METHOD STSTEMENT FOR SULPHURIC ACID PLANT

1500 MTPD Phosphoric Acid plant 4500 MTPD Sulphuric Acid plant METHOD STATEMENT

Project

1500 MTPD Phosphoric Acid plant 4500 MTPD Sulphuric Acid plant

Method Statement No CIVIL ELECTRICAL MECHANICAL INSTRUMENTATION

Date Name

Prepared by

Reviewed by

Safety Release

QA/QC Approval

Approved by

Section Engineer

Construction Manager

Safety manager

QA / QC Manager

Project Manager

Site Manager Date Name

METHOD STATEMENT FOR FINAL ABSORBING TOWER – Rev-0 Page

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1. INTRODUCTION The following is the method statement for the e rection of FINAL ABSOBING TOWER . It comes under Sulphuric acid plant (SA TOWERS).

2. Function and location, General Description, Scope of Work a) Function and Location The function of the Final Absorbing tower is to absorb so2/so3 from the process gas stream. It was located adjacent to Interpass Absorbing Tower and process stack.

b) General Description Final Absorbing tower is a brick lined Carbon steel vessel with pent house portion SS ID of the shell is 8900mm. Height of the Tower is 20723mm. It has mainly contains inlet and outlet for process air, Acid inlet and outlet. It contains upper transition, upper roof, lower roof, and Shell and bottom dish.

c) Scope of work Due to restriction in transportation the tower will be supplied in several segments like Bottom plate in 7 pieces, Lower Shell (ID8400mm) total 5 courses in 35 segments, Lower roof in 8 segments, Top shell (ID7360mm) in 3 segments, Top roof in 3 segments.

Scope Assembling, alignment and welding of bottom plate with tower supports. Assembling, alignment and welding of Lower Shells (ID8900mm). Assembling, alignment and welding of lower roof. Assembling, alignment and welding of penthouse shell (ID7600mm). Assembling, alignment and welding of top roof. Erection, Alignment and welding of the above segments to form one single Final absorbing tower. All required welding NDT test for each stage of fabrication and erection as per Technical Specifications Carbon Steel Vessels (338152-1300-45ES-0007) 3. Related Documents a) Technical specifications. b) Material Mill certificates c) Approved construction drawings. d) Weld map. e) Release of material for construction form SNC Lavalin. METHOD STATEMENT FOR FINAL ABSORBING TOWER – Rev-0 Page

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f)

Release certificate starting of erection over civil foundation from MID.

g) Vendor’s instruction/manual required. h) I.T.P (Inspection Test Plan) i)

All last revisions of Drawings, WPS, PQR, and Welder certificated, etc.

j)

Approved method and drawing for temporary supports

4. Required Material Testing, during and before work a) Material grade to be confirmed for WPS/ PQR/WELD Qualification. b) Batch number, Heat number punched on the plate to be compared with Mill certificate.

5. Environmental and Safety a) All the lifting tools gear like slings, belts, D-Shackles etc are of Tested & Certified by the TPI. b) Cranes involved in Erection are certified by TPI. c)

All the PPE used for the work is of approved quality.

d) All the Workers, Staff, Engineers involved in work are geared with full basic PERSONAL PROTECTION EQUIPMENT. e) TOOL BOX TALK will be conducted on daily basis at the starting of the job. f)

When working at height above 1.5mts from the ground every person to be wearing a safety belt.

g) When working at height proper scaffolding will be provided for ac cessing, testing, inspection for the client. h) Scaffolding work will be done by properly trained and certified workers only under the supervision of Engineer. i)

Entry Permit system for usage of scaffolding will be practiced.

j)

While starting of welding, gas cutting, grinding, gouging operations HOT WORK permit system will be practiced.

k) All the gas cutting torches are installed with approved Flash back arrestors. l)

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

m) While working in confined space CONFINED SAPCE ENTRY PERMIT system will be practiced. n) All the power tools are of certified c ertified and tagged properly. o) All the power, welding cables are of certified and tagged properly. p) For handling Plates special lifting tools like horizontal and vertical plate lifting tools are used. METHOD STATEMENT FOR FINAL ABSORBING TOWER – Rev-0 Page

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q) Good housekeeping will be practices at all the time. r)

Fire extinguishers are kept near the work for any fire incidents.

s)

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

t)

Best engineering will be practiced to avoid accidents.

u) Temporary attachments for erection purpose are to be suggested by MID (design).

