FABRICATION, Procedure FOR STORAGE TANK

Table of Contents
1. PURPOSE............................................................................................................................................. 3
2. SCOPE.................................................................................................................................................. 3
3. DEFINITIONS & ABREVATIONS...........................................................................................................3
4. REFERENCES/ CONTROLLING SPECIFICATIONS.............................................................................4
5. RESPONSIBILITY................................................................................................................................5
6. CONSUMABLE HANDLING...............................................................................................................9
7. MATERIAL HANDLING.......................................................................................................................9
7.1 Identification OF Materials.....................................................................................................9
8. PREFABRICATION.............................................................................................................................. 9
8.1 General........................................................................................................................................ 9
8.2 Annular Plates........................................................................................................................10
8.3 Bottom Plates & Sump........................................................................................................11
8.4 Shell........................................................................................................................................... 12
Marking12
8.5 Nozzles, Manhole & Cleanout Door..................................................................................15
Marking15
8.6 Roof Plate.................................................................................................................................17
Marking17
Cutting & Edge Preparation..............................................................................................................17
8.7 Roof Structure........................................................................................................................18
Marking, Cutting and Welding.........................................................................................................18
8.8 Stairway and Miscellaneous Structure..................................................................................19
9. PWHT.................................................................................................................................................. 19
10. MATERIAL TRANSPORTATION..................................................................................................20
11. WELDING REQUIREMENTS........................................................................................................21
12. SITE ................................................................................................................................................. 23
12.1 Sequence of Activities.........................................................................................................23
12.2 Foundation Takeover.............................................................................................................23

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 12.3 Bottom Annular Plate and Sketch Plan ................................................................................24
12.4 of Last Three Shell Courses & Compression Ring by Conventional Method.......27
12.5 of Roof Structure...................................................................................................................31
12.6 of Roof Plate...........................................................................................................................32
12.7 of Remaining Shell Courses by Jacking Method..................................................................33
12.8 INSTALLATION OF SHELL NOZZLES AND MANHOLE................................................................35
12.9 INSTALLATION OF SPIRAL STAIRWAY AND OTHER ATTACHMENTS.........................................36
13. PNEUMATIC TESTING OF RF PAD..............................................................................................37
14. TANK HYDRO TESTING...................................................................................................................37
15. INTERNAL & EXTERNAL PAINTING................................................................................................37
16. QUALITY ASSURANC & QUALITY CONTROL............................................................................37
17. INSPECTION & TESTING................................................................................................................37
18. JACK CALCULATION FOR STORAGE TANK...............................................................................39
19. FOR FIXING OF JACKS................................................................................................................39
20. CONTRUCTION PROCESS FLOW CHART..................................................................................42
21. HSE MANAGEMENT......................................................................................................................43
22. CONSTRUCTION RISK CONTROL SCHEDULE (Refer BSTC-00-SAF-LST-EXT-388-00001-00
for in detail control measures)
44
23. TANK CALIBRATION .....................................................................................................................49
24. MRB................................................................................................................................................. 49
25. PROPOSED MAJOR EQUIPMENTS /TOOLS / TACKLES..........................................................49
26. MANPOWER................................................................................................................................. 49
27. CATALOG OF HYDRAULLIC JACK................................................................................................50
28. CATALOG OF ROLLING MACHINE..............................................................................................51

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1. PURPOSE
Purpose of this work is to describe, monitor and control all activities related to the
fabrication, , installation of storage tank as per API 650/approved drawings and
equipment & manpower required for the same. All the tasks / activities need to be
accomplished with at most care with good workmanship and in accordance with
the specifications and requirements to achieve satisfactory completion of the
whole activities. It is only a guideline and may be revised and submit for approval
during construction depending on actual site condition; however, the final
inspection and acceptance shall be strictly as per API 650, contract
specification, and approved ITP.

2. SCOPE
This method Statement covers the requirements for the field , repair, testing of the
storage tanks as per API 650
The most stringent and installation specifications/guidelines shall be implemented, and
the order of precedence shall be as follow:

Codes, project specifications and s.

Requirements of this Method
Statement.

3. DEFINITIONS & ABREVATIONS

Company : - Contractor :-
Sub- Contractor :-
STS Sub-Contractor :-
PO : - Purchase Order
PR : - Purchase Requisition
TPI : - Third Party Inspector
ITP : - Inspection Test Plan
AFC : - Approved for Construction
ASME : - American Society for Mechanical Engineers
API : - American Petroleum Institute
WPS : - Welding Specification
PQR: - Qualification Record
BOM : - Bill of Material

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 QCP Quality Control Plan
ID Inside Diameter
OD Outside Diameter
HDG Hot Dip Galvanization
NDT Non-Destructive
Testing
RT Radiography Test
UT Ultrasonic Testing
LPT Liquid Penetrant
Testing
MPT Magnetic Particle
Testing
RF pad Reinforcement pad
COD Clean outdoor
PWHT Post weld heat
treatment

4. REFERENCES/ CONTROLLING SPECIFICATIONS

1) API Standard 650 -13th edition, March 2020 - Welded Tanks for Oil Storage
2) ASME Section V (Latest Edition) Non destructive Examination
3) ASME Section VIII, Div.1 (Latest Edition) Rules for Construction of Pressure Vessels
4) ASME Section IX (Latest Edition) Welding and Brazing Qualifications
5) Contract Documents
6) Approved Purchase Order
7) Purchase Requisition
8) Client/ Project specification
9) Approved AFC drawings
10) Approved ITP’s
11) Approved welding consumable handling
12) All applicable as per approved NDT s provided by STS.
13) Approved Weld repair
14) Approved PWHT
15) Approved RF pad pneumatic test
16) Approved Hydro testing
17) Approved Surface preparation & coating for shell plates, shell / roof
nozzles, manways, roof Plates, stiffeners with supports, external cleats /
18) Surface preparation & coating for underside of tank bottom plates, annular
plates, draw off sump external surfaces.
19) Approved Surface preparation & coating for structure
20) Approved Surface preparation & coating for roof inside surface & internal
roof structure.
21) Tank calibration provided by STS.
22) Approved HEMP.
23) Night work safety provided by STS.
24) OPAL standards.
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5. RESPONSIBILITY

Project Manager:

a) Shall be responsible for providing resources to implement this .

b) Shall be responsible for control supervision and direction for implementation.
c) Managing and coordination of all aspects of the project.
d) Acts internally across the project team particularly project coordinator,
construction manager, QAQC manager and other construction team
members.
e) Acts externally with client and subcontractors.
f) Preparation & monitoring of project schedule.
g) Conduct review meetings.
h) Focal point for all communications.
i) Co-ordination with the site representative.
j) Co-ordinate with all involved functions for obtaining the necessary
resources manpower, equipment and materials for the project and deploy
as required.
k) Review the Contract periodically, as, and when required, throughout the
execution of contract.
l) Reports to Contracts Manager.

