TATA PROJECTS LIMITED

TPL/UI-670050/QMD/MS/
URBAN INFRASTRUCTURE

HSD Fuel Storage Tank Fabrication Page 1 of 19

HSD Fuel Storage Tank Fabrication

Doc No: TPL/UI-670050/QMD/MS/

Reviewed Reviewed Reviewed Approved

Date Rev.No Description Prepared by Approved by
by by by by
Sign
First 28-06-
28-06-2021 28-06-2021 28-06-2021 28-06-
28-06-2021 R0 Date
submission 2021 2021
Sub- Quality Safety In Section In Project Customer
Designation
Contractor In charge charge charge In charge Representative
Mr.Jitend
Mr.Sudha
Name SGIC Mr.Shiva Kumar ar/Sudha
kar
kar

Record of Revisions

Date Revision No. Details of Revision Page Affected

25-06-2021 R0 First Issue
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INDEX

PAGE
S. No. CONTENT REMARKS
NUMBER
Index

1 3-7
Objective

2 7
Scope

3 8
Reference code & documents

4 8-10
Materials Required

5 11
Tools and machinery required

6 12-13
Safety PPE Requirement
Roles, Responsibilities & Authorities like as
7 13-14
project manager, safety officer, QC person etc.

8 14
Power and light requirement

9 14
Unloading and storage of material.

10 15
General preparation to start work

11 16-17
Work sequence/Procedure in details step by step

12 Testing & Commissioning if applicable 17-18

13 Protocol-Records &Quality Check list 19

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1. Objective

A. WORK METHOD FOR INSTALLATION OF HSD FUELLING SYSTEM :

All the storage systems in India undergo a licensing process and subsequent to licensing, the
system is commissioned and taken to use. The design, fabrication and erection of the tanks
have to conform to rules laid under Petroleum Rules, Act 2002 as amended by The Petroleum
(Amendment) Rules-2019 vide GSR 384(E),dt. 29-5-2019. The design and fabrication of the 3
X 150 KL HSD Aboveground Vertical Storage Tanks conforms to IS 803:1976. The Aboveground
Vertical Storage Tanks High Speed Diesel is installed at site to take care of fuel supply to run
the generators. The tank is supported by allied equipment like the electrical Pump & Motors,
Level Switches, Valves and a Control Panel.

B. DIESEL STORAGE SYSTEM:

b.1 Diesel Storage Tank:

3 X 150KL each tank (4,50,000Liters) Aboveground Vertical Storage tanks installed herein
referred to as main tank. The main tank has been manufactured with mild steel plates
confirming to IS 2062. The main tank has been provided with the following nozzles.

1) Fill: 80mm dia nozzle has been provided to unload the product from the tanker to the
installed aboveground tank. The product flows through pumping.
2) Man Hole : We have been provided to carry out maintenance of the main AG tank on
the top of tank and also 600mm dia man hole arranged with 1 mtr height from the bottom
plate.
3) Spare Nozzle: (80mm)This is for future use of any other purpose.
4) Air Vent: (50mm) This acts as breather to the main tank and ensures that the tank are
depressurized at all times.
5) Dip: (50mm) An aluminum dip rod has provide to monitor the level of fuel maintained
6) Suction: (80mm) This discharges the product from the main tank to the DG day tank by
pumps.
The main tank are installed on the RCC mat raft and sealed with a concrete slab. It is earthed
safely within the pit connected to the earthling boss provided in the tank.

b.2 Tank Truck Unloading Platform:

This is where the road tanker carrying the product is received. Once arrival the truck should
be allowed at least 10 to 15 minutes for the product to settle down before unloading. Then
we will connect the hose pipe to the tanker truck and the same will be connected to end
connections from inlet pipe to pump. In between there will be a flow meter as well as
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1 No Working 225 LPM Geared pump with 5 HP FLP Motor & 1 No standby 225 LPM Geared
pump with 5 HP Motor.

b.3 Delivery Pumps (Transfer Pumps):

1 No Working 125 LPM Geared pump with 3 HP FLP Motor & 1 No standby 125 LPM Geared
pump with 3 HP Motor installed consisting with Ball valves, strainers at inlet and NRV’s, Ball
valves and pressure gauges at outlet line to pump the fuel from the AG tanks to intermediate
tank. These pumps will be operated automatically and manually by the HSD control panel.

b.4 Piping:

Fill Line:Fill line is 80NB containing with unloading pumps and FLP motors, flow meter, ball
valves, strainers has been fixed in the fill line.