6. Detail of work supported with sketches and with special highlight for details A. SETUP-A a) Preparation of rigid leveled platform for Fabrication. b) Inspection and testing (Radiography, Dye Penetrate Test and UT etc) of bottom ring as per section 6.2 of 338152-1300-45ES-0007 dated 2010-03-17. c)

Erection of Main shell -1 course segments on the lower ring Fit up and vertical Butt w elding of lower shell segments.

d) Alignment and fit up as per section 5.2.3 of 338152-1300-45ES-0007 dated 2010-03-17. e) Inspection and Testing of vertical welding as per specifications. f)

Welding of lower shell to the lower r ing by fillet circumference welding inside and outside.

g) Inspection & Testing of welding as per the specifications. h) Erection, fit up and Welding of upper ring. i)

Inspection and Testing of welding as per the specifications.

j)

Fit up and Welding of stiffeners and Vessel supports to the lower shell.

k) Lifting of the total lower part of the Drying tower fabricated so far to a height of min 1500mm.(see sketches). l)

Arrangement of scaffolding as per requirement.

m) Positioning the centre part of the dish in the above set up. n) Erection alignment of bottom dish stiffeners. o) Welding of stiffeners p) Erection alignment of outer segments and welding. q) Erection alignment of manholes and nozzles. r)

Completing all required QA/QC formalities.

s)

Location selection for temporary supports like pipe for internal and lifting eyes at outside.

t)

Fit-up and welding of temporary supports.


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BY COMPLETING THE ABOVE STEPS THE PART OF THE DRYING TOWER SO FORMED WE ASSIGN AS SETUP-A.

B. SETUP-B a) Erection of shell-2 plates on the platform. b) Alignment of shell plates fit up and welding. c) Erection of shell-3 on shell-2by conventional method fit up and welding. d) Erection fit-up and welding of nozzles and manholes. e) Completing all required QA/QC formalities. f)


g) Fit-up and welding of temporary supports.

BY COMPLETING THE ABOVE STEPS THE PART OF THE DRYING TOWER SO FORMED WE ASSIGN AS SETUP-B.

C. SETUP-C a) Erection of shell-4 plates on the platform. b) Alignment of shell plates fit up and welding. c) Erection of shell-5 on shell-4by conventional method fit up and welding. d) Erection fit-up and welding of nozzles and manholes. e) Completing all required QA/QC formalities. f)


g) Fit-up and welding of temporary supports.

BY COMPLETING THE ABOVE STEPS THE PART OF THE DRYING TOWER SO FORMED WE ASSIGN AS SETUP-C METHOD STATEMENT FOR FINAL ABSORBING TOWER – Rev-0 Page

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D. SETUP-D th a) Erection alignment and fit-up of 6 shell (C.S).

b) Welding of shell-6 vertical joints. c) Erection alignment of penthouse shell (S.S). d) Welding of pent house shell vertical joints. e) Erection fit up and welding of nozzles and manholes of penthouse shell f)

Completing all require QA/QC formalities.

g) Erection and alignment and fit up of lower roof over the shell-5. h) Welding of lower roof and welding of lower roof to shell-5(special welding C.S to S.S ). i)

Erection of penthouse shell over the shell-5.

j)

Fit-up and welding.

k) Erection and fit up of top roof. l)

Welding of top roof.

m) Location selection for temporary supports like pipe for internal and lifting eyes at outside. n) Fit-up and welding of temporary supports.

