NUMALIGARH REFINERY LIMITED Total pages: 10

NRL EXPANSION PROJECT

GI WORKS FOR PROPOSED STORAGE TANKS (PACKAGE 2)

Method Statement for conducting Initial stone column testing

(single & group)

1U59-TT-4633/34 & 1S72-TT-1603/04

01 18-11-2022 Issued for Review PSC BV PVSR

00 26/09/2022 Issued for Review TDG BV PVSR
Rev. Date Reason for Issue Prepared Checked Approved
Discipline Discipline Contractor
Engineer Lead Representative

MISPL MPMC
Category Code Description

Facility Area Code 1S72A TANKS

Work Order No.: 4300071256-TEC Document Type MOS METHOD STATEMENT
Tender Ref.: 082176C-4300071256-TANKS2-CV-0001 System Number 0003 General
Technip Ref.: 082176C-172-WO-1431-0002-B1103-0003 Life Cycle 01 Disk Ref.: CV-0002
Contractor Ref.: MISPL-1S72A-CV-0002-MOS-0003_01
Originator/ Asset Disci Code Document Sequence Revision
This document is copyright and shall not be Contractor Code pline Type Number
reproduced without permission of NRL
TP 1S72A CV 0002 MOS 0003 01
1S1111S70
82176C-
172-WO-
1431-
0002-
Numaligarh Refinery Limited NRL Expansion Project
METHOD STATEMENT FOR CONDUCTING INTIAL TP-1S72A-CV-0002-MOS-0003_01
STONE COLUMN TESTING (SINGLE & GROUP)
_________________________________________________________________________________________________________

TABE OF CONTENTS
1. INTRODUCTION ...................................................................................................................................... 3
2. GROUND IMPROVEMENT SCHEME .................................................................................................. 3
3. LOADING DETAILS ................................................................................................................................. 4
4. PREPARATION AND LAYOUT FOR TEST ........................................................................................ 5
5. PLANT AND EQUIPMENT ..................................................................................................................... 5
6. LOADING PROCEDURE ........................................................................................................................ 5
7. RESULTS .................................................................................................................................................. 6
8. ACCEPTANCE CRITERIA ..................................................................................................................... 6
9. SAFETY PRECAUTIONS ....................................................................................................................... 7

LIST OF FIGURES

Figure 1 Typical plan and section for initial column load test.................................................................... 4

LIST OF TABLES

Table 1: Treatment scheme for the DM tank and heavy SLOP tank area .............................................. 3
Table 2: Loading details .................................................................................................................................. 4
Table 3: Load increment chart (typical) ........................................................................................................ 6

LIST OF ENCLOSURES

Annexure 1 Typical Load Test Set up Details

Annexure 2 Typical Load Test Record Format

MISPL DOC REF: MISPL-1S72A-CV-0002-MOS-0003_01

TP DOC REF: TP-1S72A-CV-0002-MOS-0003_01
Numaligarh Refinery Limited NRL Expansion Project
METHOD STATEMENT FOR CONDUCTING INTIAL TP-1S72A-CV-0002-MOS-0003_01
STONE COLUMN TESTING (SINGLE & GROUP)
_________________________________________________________________________________________________________

1. INTRODUCTION
M/s Numaligarh Refinery Limited (NRL) is proposed to expand their refinery in Numaligarh, Assam
which includes construction of storage tanks under Phase 2. M/s NRL engaged M/s Technip Energies
India Limited (Technip) as the project management consultant for this project. M/s Mahathi Infra
Private Limited is main contractor for the proposed work.
In this regard, Mahathi Infra has been awarded with the scope of design and execution of ground
improvement works to mitigate liquefaction, settlement control & enhancing bearing capacity at the
SLOP (heavy & light) tank, Demineralized water (DM) tank & Diesel Hydro Treater (DHT) tank area.
As per project requirements, 1 no. of Initial Single Column Load Test (ISCLT) and 1 no. of Initial Group
Column Load Test (IGCLT) are proposed at DM tank and heavy SLOP tank location respectively.
This document describes the methodology for the execution of initial single and group stone column
load test.

