DOC NO.

: WIELLP/MSTE/01
WESTERN INDIA ERECTORS LLP Issue Date : 27/11/2019
Method Statement For Tank Erection Rev : 0

Method Statement for Auxiliary Absorbent

Tank Erection Using Jack Lifting Method
By

Western India Erectors LLP.

SOLAPUR SUPER THERMAL POWER PROJECT
(2×660MW)

Submitted For
C1
Approval
Issued for
A2
Client Review
P. Manish
Issued For IDC 27.11.2019
A1 (Plng Engg)

Purpose of Date of
Prepared by Checked by Approved by
REV issue issue

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 DOC NO. : WIELLP/MSTE/01
WESTERN INDIA ERECTORS LLP Issue Date : 27/11/2019
Method Statement For Tank Erection Rev : 0

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 4

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

8.6 Close Out 6

8.7 Personnel Involved 6

8.8 Tank Erection Sequence 6

8.9 Scaffolding 7

8.10 QA/QC Testing 7

8.11 Summary of Tank 8

8.12 Execution Plan Date 8

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 DOC NO. : WIELLP/MSTE/01
WESTERN INDIA ERECTORS LLP Issue Date : 27/11/2019
Method Statement For Tank Erection Rev : 0

PURPOSE
The purpose of this method statement is to explain the various steps involved in lifting the Tank shells
by Jack Lifting Method.

SCOPE
The scope of this method statement describes the method of lifting Tank using Jack Lifting Method at
2 X 660 MW Solapur Super Thermal Power Project, Solapur, Maharashtra, India.

REFERENCE DOCUMENT

 EEP000090-0101147830050-MEFAB-004 “General Arrangement of Auxiliary Absorbent Tank”

– Process Data, Tank Mechanical Design Data, Material Specification
 EEP000090/0101147830050/ME/FAB/005 “Arrangement & Details of Bottom Plate layout for
Auxiliary Absorbent Tank”
 EEP000090/0101147830050/ME/FAB/006 “Arrangement & Details of Shell Plate layout for
Auxiliary Absorbent Tank”
 EEP000090/0101147830050/ME/FAB/007 “Arrangement & Details of Roof Plate layout for
Auxiliary Absorbent Tank”
 EEP000090/0101147830050/ME/FAB/0013 “Arrangement & Details of Roof Rafter layout for
Auxiliary Absorbent Tank”
 FQP NO. 9571-109-QVM-G-002 / Rev-0 Dtd 16.10.2019
 HSE Plan as per requirement.

DEFINITIONS
WIELLP - WESTERN INDIA ERECTORS LLP (SUBCON)
GEPIL - GE POWER INDIA LIMITED (CLIENT)

HEALTH & SAFETY

 As per HSE Plan, the following system to be followed
 All relevant elements of HSE Plan shall be followed.
 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.
 Daily Tool Box talk shall be conducted prior to proceed for the work.
 First Aid arrangements shall be followed as per procedure.

ENVIRONMENTAL

 Refer to Environment Management instructions.

 All activities shall comply with Environment Management Plan.

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 DOC NO. : WIELLP/MSTE/01
WESTERN INDIA ERECTORS LLP Issue Date : 27/11/2019
Method Statement For Tank Erection Rev : 0

TRAINING & COMPETENCY OF PERSONNEL

Daily Tool Box talk shall be conducted by job supervisor and weekly tool box talk shall be conducted
by respective area in-charge.

PROCESS
1. GENERAL

Prepare work permits, JSA and working procedure for GEPIL approval prior to commencing work.
Organize 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.

2. ACTUAL LOAD CALCULATION

For Auxiliary Absorbent Tank 00HTN40BB001 the Total Loads to be lifted shall be arrived from
the approved Drawings.

The Details as follows:

DESCRIPTION WEIGHT IN TONNES

Shell 47.709
Roof 9.260
Agitator support + Wall stiffeners 9.409
Baffle plate + Bottom plate 9.124
Structural steel support for access and 2.637
platform
Hand railing 1.039
Grating 2.295
Connections 0.769
TOTAL 82.242
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 82.242 MT = 123.363 MT

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WESTERN INDIA ERECTORS LLP Issue Date : 27/11/2019
Method Statement For Tank Erection Rev : 0

4. 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

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

Hydraulic Cylinder type Jack with accessories – Cap 12Ton – 12 nos.