Delivery Line: 50NB pipe used from tank suction nozzle to master day tank,

Gravity Flow Line: 40NB pipe used from master day tank to day tanks

A foot valve is fixed in the suction lines.

Ball valves, pumps Non Return valves are fixed in the delivery line which is inside the pump
hose.

b.5 Pressure Gauge:

1 No pressure Gauge installed at delivery pumps in HSD yard area

b.6 Level Switch for Master day Tank:

Level Switches provided in master day tank. The Level Switch is calibrated to Low and High
Levels. The Level Switch operates pumps to fill the master day tank at low level and shut off
pumps at high level.

b.7 Electrical control cable:

A) 4 Core X 1.5 Sq.MM copper armored cable usedfrom level instruments etc. to Control
panel, operation and emergency stop switch,
B) 4 Core X 2.5 Sq.MM copper armored cable used fromtransfer pumps to Control panel
C) From level switch in master day tank to Control Panel
D) From level indicator in main A/G tank to Control Panel.

b.8 HSD Control Panel:

From tanker unloading to main A/G tank operation we will provide 5HP Flameproof DOL
starter (1W+1S) and for Transfer pumps we will provide flameproof emergency stop switched
(Push button) operation of the diesel system. This works on AUTO and MANUAL Mode. Main
control panel will be installed near DG room area.
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b.9 Digital Flow Meter:

1). 80 mm dia digital flow meter installed in inlet line with by-pass arrangement for measuring
inlet flow to A/G tanks.

2). 50 mm dia in pumps delivery line with by-pass arrangement for measuring out flow from
UG tanks.

C Emergency Stop switch:

Emergency Stop push button installed near the pumps to shut off the total system during
emergency.

D UNLOADING PRODUCT AT DIESEL TANK FARM:

It is advised that once the product is received at site the following steps are taken:

1) Lock the truck tyre from rolling by providing solid vedge under the tyres.
2) Connect the earthing clamps to the tank till the discharge of HSD is complete.
3) Allow 10 to 15 minutes for the product to settle down before unloading from the tanker.
4) Check for water in diesel using hydrometer.
5) Connect hose pipe to the decanting line and open the valve. Do not disturb till the process
is completed and the truck is decanted fully and completely.
6) During unloading the hose connecting the road tanker to the fill line of the main tank
should be properly coupled so as prevent spillage.
7) Unload compartment by compartment.
E USING DIESEL FROM MAIN TANK:

1) Check diesel availability in Main Tank.

2) Ensure Ball Valves are open.
3) Main Incomer in Control Panel is turned to “ON” position. R Y B Indicator lamp in Control
Panel glows.
4) Auto Mode is selected in AUTO / OFF / MANUAL SELECTOR switch in Control Panel.
5) When Diesel level DG day tank are below Low Level, Main Pump switches on automatically
to pump diesel into DG day Tank.
6) In case of any power disruption during filling operation, pump will not switch on after
power resumes. Diesel in the DG day tank will remain at same level and pump will switch
on automatically only when diesel level goes down to Low Level.
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7) When diesel in the DG day tank reaches High Level flow automatically stops and pump
switches off.
8) If the motor is being used for the first time, it needs to be primed with the product to be
handled, keeping all valves in open condition.
9) Subsequently no priming is required.
F BEFORE PUMPING:

1) Self priming pumps must have the suction and delivery valves open.
2) Check the direction of rotation of the pump.
G NORMAL OPERATION:

AUTO MODE:

1) Main Incomer in Control Panel is turned to “ON” position.

2) Incomer Switch of main pump & standby pump in control panel switched “ON”
3) Auto Mode is selected.
4) When Diesel level in DG day tank is below Low Level, the pump pumps diesel into DG day
tank.
MANUAL MODE:

1) Main incomer in Control Panel is turned to “ON” Position.

2) Main Pump or Standby Pump whichever necessary switched “ON”.
3) Mode Selection – Manual.
4) Press start Push button corresponding to main pump/ standby pump to switch on.
5) When DG day tank reach required level press push button for pump to stop.
H EMERGENCY OPERATION:

AUTO: REMOTE

1) When main pump fails/trips, Standby pumps to be operates Manually

MANUAL: LOCAL CONTROL

A) Control Panel:

In case of any emergency, stop Button on the Remote Panel should be pressed to cut off power
supply for pump operation. It can be released by turning it in clockwise direction.