2. GROUND IMPROVEMENT SCHEME

The vibro stone column parameters and the treatment scheme considered in the design of ground
improvement for the foundation system are detailed below.
Table 1: Treatment scheme for the DM tank and heavy SLOP tank area

Description ISCLT IGCLT

Nominal Stone column diameter 850 mm 850 mm
Pattern Triangular Triangular
Spacing 2.00 m c/c 2.20 m c/c
Length of stone column 12.0 m below COL 12.0 m below COL
Granular blanket 500 mm thick 500 mm thick

Here, COL – Cut off Level

The typical plan and section of ground improvement scheme for initial single and group column load
tests are shown in Figure 1.

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TP DOC REF: TP-1S72A-CV-0002-MOS-0003_01
Numaligarh Refinery Limited NRL Expansion Project
METHOD STATEMENT FOR CONDUCTING INTIAL TP-1S72A-CV-0002-MOS-0003_01
STONE COLUMN TESTING (SINGLE & GROUP)
_________________________________________________________________________________________________________

Figure 1 Typical plan and section for initial column load test

3. LOADING DETAILS
Table 2: Loading details

Description Single Column Group Column

Nominal Stone Column diameter 850 mm 850
Design Loading Intensity 250 kPa 225 kPa
Test Loading Intensity 375 kPa 337.5 kPa
Spacing of stone columns 2.00 m (Triangular) 2.20 m (Triangular)
No. of test columns 1 no. 3 nos.
Test plate provided at site 2.1m dia. circular plate 3.5m dia. circular plate
Thickness of Test Plate 50mm 50mm
Area of test plate 3.46 m2 9.61 m2
Design Load (DL) 88.27 T (= 865.9 kN) 220.67 T (= 2164.75 kN)
Test Load (TL = 1.5*DL) 132.40 T (= 1298.8 kN) 331.00 T (= 3247.13 kN)
Kentledge Load (KL=1.3*TL) 172.12 T (= 1688.5 kN) 430.31 T (= 4221.27 kN)

MISPL DOC REF: MISPL-1S72A-CV-0002-MOS-0003_00

TP DOC REF: TP-1S72A-CV-0002-MOS-0003_01
Numaligarh Refinery Limited NRL Expansion Project
METHOD STATEMENT FOR CONDUCTING INTIAL TP-1S72A-CV-0002-MOS-0003_01
STONE COLUMN TESTING (SINGLE & GROUP)
_________________________________________________________________________________________________________

4. PREPARATION AND LAYOUT FOR TEST

The following illustrates preparation for initial stone column load test:
1. Location of the testing stone column shall be identified (refer Annexure 1).
2. Request for inspection shall be raised to the client / consultant within 24 hours prior to the
commencement of each load test.
3. Prior to the commencement of the load test, the test column will be prepared in the following
manner:
i. The test will be conducted at stone column cut-off level (COL).
ii. The surface of testing platform is to be cleared to expose the top of the stone column.
iii. The top of the column is to be levelled and lightly compacted to provide a firm horizontal-
loading surface.
iv. A steel plate of required size and thickness is to be placed over the effective tributary soil
area of stone column for testing.
v. The required size of stiffener plates shall be used for the proper load distribution.
4. A hydraulic jack shall be placed over the centre of the plate for loading purpose.
5. Initial witnessed results (field records) will be submitted for evaluation to Engineer in-charge.
6. Location layout and design calculations for kentledge shall be submitted to MPMC engineer for
review.
7. The detailed kentledge arrangement of load tests proposed at DM tank and SLOP tank area is
appended in Annexure 2.

5. PLANT AND EQUIPMENT

The following equipment will be mobilized for conducting the initial load test:
1. Hydraulic Jack – 200 T / 500 T.
2. Measuring devices such as pressure gauge, dial gauges for settlement measurement.
3. Kentledge setup beams, Grillage beams, supporting beams and Jumbo bags or concrete blocks
etc.
The detailed kentledge design calculations to be submitted to MPMC engineer for review are
appended in Annexure 3 and typical details of the equipment are presented in Annexure 4.