Site Manager/ Construction Manager:

a) Acts with Company Site Management and acts as focal point for all site communications.
b) Ensures requirements are correctly transferred to the Contractor and Sub-Contractors.
c) Maintain smooth functioning of site execution and subcontracts throughout
the contract period.
d) Overall execution and administration of the Contract in their specified area
as per the Contract requirements, Specifications & Contract Quality Plan.
e) Identify training needs and co-ordinate with appropriate functions for
fulfilling the training requirements.
f) Ensure appropriate actions are taken for non-conformance, if any, identified
during auditing (internal & external).
g) Co-ordinate with the QA Engineer for fulfilling the Quality System
requirements and complying with the Quality System of the Contract.
h) Ensure that the transport requirements of personnel, materials &
equipment for the Contract are met in time.

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 i) Reports to the Projects Manager. In his routine job, he is assisted by
Planning

Engineer, Supervisors and Material Controller.

j) Provide necessary support for HSE and ensure adequate resources are
available for safe operation of the task.

Planning Engineer

a) Monitoring the work progress and ensuring it is as per the schedules with Site in charge.
b) Analyze change of scope or delay, incorporate changes & if required
reschedule to meet the target.
c) Plan and arrange required manpower & resources in co-ordination with Site in Charge.
d) Prepare progress reports and submit them to the Company for review.
e) Prepare drawbacks, Manpower, and Equipment Development Chart as per in the
Contract.
f) Check the availability of all materials for the Contract with Procurement Manager.
g) Reports to the Projects Manager and assist Site in charge.

QA/QC Engineer (Shop based)

a) Acts with Contractor Representative and Customer Representative for the

quality planning and conduct daily Quality related works.
b) Provide guidance for implementing Quality System requirements in the prefabrication
shop.
c) Is responsible for the control Calibration of Inspection Measuring and Test
Equipment and maintenance of Calibration records.
d) Is responsible to ensure the dimensions of the prefabricated items are within
the required dimension of drawings and with required tolerances for site .
e) Is responsible for preparing all dimension reports.
f) Holds the authority for review and disposition of quality related non-
conformance during manufacture and installation.
g) Conduct of internal & subcontractor audits and takes corrective actions.
h) Monitoring Sub-Contractor’s performance for compliance with quality requirements.
i) Verify the documents available at the locations as identified in the
document distribution matrix and are of the latest revision and ensure
submission of project quality documentation.
j) Prepare inspection and test plans and ensure effective implementation, and
monitoring. Review of Sub-contractors’ Quality Plan statements and work
instructions.
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k) Maintain all relevant and updated Codes & Standards and Specifications.

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 l) Control further processing, delivery, or installation of non-conforming
product until its deficiency or unsatisfactory condition has been corrected
with Company approval.

QA/QC Engineer (Site based)

a) Acts with Contractor Representative and Customer Representative for the

quality planning and conduct daily Quality related works.
b) Provide guidance for implementing Quality System requirements in the project site.
c) Is responsible for the control Calibration of Inspection Measuring and Test
Equipment and maintenance of Calibration records.
d) Holds the authority for review and disposition of quality related non-
conformance during manufacture and installation.
e) Conduct of internal & subcontractor audits and takes corrective actions.
f) Monitoring Sub-Contractor’s performance for compliance with quality requirements.
g) Verify the documents available at the locations as identified in the
document distribution matrix and are of the latest revision and ensure
submission of project quality documentation.
h) Prepare inspection and test plans and ensure effective implementation,
and monitoring. Review of Sub-contractors’ Quality Plan statements and
work instructions.
i) Maintain all relevant and updated Codes & Standards and Specifications.
j) Control further processing, delivery or installation of non-conforming
product until its deficiency or unsatisfactory condition has been
corrected with Company approval.
k) QA/QC Engineer reports to QA/QC Manager & assisted by QC Inspector in his duties.
l) Is responsible to raise RFI for client as per ITP and maintain RFI register.

QA/QC Inspectors

a) Acts with the Company Site Representative for the conduct of day-to-day
quality related activities and report to QA/QC Engineer.
b) Verify latest copies of all the QA/QC s, QC plans and Work instructions are
available at site in coordination with QA/QC Engineer
c) Verity calibration status of inspection and testing equipment are valid.
d) Carryout all inspection and test requirements of the project at all stages as
per the QCP and contract requirements. Witness and interpret test results
accurately. Maintain inspection test status at every stage of inspection.
e) Maintain records of inspection and test till the end of contract.
f) Implementation and supervision of all Sub-Contractor’s QCP/ s and Work
instructions.
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 g) Monitor Sub-Contractor’s performance for compliance with Quality requirements.
h) Identify and raise NCRs for non-conformed activity.
i) Verify corrective/ preventive action taken for non-conformance.

Supervisors / Foremen

a) Ensure all activities are carried out in compliance with this method statement and
drawings.
b) Ensure all personnel are using proper PPE for the tasks specified for them
and maintain close supervision.
c) To discuss with site manager for day-to-day targets and ensure the crew
performance to achieve the planned target without compromising safety
and quality.
d) Conduct toolbox talks with crew and convey the message to crew members.
e) Supervisor must be aware of the incident investigation and reporting .
f) Cross check the requirements of resources including equipment, tools and
consumables and inform store promptly.
g) Lifting supervisor shall ensure that all lifting tools and tackles and properly
inspected and marked with the active color code. He shall monitor all the
lifting activities happening as per lifting plan.
h) Co-ordinate all disciplines of work and act with the site manager for day-to-day activities.
i) Ensure adequately trained pool availability for work.

HSE advisors:

a) To ensure a safe working environment at site.

b) Shall attend toolboxes talk in the presence of site manager, supervisor and
other crew and convey the possible hazards and avoidable measures to the
team on daily basis.
c) He shall verify the TBT records are prepared in line with the activities planned.
d) Conduct mock drills at site.
e) Attend weekly site safety meetings.
f) Shall be aware of complete HSE plan and manage all safety requirements
during the execution.
g) Report any incidents as per OQ/EFX plot guidelines.
h) Record safe manhours.
i) Ensure proper housekeeping at site.
j) Shall report to the site manager.
k) Carryout HSE inspections

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 l) Ensure all employees including line staffs are aware about the required to
follow at plot, advise line staffs about legal compliance and Incident
Reporting system.

6. CONSUMABLE HANDLING

Approved for Handling & Storage of Welding Consumable shall be followed.

7. MATERIAL HANDLING

Approved for Material handling, storage, and delivery shall be followed.

7.1 Identification OF Materials

Each Piece of Plates, fittings or any other component of tankage system shall be
clearly identified by marking heat no. on the part (e.g., Tank No- XXXX, item No
–XXX H. No.-XXXX) using hard punching. The entire activity shall be monitored
and supervised by QA/QC Inspector.