Farana – Cap 23Ton – 01 no.
Belt Sling – Cap 3Ton ~ 5Ton – 04 pairs
Chain Block - Cap 3Ton ~ 5Ton – 02 nos. each
80T/150T Crane (if required)
Vertical & Horizontal Lifting Clamp – Cap 3Ton ~ 5Ton – 02 pairs
Welding Machine – 08 nos.
Turn Buckle – 3T – 04 nos.

5. ERECTION BY JACKING METHOD

 Mark the shell I/S diameter and fix the elevators on the annular plate @ 3.8 Mtr
 Tack the guide on the elevators.
 Weld the lifting cleats. (2 nos. /Jack; capacity of hydraulic jack-12 MT)
 Weld the pad plates. (1 no for trestle & 2 no’s for stay member)
 Install trestle and stay member. Length of the trestle to be checked according to shell
heights.
 Connect the high pressure hosepipes from power pack to each jack.
 Give electrical power connection to power pack and start jacking.
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 DOC NO. : WIELLP/MSTE/01
WESTERN INDIA ERECTORS LLP Issue Date : 27/11/2019
Method Statement For Tank Erection Rev : 0

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

6. CLOSE OUT

All vehicles, tools & tackles shall be removed from the area after completion of the job.

7. PERSONNEL INVOLVED

 Construction Manager
 QA/Qc Manager / Engineer
 Site Engineer
 EHS Officer
 Site Foreman

8. TANK ERECTION SEQUENCE

 Base plate erection, fitup, and welding

 Top Ring fitup and welding (L seam fitup) - S8 (Shell S8)
 Erection of Top Ring - S8 (Shell S8)
 Shell fitup and welding (L seam fitup) - S7 (Shell S7)
 Erection of shell -S7 (Shell S7)
 Fitup & welding of Shell - S7 & S8
 Fitup & Welding of Roof Structure
 Erection, fitup & welding of Roof Structure with Shell S7 & S8
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 DOC NO. : WIELLP/MSTE/01
WESTERN INDIA ERECTORS LLP Issue Date : 27/11/2019
Method Statement For Tank Erection Rev : 0

 Shell fitup and welding (L seam fitup) – S6 (Shell S6)

 Erection of shell –S6 (Shell S6)
 Fitup & welding of Shell – S6 & S7
 Shell fitup and welding (L seam fitup) – S5 (Shell S5)
 Erection of shell –S5 (Shell S5)
 Fitup & welding of Shell – S5 & S6
 Erection, fitup and Welding of Wind Girder
 Shell fitup and welding (L seam fitup) – S4 (Shell S4)
 Erection of shell –S4 (Shell S4)
 Fitup & welding of Shell – S4 & S5
 Shell fitup and welding (L seam fitup) – S3 (Shell S3)
 Erection of shell –S3 (Shell S3)
 Fitup & welding of Shell – S3 & S4
 Shell fitup and welding (L seam fitup) – S2 (Shell S2)
 Erection of shell –S2 (Shell S2)
 Fitup & welding of Shell – S2 & S3
 Shell fitup and welding (L seam fitup) – S1 (Shell S1)
 Erection of shell –S1 (Shell S1)
 Fitup & welding of Shell – S1 & S2
 Bottom Plate Shell S1 fitup and welding
 Platform and stairs fitup and welding
 Manhole Door, Nozzles, Clean out Doors
 Agitator Support

9. 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 welding and painting activities.
Scaffolding for roof welding and touch up paint for roof under side, shall be carried out with
the help of hanging platform constructed with girder clamps on roof structures and cross
girder.

10. QA/QC Testing

Following are the testing methods for preassembly works are followed for quality controls.
Area and type to be tested.
 Butt weld horizontal joints – DPT after back gouging and after completion of butt
welding 20%
 All butt welds horizontal joints – One spot (75mm) in first 3mtr and then in 30 mtr
 All T-Joints – 100% DPT & Radiography
 Base plate to Shell plate – DPT inspection 20% (either inside or outside)
 All fillet weld – Vacuum Box Test @ 100%
 RF Pad for Nozzle – Pneumatic Leak Test
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 DOC NO. : WIELLP/MSTE/01
WESTERN INDIA ERECTORS LLP Issue Date : 27/11/2019
Method Statement For Tank Erection Rev : 0

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% DPT to find the quality of weld.

11. SUMMARY OF TANKS

Sr. No. Tank No. Dimensions Qty

1) 00HTN40BB001 14.5 Mtr Dia X 15 Mtr Ht 01

12. EXECUTION PLAN DATE

Erection Start - 04 Dec 2019

Erection Completion - 28 Apr 2020

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