6. LOADING PROCEDURE
The following procedure to be adopted as per IS 15284 (Part 1): 2003 for carrying out initial stone
column load test:
1. The load will be applied to the plate/pedestal by a suitable Kentledge with complete care in
avoiding impact, fluctuations, or eccentricity.
2. The Kentledge will be minimum 1.3 times the maximum test load.
3. Load settlement observations will be taken up to test load (i.e., 1.5 times the design load).
4. The settlements will be recorded by four dial gauges (sensitivity less than or equal to 0.01 mm)
fixed at diametrically opposite ends of the test plate.
5. Each load increment will be about 1/10 of the design load and will be maintained until the rate of
settlement is less than 0.05 mm/h.
6. The design load will be maintained for a minimum period of 48 hrs after stabilization of settlement
to the rate as given in the above statement (Point No. 5) and maximum test load will be maintained
for a minimum period of 24 hrs.
7. Load - settlement relationship will be plotted from the settlements observed for each increment of
load at intervals of 1 min, 2 min, 4 min, 8 min, 15 min, 1/2h, 1h, 1 1/2h, 2h, 4h, and so on till the
desired rate of settlement has been achieved. The time intervals may be suitably modified if so
desired.

MISPL DOC REF: MISPL-1S72A-CV-0002-MOS-0003_00

TP DOC REF: TP-1S72A-CV-0002-MOS-0003_01
Numaligarh Refinery Limited NRL Expansion Project
METHOD STATEMENT FOR CONDUCTING INTIAL TP-1S72A-CV-0002-MOS-0003_01
STONE COLUMN TESTING (SINGLE & GROUP)
_________________________________________________________________________________________________________

8. The applied test load will be unloaded in five stages. Enough time will be allowed for settlements
to get stabilize at each stage. The typical load increments calculations are given in Table 3.

Table 3: Load increment chart (typical)

Load % of Design Load (Tons) Load (Tons)
increment Load Single Column Group Column
Loading cycle
0 0 0.00 0.00
1 10 8.83 22.07
2 20 17.65 44.13
3 30 26.48 66.20
4 40 35.31 88.27
5 50 44.13 110.33
6 60 52.96 132.40
7 70 61.79 154.47
8 80 70.61 176.53
9 90 79.44 198.60
10 100 88.27 220.67
11 110 97.09 242.73
12 120 105.92 264.80
13 130 114.75 286.87
14 140 123.57 308.94
15 150 132.40 331.00
Unloading cycle
16 120 105.92 264.80
17 90 79.44 198.60
18 60 52.96 132.40
19 30 26.48 66.20
20 0 0.00 0.00

7. RESULTS
The results of the settlement measurements will be presented in graphical form as Load vs.
Settlement plot. Typical format of load test field record sheet is attached in Annexure 5.

8. ACCEPTANCE CRITERIA
The column will be deemed to have satisfied following conditions:
a. 10 mm to 12 mm settlement at design load for a single column test (according to TP-1ZZZA-CV-
SPE-0040 & IS 15284 [Part 1]: 2003 Clause 13.7 (j) (i)).
b. 25 mm to 30 mm settlement at design load for a group column test (according to TP-1ZZZA-CV-
SPE-0040 & IS 15284 [Part 1]: 2003 Clause 13.7 (j) (i)).

MISPL DOC REF: MISPL-1S72A-CV-0002-MOS-0003_00

TP DOC REF: TP-1S72A-CV-0002-MOS-0003_01
Numaligarh Refinery Limited NRL Expansion Project
METHOD STATEMENT FOR CONDUCTING INTIAL TP-1S72A-CV-0002-MOS-0003_01
STONE COLUMN TESTING (SINGLE & GROUP)
_________________________________________________________________________________________________________

9. SAFETY PRECAUTIONS
The following In-house Safety Rules shall be followed during load testing:
• The area of load tests shall be declared as hard hat area and only authorized personnel shall
be allowed.
• All the persons working should have minimum Personal Protective Equipment (PPE): safety
helmet, safety shoes and reflective vest.
• Keep the test area clean and tidy.
• Only trained and authorized persons are to be used for loading and unloading of Kentledge
material.
• All the workers and personnel should stay clear of suspended loads.
• While placing the Kentledge material with head load, due care shall be taken to avoid splinters.
• While placing the Kentledge material with head load, due care shall be taken to avoid splinters.
• Only welders can carry out gas-cutting and welding works.
• First aid box shall be available in the vicinity.
• Heavy equipment like crane, JCB shall have proper operators and cleaners who would also
take care while reversing the vehicle.
• Heavy vehicular movement should not be allowed near the trial location during the test.
• Safety signage shall be prominently displayed for the information of people involved in the
work and trespassers.