8. PREFABRICATION

All fabrication work involving material identification, marking, cutting, rolling, and
welding shall be done in accordance with this job , AFC drawings, API 650
requirements mentioned in drawing (13th edition,2020), client Spec. The
workmanship shall be good in every respect meeting all practical site HSE
requirements, QC & NDT requirements. All the plates, Structural & pipes in such a
way prior to fabrication to facilitate proper checking of dimensions & heat no.
Mark the components as per the drawings in areas possible.

8.1 General

All fabrication activities shall be carried out at MTS fabrication shop.

Prior to prefabrication, internal material receiving inspection shall be carried
out to verify the quantity, size, and the material of construction against
original MTCs, material delivery note, purchase order issued to supplier,
approved drawings & TDCs. Materials with defects or not in compliance to the
requirement shall be rejected during internal inspection & stored in

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 quarantine area.
MTC’s received shall be ensured for compliance with EN10204 also to be ensured by STS.

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 After successful internal inspection, the material shall be offered to Sub-
contractor/ contractor/company for inspection as mentioned in the
approved ITP.
Only materials inspected and cleared by QC shall be taken for fabrication.
All activities of prefabrication work involving material identification,
marking, cutting, grinding, edge preparation, fit up, welding and inspection
shall be in accordance with this method Statement, API-650 and the
approved ITP for prefabrication activities. The workmanship shall be good in
every respect, meeting all Safety & NDT requirements, as stipulated, in
close coordination with the inspection authority.
Major prefabrication activities include the following,
1) Annular plates
2) Bottom plates
3) Shell plates
4) Nozzles, Manholes & Clean Outdoor
5) Roof plates
6) Roof Structure
7) Stairway, access platforms and miscellaneous structure

8.2 Annular

Plates

Marking

The required plates for bottom annular plates shall be identified with
respect to the approved bottom plate layout drawing.
All plates shall be spread on wooden sleepers to keep the top surface in perfect level.
Plate markings shall be verified against the material test certificates and
material receiving inspection reports.
Annular plate profile shall be marked on the plates including cutting allowance
using marker and punch as per the cutting plan in the approved bottom
plate drawing.
Transfer of plate markings shall be done on top side of AP by using
permanent marker followed by stamping with hard punch. For bottom
annular plates, tank no., part no., and heat no., shall be transferred and
records shall be kept in material traceability record.
For the usable cut out pieces of plates, heat no., plate no., material
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specification and grade shall be stamped to ensure traceability during
storage in workshop.
After marking, all components shall be inspected for size, dimension by
client/ QA/QC inspector as per approved ITP & scope of each interested
parties.

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 Cutting & Edge Preparation

Cutting shall be carried out as per marking by use of Pug Cutting machine
and / or hand cuttingset with a competent Gas Cutter.
Beveling of cut edges shall be carried out by use of pug cutting machine or
Gas cutting with a competent gas cutter followed by grinding.
One make-up Annular plate shall be provided near COD with 100mm or
whichever possible additional length will be maintained.
Cut edges shall be ground to bright metal to remove all burrs and slags etc.
and visually inspected. Backing strips shall be welded to one side of ANP.
All components shall be inspected and shall be approved QAQC Inspector as
per approved ITP & scope of each interested parties.
Sharp edges shall be round off to the required level.
If any laminations found visually, Ultrasonic examination shall be carried out
to detect the extent of laminations and rectification of the lamination shall
be carried out in compliance with client.

8.3 Bottom Plates & Sump

Marking

The required plates for bottom sketch plates shall be identified with
respect to the approved bottom plate layout drawing.
All plates shall be spread on wooden sleepers to keep the top surface in perfect level.
Plate markings shall be verified against the material test certificates and inspection
reports.
Bottom sketch plate profile shall be marked on the plates including cutting
allowance using marker and punch as per the cutting plan in the approved
bottom plate drawing.
The drain sump hole shall be marked on the applicable sketch plate.
Transfer of plate markings shall be done by using permanent marker
followed by hard punch stamping on top side. For bottom sketch plates, tank
no., part no. and heat no. shall be transferred, and records shall be kept in
material traceability record.
For the usable cut out pieces of plates, heat no., plate no., material
specification and grade shall be stamped to ensure traceability during
storage in workshop.
After marking, all components shall be inspected for size/dimension by
client approved QAQC inspector.
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Special care to keep the plate heat no marking on top side for full bottom plates.

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 Cutting & Edge Preparation

Cutting shall be carried out as per marking by use of Pug Cutting machine
and / or hand cuttingset with a competent Gas Cutter.
Cut edges shall be ground to bright metal to remove all burs and slags etc.
and visually inspected.
The drain sump hole shall be cut as per the marking by use of hand cutting
set with a competent gas cutter.
All components shall be inspected and shall be approved by the QAQC Inspector.
If any laminations found visually, Ultrasonic examination shall be carried out
to detect the extent of laminations and rectification of the lamination shall
be carried out in compliance with client.

Sump Fabrication

Bottom plate, shell and top ring plate of sump shall be marked & cut as per
the required size & dimensions as per the approved drawing.
Sump shell plate vertical edges shall be beveled using pug cutting machine
or Gas cutting with a competent gas cutter followed by grinding.
Fit up and welding of shell plate, bottom plate and top ring plate of sump
shall be carried out as per the welding details provided in the approved
shell nozzle detail drawing.
Fit-up inspection, Dimensional inspection and visual welding inspection
should be carried out as per the weld details provided in the approved shell
nozzle detail drawing & as per approved WPS/PQR.
Welding shall be carried out by a welder qualified to weld as per approved WPS/PQR
Diesel-chalk test of weld joint shall be carried out as per approved
fabrication ITP and API 650.

8.4 Shell
Markin
g
The required plates for shell plates shall be identified with respect to the approved
shell
plate layout drawing.
All plates shall be spread on wooden sleepers to keep the top surface in perfect level.
Plate markings shall be verified against the material test certificates and inspection
reports.

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Shell plate profile shall be marked on the plates including cutting allowance
using marker and punch as per the cutting plan in the approved shell plate
drawing.

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 FABRICATION, ERECTION METHOD STATEMENT FOR PRODUCED
WATER STORAGE TANK (12-T-3053)

TREATED PRODUCED WATER STORAGE TANK - 12-T-3053 -

48.768 MTR. DIA X 14.874 MTR. HIGH
BISAT-C OIL PROCESSING FACILITY
PROJECT:
(EXPANSION-C) PROJECT
STS DOC NO: PRP00145-STS-MST-TNK-7003
MTS DOC NO: FAB-004-24-CON-MST- Rev K-01
001 No.
Transfer of plate markings shall be done by using permanent marker followed by
stamping
and ensure it appears at outer side. For shell plates tank no., part no. and
heat no. shall be transferred, and records shall be kept in material
traceability record.
For the usable cut out pieces of plates, heat no, plate no., material
specification and grade shall be stamped to ensure traceability during
storage in workshop.
Plates which are to be rolled are marked for required dimensions like
length, width, & diagonal as mentioned in the cutting plan as approved shell
plate layout drawing.
After marking, all components shall be inspected for size/dimension by
client approved QA/QC inspector.