B) Emergency push button:

Push Button stations to be pressed to stop main or Standby Pump.

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I SAFETY FEATURES:

1) Non Return Valves ensure that the product does not return to the main tank.
2) Level Switches calibrated in the FAIL – SAFE Mode to ensure no diesel overflow in case of
power failure.
3) Strainers ensure that diesel is free of foreign matter.
2. SCOPE

This method statement provides the details methodology for carrying out HSD
Vertical

Storage Tank Fabrication which covers different activities like Handling of material,
it’s storage, preservation, Cutting ,Forming, fit up, welding , NDT, Painting

This statement also consider the safe working Methodology to meet zero accidents.
2.1 ACTIVITIES

The followings activities are to be involved during Fabrication stages.

2.1 Required Raw material received & it's inspection
2.2 Cutting, forming
2.3 Fit Up
2.4 Welding/Assembly
2.5 Testing (DP Test) & Hydro/ Pneumatic testing
Surface

2.6 Cleaning
2.7 Painting
2.8 Final Inspection
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3. REFERENCES:

The following specifications and standards shall be

used in practice

Vertical Storage tank design

IS 803 code

IS 2062 Structural steel material

IS 1239 piping material

Latest fabrication drawing

4. Material required for completion of HSD Fueling system for TPL-Hosur

BOQ DESCRIPTION MAKE/BRAND TECHNICAL SPECIFICATIONS

SL.
NOS
A.1 MAIN TANK SAIL/JINDAL A/G VERTICAL TANK DIMENSIONS : 5.10 Mtrs DIA X
HSD 3 x 150 KL (This tank will be 7.50 Mtrs HEIGHT
VERTICAL ABOVE fabricated by Sri SHEET MAKE : SAIL/JINDAL
GROUND STORAGE Gananadha at your MOC: As per IS-2062 grade
TANK project site @ Hosur) STEEL THICKNESS: 8,10,12 mm THK FOR SHELL &
TOP CONE 8 mm THK & BOTTOM PLATE 16 mm THK
SHEET SPECIFICATION : As per IS- 2062 grade ‘B’
TANK FABRICATED : As per IS-803 STANDARD
WELDING SPECICATION : IS- 812:1987
WELDING ELECTRODES : IS- 814:1991
TANK TESTING : PNEMATIC @ A PRESSURE OF
0.05MPA (0.5KG/CM2)
TANK PAINT : 1 COAT OF EPOXY PRIMER & 2 COATS
OF EPOXY WHITE PAINT
B 4 KL CAPACITY MASTER SAIL/JINDAL HORIZONTAL MASTER DAY TANK DIMENSIONS :2.7
DAY TANK (This tank will be Mtrs Length x Ø 1.4 Mtrs (Width),
fabricated by Sri 2.5 Mtrs Height steel support structure
Gananadha at our work SHEET MAKE : SAIL/JINDAL
site @ Hyderabad) MOC : As per IS-2062 grade
STEEL THICKNESS : 6 mm Thick
SHEET SPECIFICATION : As per IS- 2062 grade ‘B’
TANK FABRICATED : As per IS-10987 STANDARD
WELDING SPECICATION : IS- 812:1987
WELDING ELECTRODES : IS- 814:1991
TANK TESTING : PNEMATIC @ A PRESSURE OF
0.05MPA (0.5KG/CM2)
TANK PAINT : 1 COAT OF EPOXY PRIMER & 2 COATS
OF EPOXY WHITE PAINT
C 990 Ltrs CAPACITY SPILL SAIL/JINDAL A/G VERTICAL TANK DIMENSIONS : 1.26 Mtrs Length X
TANK (This tank will be 0.80 Mtrs Width X 1.0 Mtrs Height
fabricated by Sri SHEET MAKE : SAIL/JINDAL
Gananadha at our work MOC : As per IS-2062 grade
site @ Hyderabad) STEEL THICKNESS : 6 mm Thick
SHEET SPECIFICATION : As per IS- 2062 grade ‘B’
TANK FABRICATED : As per IS-803 STANDARD
WELDING SPECICATION : IS- 812:1987
WELDING ELECTRODES : IS- 814:1991
TANK TESTING : PNEMATIC @ A PRESSURE OF
0.05MPA (0.5KG/CM2)
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TANK PAINT : 1 COAT OF EPOXY PRIMER & 2 COATS

