Method Statement for Tank Jack Lifting

CAIRN ENERGY INDIA PTY LIMITED MANGALA PROCESSING TERMINAL (MPT)

MANGALA ASSOCIATED FACILITIES PROJECT (EPC-1) TANKS AND EXPORTS SYSTEMS - PROJECT NO: M201 METHOD STATEMENT FOR SETTLING TANK ERECTION USING JACK LIFTING METHOD M201TPL-MPT-M-PRO-5029

A3

For approval

08.03.13

A2

Issued for Client Review

05/02/13

A1

REV

Issued For IDC

Purpose of issue

Sandeep

04/02/13

Arnab Goswami

Date of issue

Prepared by

Ajit

Amit

P.Natrajan

Supriyo Mitra

Checked by

Approved by

TATA PROJECTS LIMITED CAIRN ENERGY INDIA PTY LIMITED

MANGALA ASSOCIATED FACILITIES PROJECT (EPC-1) METHOD STATEMENT FOR SETTLING TANK ERECTION USING JACK LIFTING METHOD

SL.NO

DESCRIPTION

PAGE NO

1

Purpose

3

2

Scope

3

3

Reference Documents

3

4

Definitions

3

5

Health and Safety

3

6

Environmental

3

7

Training and competency of personnel

3

8

Process

4

8.1

General

4

8.2

Actual Load Calculation

4

8.3

Safe Working Load Calculation

4

8.4

Description of Equipment

5

8.5

Erection By Jacking Method

5

9

Closeout

7

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    

M201TPL-MPT-Q-PLN-0001 “Project Quality Plan” M201TPL-MPT-M-DS-3006 MECHANICAL DATA SHEET SETTLING TANK M201TPL-MPT-M-DS-3007 MECHANICAL DATA SHEET Export TANK HSE Plan M201TPL-MPT-R-PLN-001 and relevant HSE Procedures

4. DEFINITIONS CEIL - Cairn Energy India Pty. Limited(Client) EIL

- Engineers India Limited (PMC)

TPL

- TATA Projects Limited (EPC Contractor)

5. HEALTH & SAFETY 5.1

As per HSE Plan, the following system to be followed

5.2

All relevant elements of HSE Plan shall be followed.

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

First Aid arrangements shall be followed as per procedure.

6. ENVIRONMENTAL 6.1

Refer to Environment Management instructions.

6.2

All activities shall comply with Environment Management Plan.


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7. TRAINING AND COMPETENCY OF PERSONNEL 7.1

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

PLATFORM & STAIRWAYS

11.20

SHELL COURSES

142.00

WIND GIRDER

3.50

TOTAL


300.00

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8.3

SAFE WORKING LOAD CALCULATION Before going for JACK capacity calculation Safe Working Load shall be derived from the actual load calculation. The Safe Working Load will be 1.5 times of the actual load. SWL=1.5 X 300.00 MT

8.4

=450.00 MT. DESCRIPTION OF EQUIPMENT Hydraulic Cylinder Type BW 12-200 Lifting Capacity

12tonnes

Maximum lift height

100mm.

Weight

Approx. 25kg

Lifting Trestle with Two Supporting Stay legs

8.5

Safe Working load

12tonnes

Maximum lift height

2.5m or 3m

Total unit weight

approx. 200kg

Largest component

Approx. 75kg

Jack rod

40 mm diameters

ERECTION BY JACKING METHOD 1)

Mark the shell I/S diameter and fix the elevators on the annular plate.

2) Tack the guide on the elevators. M201TPL-MPT-M-PRO-5029

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3)

Weld the lifting cleats. (2 nos. /Jack; capacity of hydraulic jack-12 MT; For settling Tank – 38Nos (Min.), Export Tank – 55Nos (Min.).

4)

Weld the pad plates. ( 1 no for trestle & 2 no’s for stay member)

5)

Install trestle and stay member. Length of the trestle to be checked according to shell heights.

6)

Connect the high pressure hosepipes from power pack to each jack.

7)

Give electrical power connection to power pack and start jacking.

8)

Continue jacking till the assemble is lifted to a height of 50 mm more than the width of the shell course to be erected next.

9)

Erect the shell course by using crane or by any mechanical means.


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9. CLOSE OUT: All vehicles, tools & tackles shall be removed from the area after completion of the job. 10. PERSONNEL I

Peoples Involved 

Construction Manager.



Project QA/QC Manager.



QC Engineer.



Site Engineer.



HSE Engineer.



Site Foreman.

II Roles and Responsibilities – Refer Project Quality Plan M201TPL-MPT-Q-PLN-0001 Responsibility and authority section.