Cutting & Edge Preparation

Cutting shall be carried out as per marking by use of Pug Cutting machine
and / or hand cuttingset with a competent Gas Cutter.
Beveling of cut edges shall be carried out by use of pug cutting machine or
Gas cutting with a competent gas cutter followed by grinding.
One make up plate to be fabricated with 100mm or whichever possible
additional length will be maintained each Shell course.
The edge preparation and beveling of plates shall be carried out as
mentioned in the approved shell plate layout drawing.
Cut edges shall be ground to bright metal to remove all burrs and slags etc.
and visually inspected. Holes shall be dressed as required to remove burs &
protruding edges. Sharp edges shall be smoothened by grinding.
All components shall be inspected by a client approved QAQC Inspector.
Minor weld build ups on damage bevels if required shall be carried out by approved WPS.
If any laminations found visually, Ultrasonic examination shall be carried out
to detect the extent of laminations and rectification of the lamination shall
be carried out in compliance with client.

Rolling of Shell Plates & Compression Ring

After cutting edge preparation, the shell plates are shifted by the help of
crane to nearby rolling machine area. Proper care shall be taken during
shifting of plates to avoid damage to the edges of plates.
The feeding bed and receiving bed of rolling machine shall be at same level.

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 FABRICATION, ERECTION METHOD STATEMENT FOR PRODUCED
WATER STORAGE TANK (12-T-3053)

TREATED PRODUCED WATER STORAGE TANK - 12-T-3053 -

48.768 MTR. DIA X 14.874 MTR. HIGH
BISAT-C OIL PROCESSING FACILITY
PROJECT:
(EXPANSION-C) PROJECT
STS DOC NO: PRP00145-STS-MST-TNK-7003
MTS DOC NO: FAB-004-24-CON-MST- Rev K-01
001 No.
Rollers shall be set on the feeding bed to feed the plates smoothly without
causing scratches.

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 FABRICATION, ERECTION METHOD STATEMENT FOR PRODUCED
WATER STORAGE TANK (12-T-3053)

TREATED PRODUCED WATER STORAGE TANK - 12-T-3053 -

48.768 MTR. DIA X 14.874 MTR. HIGH
BISAT-C OIL PROCESSING FACILITY
PROJECT:
(EXPANSION-C) PROJECT
STS DOC NO: PRP00145-STS-MST-TNK-7003
MTS DOC NO: FAB-004-24-CON-MST- Rev K-01
001 No.
Before rolling, plate & roller surface shall be ensured free from any projections, dust
and
rust.

During rolling straight feeding to be ensured by using right angle & scale.
The plate shall be rolled as per ID of the tank. The required radius and
curvature shall be monitored/checked by use of metallic rolling template

during and after Rolling.

If the plates are not matching, then re-rolling shall be performed at shop.
After re-rolling activity, the radius and curvature shall be checked by using
metallic template. The same shall be repeated for all the shell plates.
There should not be any visible gap between the template and rolled plate.
Rolled plates shall be placed one above the other in a saddle designed for
maintaining the profile of the rolled plate and the same shall be used for the
transportation of the shell plate from shop to the project site.
Compression rings edge preparation shall be as per the approved drawing.
The shell plates shall be rolled as per ID of the tank and same shall be ensured
during rolling by metallic templates.

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8.5 Nozzles, Manhole & Cleanout
Door Marking

For nozzles, the required pipes shall be identified with respect to the
approved nozzle detail drawing.
Pipe markings shall be verified against the material test certificates and
inspection reports. Transfer of pipe markings shall be done by stamping or
by using permanent marker.
For the usable cut out pieces of pipes, heat no., pipe no., material
specification and grade shall be stamped to ensure traceability during
storage in workshop.
Neck length of nozzle shall be marked on the OD of the pipe using punch
leaving a positive tolerance of 3-5 mm to grind smooth after cutting.
For nozzles of size 16” and above, the nozzle neck can be fabricated from
plate as per approved nozzle detail drawing.
For manhole neck, bolting flange and cover plate the required thick plates
are identified as per the approved nozzle detail drawing and marked using
punch.
The plates required for neck, bolting flange, cover plate, bottom
reinforcement plate, RF pad and shell plate of Cleanout Door (COD) assembly
shall be identified. The cut profile shall be marked on the plates as per the
required dimension in approved COD detail drawing. Transfer of plate
markings including heat no., plate no., material specification and grade
shall be ensured. Plates which are to be rolled are marked for required
dimensions like length, width & diagonal.
After marking, all components shall be inspected for size/dimension by Sub-
contractor/ contractor/company QAQC inspector as per approved ITP.

Cutting & Edge Preparation

Cutting and beveling of pipes shall be carried out as per marking by use of
hand cutting set with a competent Gas Cutter.
The edge preparation and beveling of pipes shall be carried out as
mentioned in the approved nozzle detail drawing.
Cut edges shall be ground to bright metal to remove all burrs and slags etc.
and visually inspected. Sharp edges shall be smoothened by grinding.
For manholes and cleanout doors, the bolting flange and cover plate shall
be cut and machined at the gasket face in a lathe. The bolt holes are drilled
on bolting flange and cover plate maintaining the bolt circle diameter and
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hole diameter as per the approved nozzle detail drawing.

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 Holes shall be done only by drilling machine and flame cutting shall not be
used for holes making.
The RF pads of nozzles and manhole shall be marked cut at required
dimension from rolled plates using hand cutting set with a competent Gas
Cutter.
All components shall be inspected for proper dimensions by Sub-
contractor/ contractor/company QAQC Inspector as per approved ITP.
All reinforced plates shall be provided with a tapped 1/4” API(NPT) telltale for
leak test and location of holes shall be as per approved GAD drawing.