OF EPOXY WHITE PAINT
D UNLOADING PUMPS & TUSHACO & PUMP MAKE : TUSHACO
FLP MOTORS KIRLOSKAR TYPE: GEARED
FLOW RATE : 125 LPM
PRESSURE : 6 Kg/CM2
TEMPERATURE : 370C
VISCOSITY : 88Cst
QTY : 3 No’s

MOTOR MAKES : KIRLOSKAR

SPECIFICATIONS : AS PER IS/IEC 60079-1:2007
(Superseding IS 2148: 2004)II-PHASE INDUCTION
MOTOR
CAPACITY :5 HP
QTY : 3 No’s
(As per your SLD we will use these Transfer Pumps &
FLP Motors for Delivery/ Supply line)
E UNLOADING PUMPS & TUSHACO & PUMP MAKE : TUSHACO
FLP MOTORS KIRLOSKAR TYPE : GEARED
FLOW RATE : 225 LPM
PRESSURE : 6 Kg/CM2
TEMPERATURE : 370C
VISCOSITY : 88Cst
QTY : 4 No’s

MOTOR MAKES : KIRLOSKAR

SPECIFICATIONS : AS PER IS/IEC 60079-1:2007
(Superseding IS 2148: 2004)II-PHASE INDUCTION
MOTOR
CAPACITY : 5 HP
QTY : 4 No’s
(As per your SLD we will use these Pumps & FLP Motors
for Tanker unloading inlet line)
F PIPES JINDAL (MSL) PIPE MAKE : JINDAL (MSL)
SIZE : 50, 40 & 25 mm
MOC : Seamless Pipe -CS Class Schedule 40 ASTM
Gr106B
SPECIFICATIONS : CS Class Schedule 40 ASTM
Gr106B
G.1 BALL VALVES HAWA ENGINEERS MAKE : HAWA ENGINEERS LTD
LTD SIZE : 50, 40 & 25 mm dia
TYPE : FLANGED END
SPECIFICATION : ASTM- A216 Gr WCB
MOC : CAST STEEL TWO PIECE DESIGN ASA 150
CLASS
G.3.a SOLENOID VALVES AIRA MAKE : AIRA
SIZE : 50 MM DIA
BODY & COVER : ASTM A 351-CFB/CF8M
PRESSURE RANGE : 0.5 TO 10 BAR
TEMPRATURE RANGE : 50c to 850c
COIL VOLTAGE : 12V, 24V, 48V, 110V, 230V, AC/DC
COIL INSULATION : ‘F’ CLASS (FLAME PROOF COIL)
G.4.a Y-STRAINERS HAWA ENGINEERS MAKE : HAWA ENGINEERS LTD.
LTD. SIZE : 50 & 40 MM
TYPE : FLANGED END
MOC : CARBON STEEL/ CAST IRON
SPECIFICATIONS : IS 210 Gr FG 200/220
G.5 PRESSURE H-GURU MAKE : H-GURU
GUAGE(INDICATOR) SIZE : 6” DIAL
TYPE : SCREWED
SPECIFICATION : Range 0 to 10Kg/CM2,
MOC : CAST ALUMINIUM
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G.6 HOSE PIPE FOR KANTAFLEX MAKE : KANTAFLEX