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11.

Tank erection Sequence

Sand Blast , complete Painting On Bottom Surface of Annular Plates

STOOL ERECTION

6th Shell – Painting on outer surface one coat - and Bottom Plate along with complete painting

Compression Ring Painting on outer surface one coat

Centre Column along with complete painting

Trusses And Cross Girder along with complete painting – Lift Assly

5th Shell along with one coat painting

Wind Girders / Foam Chambers/ Stair case along with one coat painting /Roof Plat form / Roof Nozzles - LIFT


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4th Shell along with one coat painting

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

Nozzles / Stair case/Balance Roof Plat form - LIFT

2nd Shell

Nozzles / Stair case/ - LIFT

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 3. One Plate S1A 25 mm Thk @ 270 ° to Nozzle N3 After installation above plates, following activities to be taken up, 1. Oil suction bucket assly shall be installed along with all structural support. 2. Fixing of base plates on the tank shells and oil bucket for support of Bumper supports to hold Main Distribution and lateral distribution supports. M201TPL-MPT-M-PRO-5029

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3. Main distribution holding supports shall be drilled for bolting holes as per Drg before welding on base plates on shells & suction bucket assly. 4. Marking shall be done for welding of 8 mm x 300 mm x 300 mm base plates for supports for Steam pipe on entire Bottom plates as required. 5. Fabricate all Steam Pipe Supports in workshops as per Drg and keep ready for installation. 6. Fabrication of Steam pipe ( Flange to flange) spools shall be kept ready for assly inside the tank along with U- clamps. Also supports shall be pre fabricated out side tank before erection along with pipe. 7. Base plate for Bumper assly shall be fabricated on shell plate. Lateral distribution Bumper assly shall be fabricated as per the Drg. Fabricated Bumper support to be welded to the shell as per the Drg. 8. Draw off sludge support shall be kept ready for assly on the bottom of the shell dully painted as required. 9. While prefabricating the main and lateral distribution shells at work shop, please (ensure)fabrication of adjacent lateral distribution shell with respective main distributive shell shall also be completed to avoid local welding inside the tank. 10. Main and lateral distributer shells shall be one coat painted with Glass flake paint before shifting for assly. 11. Assemble the main distributing shell with bumpers fixed on the shell. 12. After completion of alignment of main distributing shell , Seal weld shall be done for complete assly of the Main distributive shall. 13. Similarly lateral distributive shell shall be aligned and seal welded. 14. After complete erection of main and lateral distributers, Oil through, oil suction buckets, and draw off sludge assly with pipes – Now the inside of tank is ready for copper blasting. 15. Keep the shell -1 open (only with 4 plates in place and welded), start the copper blasting for entire shell plate, before start of blasting the shell plates, roof structure and plates shall be covered by appropriate coverage to avoid damage of paint due to copper grit striking the paint surface during copper blasting of shell plates. 16. VEGF (Vinyl Easter Glass Flake) paint holding primer is to be applied on the inside of the shell within 4 hrs from the time of completion of copper blast. Keeping the shell-1 open helps to 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.


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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.


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13. QA/QC Testing ( NDT testing )

Following are the testing methods for fabrication works are followed for quality controls. Areas and type to be tested. a. b. c. d. e.

All butt welds horizontal joints All T- JointsAnnular to Shell Plate – All fillet Weld – RF pads for Nozzle –

10% Radiography 100% radiography. Chalk test by High Speed Diesel. Vacuum tests 100 %. Pneumatic test.

However other than tests mentioned above, as per standards, following additional test are also taken up for higher quality standards. All fillet Welds and Butt welds – Shall be provided with 100% DP test to find the quality of the weld.


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14 Sand Blasting / Painting / Hydro test / – Further to the sequence of operation of Tank fabrication and erection the following are the sequence of operation to be followed for Sand Blasting / Painting / Hydro test / 1. All Shell plates shall be pre fabricated, tank external surfaces of shell plates copper blasted & one coat painted before the shifting to site for erection. Similarly all roof structure members shall be cut to required size, copper blasted painting as pr requirement shall be completed and then proceed for fabrication of Roof structure /cross girder assly. After fabrication and before erection heat affected zone shall be painted for final coat. 2. All bottom plates shall be prefabricated, copper blasted and painting is completed with all respect for erection and welding of bottom plates. 3. All internals shall be pre fabricated / copper blasted and final coat painted before erection. However Oil through shall be copper blasted and covered with adhesion paper to avoid cleaned surface contamination with atmospheric contamination to lead rust. After erection adhesion paper shall be dismantled and proceed for final painting. 4. After complete erection of Tank shells, Roof structures and all other internals proceed for copper blasting of tank internal shell surface, however shell course No 1, shall not be closed to form full tank. This sis to avoid dust particles to escape from tank inside area to prevent contamination with tank internal shell surface while painting hold primer. 5. After complete copper blast and primer paint of tank internal shell surfaces, while 1st shell is still open, cover the tank open area by temporary cloth to avoid spreading of copper grits to escape while copper blasting of bottom plate and annular plate. Complete the bottom plate and annular plate primer paint and thus completing the copper blasting and primer painting on all internal surfaces of the tank. 6. Now clean the all internal surfaces of tank shell plates including all internals by water and thus preparing the tank internal surface ready for Vinyl Easter Glass flake paint as per specification requirement. 7. Complete the Vinyl Easter Glass flake painting in presence of NACE-II expert and obtain the clearance from CAIRN. Above all activities shall allow proceeding for Hydro Test of Tank Shell.