Rolling, Welding and PWHT

Neck of plate fabricated nozzles, manholes and COD shall be rolled

at required diameter.
Long seam of neck of manholes and plate fabricated nozzles shall be welded
from workshop by a competent welder qualified to weld as per approved
WPS/PQR followed by 100 %RT of the weld.
Flange to pipe and bolting flange to manhole neck welding shall be
carried out by a competent welder qualified to weld as per approved
WPS/PQR followed by 100% MPI
NDT shall be carried out as per approved ITP and IFC drawings.
The prefabricated nozzle assembly shall be tagged to ensure traceability
during material receipt and storage at site. The tag shall be punched with
tank no. and nozzle no.
The serrated gasket seating face of nozzle flanges shall be protected
using temporary coveringslike masking tape or plywood cover.
Nozzle openings shall be covered using plastic caps/cover to prevent entry
and settlement offoreign particles during transportation and storage.
The components of COD including shell plate, RF pad, bottom reinforcement plate,
neck and bolting flange shall be welded together to form the COD assembly.
PWHT shall be carried out as per approved PWHT as per API 650,
Cl:no:5.7.4.3 and general notes of shell development drawing.
COD Davit holder shall be welded on the assembly at shop before PWHT.
NDT of weld joints shall be carried out as per approved ITP for
fabricationactivities and as per API 650
Welding is permitted on COD and any other PWHT completed assembly
after PWHT as permitted by API 650 code requirement.
Verify the levelness of COD bolting flange after PWHT.

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COD shall be tagged with tank no. to ensure traceability during material
receipt and storage at site.

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8.6 Roof Plate

Marking

The required plates for roof plate shall be identified with respect to the
approved roof platelayout drawing.
All plates shall be spread on wooden sleepers to keep the top surface in perfect level.
Plate markings shall be verified against the material test certificates and inspection
reports.
Roof plate profile shall be marked on the plates including cutting allowance
using marker and punch as per the cutting plan in the approved roof plate
drawing.
Transfer of plate markings shall be done by stamping or by using
permanent marker. For roof plates, tank no., part no. and heat no. shall be
transferred, and records shall be kept in material traceability record.
For the usable cut out pieces of plates, heat no., plate no., material
specification and grade shall be stamped to ensure traceability during
storage in workshop.
After marking, all components shall be inspected for size/dimension by Sub-
contractor/ contractor/company QAQC inspector as per approved ITP.

Cutting & Edge Preparation

Cutting shall be carried out as per marking by use of Pug Cutting machine
and / or hand cutting set with a competent Gas Cutter.
Cut edges shall be ground to bright metal to remove all burrs and slags etc.
and visually inspected.
All components shall be inspected by Sub-contractor/ contractor/company
QAQC Inspector as per approved ITP.
Rolling to be done if required
If any laminations found visually, Ultrasonic examination shall be carried out
to detect the extent of laminations and rectification of the lamination shall
be carried out in compliance with client.

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8.7 Roof Structure

Marking, Cutting and Welding

The structure shall be rolled as per drawing of the tank and same shall be
ensured during rolling by metallic templates at shop.
The required structural materials including rafters, bracings, crown plates and
gussets shall be identified with respect to the approved roof structure detail
drawing.
Markings on structure shall be verified against the material test certificates
and inspection reports.
Transfer of structure markings shall be done by using permanent marker
followed by hard punching to identify the materials after shop painting. For
structural materials heat no., shall be transferred and records shall be kept
in material traceability record.
For the usable cut out pieces of structure, heat no. and material
specification and grade shall be stamped to ensure traceability during
storage in workshop.
The required length of structural materials shall be marked using punch and
cut using hand cutting set with a competent Gas Cutter.
Bolt holes and slot holes shall be drilled on rafters, bracings and gussets
using magnetic drilling machine. Burr edges of slots and holes shall be
removed using counter bit. No flame cutting shall be used for holes making.
To avoid mismatch at site 90 degree mockup assembly suggested and no
flame cutting is allowed at site for roof structure.
Bracing support cleats shall be welded with primary rafter at the required
location as per approved drawing and WPS by approved welder.
Crown plate assembly of roof structure shall be welded together as per the
approved roof structure detail drawing.
Dimensional inspection shall be carried out by Sub-contractor/
contractor/company QC inspector as per the approved ITP.
All structural components shall be properly tagged with tank no. and part
no. wherever possible to ensure traceability during material receipt and
storage at site.
The structure shall be rolled as per drawing of the tank and same shall be
ensured during rolling by metallic templates.

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8.8 Stairway and Miscellaneous

Structure Marking, Cutting and

Welding

Spiral stairway components including stringer flat bars, angles for handrail
post, handrail, mid rail and stringer supports, HDG gratings for step tread
and platforms, channel for platforms etc. shall be identified with respect to
the approved roof structure detail drawing.
Bolt holes on the stringer flat bar shall be marked with permanent marker
at required locations as per approved stairway detail drawing. Holes shall be
drilled using magnetic drill followed by burr removal using counter bit.
Angles for handrail and mid rail shall be cut and rolled at required diameter.
Angles for vertical posts and stringer supports shall be cut as per required
length followed by drilling of bolt holes.
Flat bars for stringer and toe plate shall be slightly rolled in rolling machine
for ease of assembly at site.
Gratings shall be pre ordered by STS with required dimensions as per approved
drawings.
Step treads shall be fabricated as per details provided in the approved
stairway detail drawing. Anti-slip nosing plate shall be welded on each step
tread as per the details in the approved drawing.
Platform gratings and step treads shall be hot dip galvanized after complete
fabrication. & Stairway will be assembled on the support cleats welded with
tank shell at site.
Other structures including roof handrail, roof walkway and internal pipe
supports shall be fabricated as per the approved detail drawings.
All structural components shall be properly tagged with tank no. and part
no. wherever possible to ensure traceability during material receipt and
storage at site.

9. PWHT

PWHT shall be carried out as per approved and WPS.

PWHT shall be carried out at MTS workshop by external gas firing method.
Complete prefabricated shell nozzle & COD assembly PWHT shall be
carried out & relevant NDT will be done as per the general notes in the
applicable approved GAD, ITP & NDE plan.
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PWHT Cleats will be provided for logistics purpose which will be removed
in grinded at site level as agreed with Engineering team.

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10. MATERIAL TRANSPORTATION

All prefabricated items shall be transported to the project site from MTS
Fabrication facility at Sohar by road.
The trailers / canters used for transportation shall be following client
requirements and the local rules and regulations.
Following are the precautions to be followed for safe transportation of
prefabricated items to site from workshop.
1. Flat plates including bottom annular plates, bottom sketch plates and
roof plates shall be spread uniformly over the trailer bed without
protruding out from the bed. The plates can be stacked one above the
other but shall be protected from tipping off by firmly tightening the
plates against the trailer bed with lashing belts.
2. Horizontal clamps (or other suitable methods) shall be used to load
these flat plates on trailer bed.
3. Wooden blocks shall be placed below and in between the stacked
plates to prevent the damage of paint and scratching between plates.
This will also provide sufficient space to hold the plates using clamp
while unloading at site. Proper softeners to be provided to avoid paint
damages
4. Rolled plates shall be transported in saddles fabricated to maintain
the shape and profile of rolled plate. The plates shall be stacked in
saddle. The plates can be stacked one above the other for a total
weight less than 25 ton.
5. Prefabricated nozzles are preferred to keep in wooden pallet while
transporting and shall be properly secured to avoid dis-location during
transportation.
6. Structural materials including rafters, stairway components, curb angle
etc. shall be evenly placed and firmly tightened on trailer bed using
lashing belts. Care shall be taken to avoid dislocation of items during
transportation leading the items to protrude outside the trailer bed.
7. Clean outdoor assembly shall be securely tightened with trailer bed
using lashing belts during transportation.
To ensure that the prefabricated items are not damaged during
transportation, all items shall be inspected visually upon receipt at the site.
Traceability markings including punch marks on plates and tags on other
components shall be checked and verified against the traceability record
and approved drawings.
All the vehicles must be approved with OPAL RAS and IVMS /Speed limiter as
per block 60 requirements ordinate with Site Journey manager prior to start