UNLOADING PURPOSE SIZE : 80 MM x 3.6 Mtrs Length
SPECIFICATIONS : AS PER BS -1435/1968” ”
G.11 EARTH ELECTRODES ASHLOK MAKE : ASHLOK
SIZE : 100 mm dia x 13 mm Thick
SPECIFICATIONS : AS PER IS 3043 ”
G.12 VORTEX FLOW METER EUREKA MAKE : EUREKA
METER SIZE : DN 50 mm
TYPE : VORTEX FLO W METER
FLOW : LIQUID 1.2-6.2 to 200-2000 m3/h, GAS/STEAM
5-25 to 1380-11000 m3/h
AMBIENT TEMPRATURE : -200 to +700C
FLUID TEMPRATURE : -200 to +3500C
OPERATING PRESSURE : As per Flange rating
WETTED PARTS : SS316/SS304
NOMINAL BORE SIZE : 50 mm
REPEATABILITY : -+0.1%
ACCURACY : -+1% of reading, Gas/ Steam -+1.5% of
reading
LIQUIDS : PETROLEUM PRODUCTS (HSD)
(These Flow Meters we will use in delivery line after pump
and also tanker truck unloading line also.)
G.13 CABLES KEI / POLYCAB MAKE : KEI / POLYCAB
SIZE : 2.5 Sq. mm x 4 CORE (These cables for Pumps &
FLP Motors connections purpose & 1.5 Sq. mm x 4 CORE
(These cables for Level indicators & Instrumentation etc.)
TYPE : PVC SHEATHER COPPER ARMOURED CABLE
bgt
SPECIFICATION : IS-1554 (PART-1)
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5. Plant &CONSTRUCTION EQUIPMENTS (Tools and machinery)

The Tools & tackles are to be used during Fabrication list.

Sr. No. Item Description

5.1 Sheet Rolling Machine (For at site tank fabrication purpose)

5.2 MIG Welding Machines

5.3 Grinding Machine

5.4 Pipe cutting Machine

5.5 High speed angle grinder

5.6 Right Angle

5.7 Cutting Sets

5.8 Measuring Tape/Steel Scales

5.9 Slings/Guys, Spreader beam

5.10 D’ shackles.

5.11 Chain Blocks

5.12 Elcometer

5.13 MS Lifting – permanent Structure for tank fabrication job purpose

5.14 Hydra (10 tonne crane for Temporary arrangement at site

5.15 Tools & Tackles

5.16 Air Compressor for Tank pressure testing purpose

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6. Safety PPE Requirement

 The following precautions are necessary:
 Do not carry out paint in spaces, which are not well ventilated

 Do not allow the presence of any fire, flame or naked light near the space
 where pain is carried out.

 No smoking in paint and thinner storage rooms, or paint application areas.

 Respiratory masks and eye protection is to be used by the workers
 Good housekeeping is essential; rags soiled with paint shall be safely
 disposed of.

 All metal parts of spray booths, exhaust ducts, or any conductive body
 coming into Paint circuits, shall be earthed

 Spark free, flameproof electrical equipment and wiring shall be used in the

area where Painting is performed


 Eating or smoking with paint smeared hands is to be discouraged


 Select and use lifting equipment and lifting accessories (tackle) which are
suitable for the task. In particular, do not exceed their safe working load.

 A safe exclusion zone should be established around the working area,

vehicle and lifting equipment prior to commencing the operation.

 Riggers or anyone else attaching lifting accessories to material (‘slinging’)

must be away from the load before it is lifted

 Do not use the banding wire or straps to lift the material;

 Safety kick off meeting given to all personnel involve in fabrication process.

 When unloading Workers operating the crane should have been trained in
 its safe use and safe slinging techniques

 Where possible loose flammable materials should be removed and other

 flammable materials protected within the working area.

 PPEs must be worn. Second person must be in attendance.

 Extra ventilation should be considered in work area. Effective fume control
 equipment should be used if required.
 Welding equipment must be inspected for good condition before use.
 Cylinders must be properly secured.
 Work area to be kept clear of debris etc.
 Galvanized steel should not be welded due to the toxic fumes produced.
 The galvanizing should be removed by machine or grinding until clean
steel is exposed.
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 Have a fire extinguisher available.

 Training for staff in resuscitation in the event of an incident.

DOCUMENTATION

The coating / painting inspection report shall be prepared and documented

which will have humidity, ambient temperature. Paint Batch certificates, references,
surface preparation and primer, intermediate, and finish coating dry film thickness.
The below documents shall be maintained during the installation of work
I. IMIR
II. Installation check list
III. Commissioning check list
IV. Weld and NDT inspection report
7. Roles, Responsibilities & Authorities

