At the first station the theodolite in set up with its standing axis at
a known distance from the tank wall. The movable scale assembly
is placed against the tank wall and pulled upwards until the
graduated rule is at the same level as eyepiece of the theodolite a
reading on the graduated rule is taken.
Subsequently reading is then taken at all required levels. Two
reading per course minimum.
b). Bottom Calibration
Similar number of horizontal stations marked inside the tank at
equal distance around the circumference.
Vertical stations are taken from the center of the tank to the inside
of the wall, 5M apart with the first station at 0.5M from the wall.
By placing a water tube at the center of the tank and taking
reading with a water tube at each vertical station, the profile of the
tank bottom can be obtained.
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From this profile the volume can be calculated using the correct
formula for the geometrical shape for the floor with irregular
configuration.
c).
Deadwood Measurements
The entire deadwood is accurately accounted for as to the volume and location in
order to permit adequate allowances for volumes of liquid displaced by various
objects and allocation of these effects at various elevations within the tanks.
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