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the journey from Origin and follow the schedule of Journey plan.
If any damage occurred during transport same shall be notified to the
STS/contractor, rectification shall be carried out as per the direction of
STS/contractor with additional cost.

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 Incoming material inspection at site shall ensure that the materials are as per the
approved
drawings and the quantity must be cross checked against the BoM in
respective drawings. For unloading the plate components like bottom plates,
roof plates and shell plates at site,
crane and horizontal clamps or other suitable methods shall be used.
During unloading proper control of the items shall be maintained. Guide
ropes attached to the items will enable easy manual control when lifting and
handling. Do not drop, impact, or bump the materials, particularly at ends.
All lifting accessories like slings, “C” clamps, belts, “D” shackles shall be third
party approved as per OPAL standards. Flat plate components like bottom
plates and roof plates shall be placed over wooden blocks.
Shell plates shall be stacked one above the other in saddles to maintain the
shape and profile of shell plates. Ensure the stacks will be stable for
conditions such as high winds, un- level storage area or other horizontal
loads.
All prefabricated materials including plates, structural assemblies, nozzle and
clean outdoor shall be properly stored in designated laid down area at site and
shall be placed on wooden blocks / pallets to avoid direct contact with soil.
Gasket seating face shall be protected using masking tape and entry of
foreign particles shall be prevented by covering the nozzle openings using
plastic caps / covers.
Proper storage shall ensure ease of accessibility of components and shall not
hinder access to site.

11. WELDING REQUIREMENTS

All welding activities including tacking shall be carried out as per

approved welding s.
Welding Specification (WPS) and applicable Qualification Record (PQR)
shall be submitted to the client for approval prior to start of any welding
operation.
Tack welding activity shall be by qualified welders all joints before welding
activity shall be clear from any contaminations or rust.
Any welder qualification tests shall be as per the approved WPS.
Welding shall include but not limited to detail of joint preparation,
electrode, welding process and base materials.
Welding shall be following ASME
Section IX. A manual arc welding
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method will be used.
Welding of structural materials like stairway and handrail components, pipe
support structure etc. except their attachments to tank shall be following
either of ASME Section IX or AWS D1.1.

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 Selection of filler materials shall be based on the general chemistry of deposited weld
metal
which shall be the same as that of the base metal. Welding electrode
specification shall conform to ASME Boiler and Vessels Code Section II Part
C
Welding consumables shall be used as mentioned in
approved WPS. Fit-up & welding activities are carried out
by qualified welders only.
No welding of any kind shall be performed when the surfaces to be welded
are wet from rain, when rain is falling on such surfaces or during periods of
high winds unless the welder and work are properly shielded.
Also, preheat shall be applied as per approved WPS.
Each layer of weld metal or multilayer welding shall be cleaned of slag and
other deposits before the next layer is applied.
The edges of all welds shall merge smoothly with the surface of the plate
without a sharp angle.
All single side butt weld seams without backing strips shall be chipped back to
sound metal and re-welded unless otherwise specified. Rat hole shall be
provided to avoid contact between the radial welds of stiffener angle and
shell welds.
All welding shall be free from coarse ripples, grooves, overlaps, abrupt
ridges, and valleys that interfere with interpretation of NDE results.
During the welding operation, plates shall be held in close contact at all lap joints.
Welding electrode shall be stored in accordance with As per approved welding
consumables handling or manufacturer recommendation.
Before utilization of electrodes, the packet will be open, and electrodes will
be baked in the baking oven at temperature and duration recommended by
manufacturers.
The electrodes shall be issued in first in first out policy.
Electrodes will be transferred to holding oven from the baking oven and baked
maintaining temp at 150 as per manufacture recommendation before
issuing to welders.
Welders shall keep the baked electrodes in quiver oven / portable oven at
70º C to 90º C during welding activity.
The excess electrodes in the shall be taken back to baking oven and re-
baked as per approved .
Shell internal horizontal & vertical welding seams shall be smooth with no
sharp or abrupt edges.
During welding activity "Arc strike" strictly prohibited to avoid any stressing of metal.
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 All lifting accessories and tackles include Hydraulic jack systems shall be certified by a
third
party (certificate of thorough Visual examination of lifting equipment) approved as per
OPAL standards.

12.8 INSTALLATION OF SHELL NOZZLES AND MANHOLE

All the shell nozzles and manholes shall be lifted by a crane using horizontal
lifting clamps or temporary attached lifting lugs.
In case of shell courses which are erected using conventional method (4th,
5'h & 6th shell course), opening of tank shell can be carried out after roof
structure parallelly during roof plate . Nozzles on these shells can be installed
making use of the external and internal scaffolding in parallel with roof plate /
nozzle installation. The nozzle location shall be carefully marked as per the
orientation and elevation mentioned in the approved shell plate layout
drawing.
To mark the nozzle on the shell, vertical elevation of the nozzles shall be
marked on the shell first. Then mark the nozzle orientation by converting
degrees to linear measurement as mentioned in the shell plate layout using
measuring tape.
In case of shell courses which are erected during jacking up phase, opening
of shell and installation of nozzles can be carried out when the respective
shells are resting on the stool, but after completion of welding of vertical
seam and circumferential seam of the shell.
Nozzles excluding manholes shall be installed as per tolerance mentioned in API 650 cl
7.5.6.
Nozzle & manhole neck to shell fit-up shall be carried out such that the bolt
holes shall straddlewith the tank center line. Manholes shall be installed
within the tolerances of API 650 Cl:7.5.7
Nozzle & manhole neck to shell welding shall be carried out by competed
welder qualified for the respective approved WPS/PQR. The weld details are
provided in approved nozzle detail drawings.
Nozzle & manhole neck to shell weld joint shall be examined visually and by 100% MPT.
All lugs and fixtures shall be progressively removed by careful grinding
attachment surface shall be dressed up and examined visually and by
magnetic particle method.
Carry out required NDT as per ITP and NDE plan.
The reinforcement pads of nozzles shall be welded as per the details given
in approved nozzle detail drawing.
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PWHT should be done for shell nozzles as per approved PWHT .