A toolbox meeting shall be conducted by the safety officer/Engineer-In-Charge prior to start of testing
works. The meeting will be highlighting the potential risks involved in process of conducting load
tests, safety precautions to be followed by the workers and personnel involved in the testing.

MISPL DOC REF: MISPL-1S72A-CV-0002-MOS-0003_00

TP DOC REF: TP-1S72A-CV-0002-MOS-0003_01
Numaligarh Refinery Limited NRL Expansion Project
METHOD STATEMENT FOR CONDUCTING INTIAL TP-1S72A-CV-0002-MOS-0003_01
STONE COLUMN TESTING (SINGLE & GROUP)
_________________________________________________________________________________________________________

Annexure 1: Typical Load Test Set up Details

LOAD TEST: Initial Trials

FINISHED DIA.: 850 mm
DATE OF INSTALLATION:
DESIGNED COLUMN
CAPACITY:
TEST LOAD REQD.:
KENTLEDGE TYPE: Gravity Loading
KENTLEDGE LOAD PROVIDED:

DATE OF TEST:
REACTION DETAIL:
CAPACITY OF JACK:
NO. OF JACK:
RAM DIA.OF JACK:
AREA OF ONE JACK:

PRESSURE GUAGE:
MAKE:
CALIBRATION DATE:
LEAST COUNT OF PRESSURE
GUAGE:
MAXIMUM RANGE:
LOAD PER LEAST COUNT
DIAL GUAGE:
MAKE:
LEAST COUNT:
NO. OF DIAL GUAGES USED: 4 nos.

Details of the load test equipment furnished above are subjected to change, hence will be provided during
the test.

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TP DOC REF: TP-1S72A-CV-0002-MOS-0003_01
Numaligarh Refinery Limited NRL Expansion Project
METHOD STATEMENT FOR CONDUCTING INTIAL TP-1S72A-CV-0002-MOS-0003_01
STONE COLUMN TESTING (SINGLE & GROUP)
_________________________________________________________________________________________________________

Annexure 2: Typical Load Test Record Format

Mahathi Infra Services Pvt. Ltd.
Project:
Test No: Probe No.:
Drawing
No.: Date Installed: Page no.: of

Loa Pr. Avera

Date Time % of Dial Dial Dial Dial Incr. Total Datum /
d Gauge ge

Worki Gauge Gauge Gauge Gauge Readi Settleme Settleme Test performance (Pass / Remar
Reading Jack
ng 1 2 3 4 ng nt nt Fail) ks

Ton Measurem
Load Kg/cm2 mm mm mm mm mm mm mm
s ent

Recorded by Witnessed by

Contractor MAHATHI TECHNIP / NRL

 NUMALIGARH REFINERY LIMITED
STORAGE TANKS PACKAGE PHASE - 2

COMMENTS RESOLUTION SHEET

Document No: TP-1S72A-CV-0002-MOS-0003 Rev: 1

METHOD STATEMENT FOR CONDUCTING INTIAL STONE COLUMN TESTING (SINGLE & GROUP) - COMMON Doc.
Document Title: 1
FOR ALL ITEMS Class:
CONSULTANT Transmittal
Date: 18-Nov-22
No:
Comment Sheet No: CRS_TP-1S72A-CV-0002-MOS-0003_00

Code 1 – Revise and Resubmit

Document Status Code: 1 Code 3 – No Comments – Final issue

Code 2 – To be Issued As Final Provided Comments are
Incorporated

No Rev Page No CL.No & SUBJECT OWNER / MPMC COMMENTS MISPL Reply PMC Decision

1 1 PG- 1-19 Table of contents Keller name to be removed Noted and updated in revised document

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