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Hydro Test – Since erection of tank has been completed as per approved Drg and Painting is also completed as per quality requirements and approved documents, now the tank is ready for Hydro test. Sequence of operation for hydro test. 1. Check the completeness of tank with respect all approved Drg for mechanical erection completion. 2. During the hydro test, all instrumentation shall be excluded to avoid the damage to instruments. 3. Since the hydro test is to be carried out by produced water, ensure all Hook ups of pipes with tank nozzles so that, produced water from operating plant can be fed to settling tanks.

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 1 2 3 4 5 6

7

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 M201TPL-MPT-M-PRO-5029

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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 24 ours max between each stage of filling. 12. During the stabilization period the settlement reading shall be observed and recorded jointly with CAIRN/EIL through dumpy level. 13. Filling rate shall be not exceeding 5 meters per day. 14. After completion of the water filling the water load shall be maintained for 24 hours. After 24 hours the final settlement reading shall be recorded jointly with client. 15. Tank shall be emptied at a maximum water level variation rate of 5 meters per day. Care shall be taken that top manholes are open during empty operation of conical roof tanks. 16. If salt water is used then corrosion inhibitor should be sprayed (mixed) prior to filling / after hydro test the tank should be thoroughly cleaned with sweat water. 17. After hydro test all instrument and Electrical items shall be restored to connection as per project / documents requirements.


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TANK CALIBRATION PROCEDURE 1. Definition Tank Calibration is the process of determining the Volumetric Content of a tank per unit height of liquid. 2. Scope This procedure shall be intended for calibration of Oil Storage Tanks for M/s. Cairn Energy India Pty. Ltd., Barmer Mangala Process Terminal in the state of Rajasthan. 3. Calibration standards The calibration shall be carried out by Optical Reference Line Method (ORLM) in accordance with following API Standards. : API 2550, Section 2B : ISO 7507, Part 2 4. Calibration Agency The calibration shall be carried out by the following agency. M201TPL-MPT-M-PRO-5029

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R.P.J. CONSULTANTS & ENGINEERS B-6/2, Saptarishi, Anand Nagar, Manpada Road, Dombivili (East), Dist. Thane – 421 201 (MS) Person to contact Mr. P.L. Mahajan, Phone No.: (0251) 22456677 Fax No.: (0251) 2456489 e-mail: [email protected] Mobile: 09821063498 5. Summary of Tanks Sr. No. Tank No.

Dimensions

Type Qty.

1 2

32.7M Dia X 11.9M Ht 51M Dia X 11.9M Ht

CR CR

MPT-D-234/244 MPT-D-250E/F

02 02

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 M201TPL-MPT-M-PRO-5029

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Sr. No.

Equipment

Size

Make

1.

Strapping Tape

100 M

Ritcher Metri, Germany

2. 3. 4. 5. 6.

Dip Tape with Dip Wt. 30 M Measuring Tape3 M Spring Balance 10 Kg Theodolite/Tripod Water Tube 50 M

Ritcher Metri, Germany Freemans Salter Lieca, Germany/ Kolida, China

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) M201TPL-MPT-M-PRO-5029

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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%.

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. M201TPL-MPT-M-PRO-5029

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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. 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.

d). Computation of Capacity Table Once the field measurements have been carried out the accumulated data is input onto our computer program to obtain the tank table on recommended format of non-tearable tracing paper showing the capacity in liters at every 1 cm depth and fractions in mm to interpolate dip readings and get the Calibration Chart duly certified and Approved by Competent Government Authority. A Soft copy of EXCEL file of Tank Capacity table shall also be submitted to load tank capacity in the tank gauging system.


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Method Statement for Tank Jack Lifting

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