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 Reinforcement pads shall be provided with 1/4” NPT telltale hole on the horizontal
center
line as mentioned in the nozzle detail drawing.
Reinforcement pads shell be pneumatically tested to 100 kPa(g) as per
approved pneumatic test before hydrotest.

12.9 INSTALLATION OF SPIRAL STAIRWAY AND OTHER ATTACHMENTS

Spiral stairway support cleats on the tank can be installed progressively during
shell course .
As spiral stairway is rolled in helical radius, of stringers are required along
with support cleats.
Location of support cleats shall be obtained from approved spiral stairway
detail drawing. Dimensions of handrails and stairways shall be ensured by
trail assembly.
After completion of shell , inner stringer shall be installed by bolting with the
support cleats.
Outer stringer and step tread installation can be done parallelly by bolting the
outer stringer with outer stringer support cleat and with step tread.
Intermediate and top landing platform frames shall be bolted with the support cleats.
Platform gratings shall be installed and secured with the platform frame using grating
clips.
External pipe support cleats can be welded at the locations specified in cleat
support detail drawing progressively during shell .
Internal pipe supports shall be welded at the locations specified in nozzle detail drawing.
Earthing boss, name plate bracket, CP cleat and settlement markers shall be
welded on the bottom shell course at the locations specified in the approved
drawings.
Internal drainpipe shall be installed as per the approved detail drawing.
Impingement plates shall be welded on bottom plates as shown in the
bottom plate detail drawing.
Bottom plate lapped weld joints falling directly below the impingement plates
and internal pipe support pads shall be vacuum box tested before the
installation of the pad
Anchor chairs shall be fixed, and welding shall be carried out as per
approved drawing and WPS. The tightening of anchor bolts and nuts shall be
carried out as per approved drawing details.
The permanent attachment welds shall clear horizontal welds by 75mm and
vertical seam by 150mm, where it is not possible to avoid overlapping seams,

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the overlapping seams which will covered shall be ground flush 100% RT and
DPT inspected before the attachment is fixed.

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13. PNEUMATIC TESTING OF RF PAD

Approved for pneumatic testing of RF pad

14. TANK HYDRO TESTING

Before hydro test all the applicable inspections shall be completed and
approved as per the ITP and API650. Water filling shall be carried out after
obtaining the clearance from Sub- contractor/ contractor/company only.
Hydro testing shall be carried out as per the approved .

15. INTERNAL & EXTERNAL PAINTING

Surface shall be blasted to grade of Surface finish and degree of surface roughness
as specified in the painting system to be used.
Internal & External painting shall be applied as per approved s and Painting
inspection shall be as per respective ITP’s.
Details of applicable paint system are provided in approved Paint finish
requirement details drawings.

16. QUALITY ASSURANC & QUALITY CONTROL

All the inspection and testing shall be carried out as per the approved ITP and as per API
650 requirements mentioned in AFC drawings.
All measuring instruments shall be calibrated before use.
All NDT activities shall be done as per approved lTP’s and NDT s.
All inspection reports shall be documented in the Manufacturer Record Book and
submitted to the client.

17. INSPECTION & TESTING

S. No. Description Format No.

1 Request for Inspection -RFI MTS-QMS-F-37

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x

21. HSE MANAGEMENT

All HSE requirements shall comply to the OQ/EFX specifications.

Good housekeeping to be maintained for the easy approach for the man and
machinery to the work area.
Required permits shall be in place prior to start of work. Ensuring all the
safety requirements is satisfied.
Proper luminous intensity areas to be provided when work to be carried out at night.
Proper insulation & lying of electrical cables and good earthling at every point
to be done to avoid electrical hazards.
Tools and tackles having valid test certificates shall be used for lifting &
shifting of the materials.
Ensure the TPI certificate for crane shall be available.
Wire ropes used for load lifting purpose, though being TPI certified should
be visually checked again to ensure the physical damage like birdcage,
broken strands etc. in the rope.
Tag lines should be used at both ends to ensure safe shifting of the load.
Proper barricading around the work area to be provided to avoid
unauthorized trespass of people inside.
Tank area shall be isolated with green net while blasting and painting.
Good approaches like ladders and working platform should be provided to
facilitate smooth work.
Fire extinguishers shall be placed in hot work area before starting any hot works.
Housekeeping to be done at regular intervals and the materials should be kept
in its proper place at site.
All necessary PPEs safety shoe, Safety helmet, hand gloves, safety belt, fall
arrestor, welding shield for welders, safety goggles for grinders etc. are to be
provided to the workmen to assure their safety and good health at work.
Safety training at regular intervals and safety pledge on daily basis should be
worked out at site premises to increase the safety consciousness and skill of
the workmen.
All operators shall hold OPAL DD license.
Ensure Blasting and Painting to be performed in a way that the activity will not
degraded the air quality of environment and reduce the exposure to adjacent
employees.
All testing activity shall be 24hrs prior notified to contractor along with testing plot
details

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x

,no unplanned testing activities such as hydro test ,Radiography etc are
permitted without informing all affected personnel

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x

Work at height and confined space Rescue measures shall be in place for
immediate response. Rescue plan should provide in advance to Contractor
for review and approval.
the availability of all trained pool (First aid, Fire Watcher, AGT,Confined space
team, scaffold team ,Lifting crew etc.) shall be ensured

22. CONSTRUCTION RISK CONTROL SCHEDULE

Risk assessment shall be done at site along with construction and HSE team.
It shall be discussed with the crew prior starting of any job.

Danger Person
Sl No. Safety Technical to be Adopted
in
Point Charge
Description
All lifting tools & tackles and crane should be in good Lifting
condition supervisor
& certified by approved agency.
Regular checking of Moving vehicle HSE
1 Material advisor
Shifting Certified sling or belt should be used to lift load.
Tag line to be tied to fabricated member & load Rigging
guided by two people with the help of guide rope. Fore
Never try to lift a bunch of man
fabricated members.
Area should be barricaded. Proper stacking of material Safety
should Engineer
be done in designated place.
Height work permits as well as lifting permits (check
list) must be issued after checking the entire site
Permi
conditions as well as safety precautions, whether
t
they are properly taken or not. After ensuring these
Holde
of shell things site permit shall be obtained for
2 r
and roof doing job.
Fixed ladder should be checked daily by tank foreman Tank
before foreman
staring of working.
No person allowed to work without safety
belt/lifeline. Signal man should give the signal to the HSE
operator. Always use advisor
your required PPEs.
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x

Other activity Hot work permits and height work permits must be
(bolt taken before starting work. Both HSE and execution
Permit
tightening / people shall jointly check and ensure that the
3 holder
welding /gas precautions are properly taken.
cutting Clearance for work will be given only after this.
/Grinding Scaffolding shall be done by scaffolding team in
during supervision of olding
preassembly
and