BY COMPLETING THE ABOVE STEPS THE PART OF THE DRYING TOWER SO FORMED WE ASSIGN AS SETUP-C

E. ERECTION OF SETUP-A, B, C & D OVER THE CONCRETE FOUNDATION.

a)

Arrangement of scaffolding at the foundation to the re quired levels.

b) Chipping and leveling of concrete c) Cleaning and preparation of foundation bolts. d) Erection leveling and alignment of shear keys. e) Grouting of shear keys. METHOD STATEMENT FOR FINAL ABSORBING TOWER – Rev-0 Page

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f)

Transporting the SETUP-A to the foundation.

g) Erection of SETUP-A on the foundation. h) Leveling and tightening of bolts. i)

Increase the height of the scaffolding to the required level.

j)

Transporting the SETUP-A to the foundation.

k) Erection of SETUP-B on the SETUP-A. l)

Fitup and welding between SETUP-A & SETUP-B.

m) Completing all require QA/QC formalities. n) Transporting the SETUP-C to the foundation. o) Erection of SETUP-C on the SETUP-B. p) Fitup and welding between SETUP-B & SETUP-C. q) Completing all require QA/QC formalities. r)

Completing the erection, alignment, fit up and we lding of ACID DISTRIBUTORS.

s)

Removing all the temporary supports and finishing the location.

t)

Completing the QA/QC formalities for the temporary support wel d areas.

7. Curing and Weather Protection a) All the plate will be supplied with sand blasted and primer coated by supplier. b) All the welding edges will be protected by tape while painting. c)

Any additional welding made on painted are will be power brushed and coate d again as per Technical Specification 338152-1000-40EG-0002.

d) For locations with scratches, burns on painting etc during e rection will be painted again. 8. Show hold points for internal and external required inspection including specified tests on

products. a) Fit up inspection for levels; weld gaps, etc as per ITP.

b) Dye Penetrate testing of all Root and F inal of all butt welds section 6.2.4 of 3381521300-45ES-0007). c) All the welded T-joints will be radio graphed 100% as per section 6.2.2 of 338152-130045ES-0007). d) Inspection and Testing as per the section 6.2 of 338152-1300-45ES-0007 dated 2010-03-

17. 9. Construction Equipment to be used , including standby Arrangement for breakage METHOD STATEMENT FOR FINAL ABSORBING TOWER – Rev-0 Page

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While the shells are erected using high capacity carne will be used with a large margin for safety.

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 a) Welding equipment and consumables. b) Gouging Torch c)

Gas cutting torch.

d) Grinding machines e) Surveying tools. f)

Hand tools.

g) Shim plates. h) Alignment Tools i)

Scaffolding

12. Manpower involved and Trades, who does what and when.

a) Mechanical Engineer: - 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. b) Fabricator;-He is responsible for fit ups, alignments, verticality and tolerances of the Interpass absorption tower. c)

Fitter: - He installs all the mechanical fittings inside and outside the Interpass absorption Tower.

d) Riggers: - These will involve in handling the plates for erection, alignment etc. e) Rigging Foremen: - He takes the takes the lead role in Transportation, Erection of Interpass absorption tower. f)

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

g) Welders: - These will do all the welding operations. h) Grinders: - These will do grinding operation for the tank. i)

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

j)

Crane operator: - These will operate the crane.

k) QA/QC Team: - These will guide the job for r equired 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. METHOD STATEMENT FOR FINAL ABSORBING TOWER – Rev-0 Page

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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 be ginning 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 cer tified. Regular monitor of welders and if necessary training will be given regularly.

15. Tests on Systems (QA /QC ) a) All test and Inspection will be in accordance to section 6.2.of 338152-1300-45ES-0007 dated 2010-03-17. b) Radiographic Test of all T-Joints by 100%. c)

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

d) Dye Penetrate Test for all Root pass and Final. e) In case Repair is needed, extension e xtension shots (penalty) to be match with API650 f)

To be advised for any other test is ne eded.

16. Logistics involved if work is expected to extend beyond normal working hours. a) Lighting while working at night.

b) Shade protection while the wind velocity is very high.

17.

Annexes and sketches lists. Note – All the pictures mentioned for purely general idea purpose only. These pictures will not influence the work directly or indirectly .


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METHOD STSTEMENT FOR SULPHURIC ACID PLANT

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