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x

) scaffolding supervisor. of scaffold required for any Inspector

operation at height.
Identification tag will be provided for each
member of scaffolding materials (green for good
condition and red for
damaged items).
If working at height, always ensure others working
Site
below are aware of the work above and
Supervis
collecting tray and fire
or
extinguisher will be provided for ensuring protection.
Before starting the work in conformed space, inside Approved
oxygen level must be checked and confined space gas
permit has to be taken. Proper ventilation
arrangement shall be done for works tester and
inside the tank. Permit
holder
Wheel guard is to be ensured. Grinding wheel
“RPM” to be checked & condition of grinding wheel is
Site
4 Grinding to be checked. Check and avoid motor short
Enginee
circuiting. Face shield / safety goggles to be used.
r
Leather hand gloves to be ensured. Plug top is to
be ensured. Connection to be taken through ‘ELCB’
Power connection to be taken through ‘ELCB’.
Proper main earthling & body earthling are to be
ensured. Welding cable insulation shall be checked Site
before welding Shed Engineer
/ cover is to be provided for welding / HSE
5 Welding machine. Welding job to be done on advisor
dry surface.
Cable condition is to be checked & leather hand
gloves to be
used Portable fire extinguisher (CO2 / DCP) shall be
available.
Proper housekeeping is to be maintained. Welding
Site
shield is to be used.
engineer
Area is to be cordoned off.
/ HSE
Proper warning board is to be displayed.
advisor

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x

Hose Joints to be checked by using soap solution &

hose clamps are to be used.
Flash back arrestor is to be ensured at both torch
end & cylinder end, Correct size nozzle is be
HSE
ensured.
6 Gas Cutting advisor
Proper clearance is to be maintained between job &
/
Nozzle. Condition of regulator, hose & torch to be
checked. Proper housekeeping is to be maintained. Site
Stone lighter is to be used. engineer
Fire extinguisher is to be kept
ready. Area to be cordoned off.
7 Rolling Following personal protective equipment is mandatory Execution
while

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x

using the rolling machine: Engineer /

Safety Glasses HSE
Safety Gloves advisor
Safety glass is to be worn at all times during the
operation of the rolling machine.
Wear safety glasses to protect your eyes from
chipped fragments that may be produced during HSE
rolling operation. Safety gloves for Protection of advisor
hands, while material feeding. Wear safety gloves
for any excess temperatures that may be
produced.
Don't walk through flooded water without knowing
the condition of ground.
During lightening, stay away from hill tops and
other high points of land like electrical poles, high
structures, fences, metal pipes etc.
Keep electrical appliances away from water
(including rain, wet ground).
Observe if any power line fallen on ground, vehicle,
don't touch anything metallic in the vehicle and
8 Rain & Strom HSE
stay inside until professional help arrives.
advisor
All works shall be suspended in case of rain or
storm and proper isolation shall be ensured to avoid
any accident.
Try to get inside a shed, protected area. Flying
debris can cause injury.
Weather report will be given to the department
daily. In case of bad weather report, tank shall be
adequately supported to avoid any overturning in
case of storm. Support
can be either by guide wires or any other adequate
means.
Rain and wind
9 Lifting activities shall be stopped during heavy rain
during HSE
and storm. Stop work at places with risk of falling
advisor
objects or fall of persons
heavy
lifting

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x

Remove or secure loose materials at elevation and

avoid handling
of sheet materials especially at height.
Site
Ensure all sheet metals are secured to avoid any
10 Heavy Wind engineer
accident. Secure scaffolds rigidly.
/ HSE
Don't perform lifting work and height work.
advisor
If wind speed cross the limit of 9.5 m/s (34.2 km/hr.)
the activity will be stopped.

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x

The erected material should not be hanged with PP

rope, chain
block or sling.
Confined space permits have to be taken before
starting work. The permit is an authorization in
written which states that the space has been tested
Permit
Confined by qualified persons, that the space is safe for
11 holder /
entry.
HSE
Space Entry The confined space shall be checked for presence of
advisor
H2S, HC & CO2
Proper ventilation should be provided.
Proper cleaning required before entering the confined
space.
Night work permits must be taken before starting
work. Proper Permit
12 Night Work Lighting should be provided. holder/
No job to be carried out at the height at the time HSE
of rain. The night work s shall be followed for the advisor
location
MPI:
All electric circuits should be installed and
grounded. Local exhaust should be provided
to control the dust particles used for testing.
If the local exhaust is not feasible, the operator
should wear respiratory protective equipment.
Eye protection should be worn by the
operator to guard against the irritating effects
of dust particles and arcing.
Personal protective equipment should be
worn to protect against the possible skin
Permit
irritation from the powder.
13 NDT(MPI,DPT,R holder/
DPT:
T) HSE
The certified Inspector shall be responsible
advisor
for compliance with applicable safety rules in
the use of liquid penetrant materials.
Liquid penetrant should not be heated or
exposed to open flames.
Penetrant materials may be highly volatile,
relatively toxic and the liquid may cause skin
irritation. Adequate ventilation at all times
shall be used.
Aerosol cans of penetrant materials should be
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x

kept out of direct sunlight or areas in

excess of 130
°F. Excessive heat may cause aerosol cans to
explode.

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x

RT
Ensure necessary permits are obtained and
validated. Only authorized radiography
personnel should carry out the job
Controlled area shall be calculated and safe
distance to be cordon off
RPS shall check the safe distance / barrier is
in the acceptable limit, if not adjust the
barrier and use survey meter to measure the
acceptable limits.
Radiographic personnel shall have a personal
dosimeter while doing the inspection activity
(TLD, Pen dosimeter)
Ensure adequate lighting at the work area as
well as at the access and egress routes /
points.
To protect the safety of personnel involved in
testing all workers must wear protective
equipment, such as equipment eyes and
ears.
Barricade the hydraulic test area and provide
warning signage to prevent unauthorized
entry of personnel.
Site
Use only calibrated pressure gauges and
14 Hydro test engineer
pressure relief valves. The rating of fittings,
/ HSE
gauges, vent and valves must be adequate
advisor
for the test pressure.
Personnel should not approach the high-
pressure system.
Access to allow only essential and trained
persons for Hydro test.
Access will be free of obstacles.
Supervisors must be present at the job site
during Hydro test testing activities.
Conduct a risk assessment before hydro test
work.
Schedule blasting and spraying tasks at times
when fewer workers are in the immediate
area Site
Painting
15 Prohibit eating and drinking in areas where engineer

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x

and Blasting spray painting or sandblasting takes place / HSE

Issue the correct personal protective advisor
equipment for specific tasks and
environments
Provide thorough training and hazard
communication.

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