CONTACT PERSON NAME & DESIGNATION CONTACT NO’S

1 Mr.Jitender Singh
(Project Manager) Cell No: 9346387816

2 Mr. Sudhakar Singh

(Total Site Incharge) Cell No: 9866242643

3 Mr. Ranjan Kumar

(Electrical Engineer)) Cell No: 8341897644

4 Mr.Pramod Kumar Singh

(Store Supervisor) Cell No: 9182354962

5 Mr. SukhdebBiswakarma
(Site Engineer) Cell No: 9556044523

6 Mr.Ayush Jain
(Supervisor) Cell No: 7231904040

7 Mr.Shiva Kumar
(Safety cum Quality Engineer) Cell No: 7708841435

8 Mr. Shivji Prasad

(Fitter) Cell No: 9556044523

9 Mr. Hiraman Prasad

(Welder) Cell No: 73920204105

10 Mr. Sonu Kumar

(Helper)

11 Mr. PramodYadav
(Welder)
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12 Mr. Sandeep Yadav

(Grinder Men)

13 Mr. BrijeshYadav
(Rigger/ Gascutter) Cell No: 7311160819

14 Mr. Hridyanandpal
(Rigger)

15 Mr. DhanajayYadav
(Welder)

8.Power and light requirement.

TPL has to arrange incoming power for 4-5 power points near the vertical tank fabrication
purpose and also HSD Yard area for pipe lining and transfer pumps as well as unloading
pumps for temporary lighting arrangements. We shall arrange lighting for tank fabrication
area.
9. Loading and storage of material.

Select and use lifting equipment and lifting accessories (tackle) which are suitable for
the task. In particular, do not exceed their safe working load.

A safe exclusion zone should be established around the working area, vehicle and
lifting equipment prior to commencing the operation.

Riggers or anyone else attaching lifting accessories to material (‘slinging’) must be

away from the load before it is lifted

Do not use the banding wire or straps to lift the material;

Safety kick off meeting given to all personnel involve in fabrication process.

When unloading Workers operating the crane should have been trained in its safe use
and safe slinging techniques

Flame cutting / welding operations

Prior to work commencement

Must have PPEs, welding goggles, or welding mask, safety footwear, long sleeved
overalls, apron if required, protective headgear.

Must have appropriate tools and equipment for task (ensure equipment in good
condition and safe to use), portable local exhaust ventilation (LEV) if required.

Ensure fire extinguisher to hand at work area.

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10. General proration for to start work.

10.1 MATERIAL

10.1 All materials shall be procured with MTC and stored properly

10.2 All materials shall conform to the contracts requirements.

Mill test certificate of the material shall be furnished.

10.3 The Material test certificates for Raw materials including Welding consumables
certificates and Paint batch certificates shall be reviewed and approved by
QA/QC.

10.4 The raw materials shall be taken up for fabrication only after the QC clearance.

10.5 Materials shall not be kept directly on ground

10.1.1 FABRICATION PROCESS:-

The fabrication of work shall be carried out as follows

10.1.2 Material Preparation

To the greatest extent possible, all the materials shall be prepared in the machines.

After preparation, all the components shall be identified with its mark number / code
number.

10.1.3 Cutting Plans

The cutting plan shall be prepared before commencement of fabrication work for all
the raw material.
10.1.4 Straightening

All steel material shall be free from bends or twists and if noted shall be
corrected by the mechanical Means.
10.1.4 Cutting
To the greatest extent possible the materials shall be cut by oxy acetylene machines.
The Cut edges shall be free from defects.

10.1.5 Cutting Edges

The cutting edges to be welded shall be within the limits shall be rectified by welding
and grinding as per code.

10.1.6 Holes
To the greatest extent possible the holes shall be drilled by drilling machine
Drilled holes shall be free from burrs.
Forming Process:
The plate shall be bend to the required dimension by bending machine. Any cracked
developed at bend portal shall be visual checked.
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11. Work sequence/ Procedure in details step by step.

The components shall be fitted for welding as per the requirements of relevant IS
code

Proper Root Gap, Root face, bevel angle shall be maintained as per approved WPS.

Both side of the fit up joint shall be cleaned. There should not be any debris,
grease, and rust at the adjacent of Fit up joint

The root gap and welding edges shall not exceed the limits of relevant IS code

Welding groove dimensions shall be ensured as per fabrication drawings.

The Allowable misalignment of adjoining members to be butt-welded shall be 1.5mm

The edges or surfaces of parts to be joined by welding shall be clean and free
from contaminations like moisture, slag, oil, grease, paint, scale, rust etc.

11.1 Welder Qualifications

Each welder shall be qualified by welder qualification test at site.

11.2 Electrodes

All the welding consumables shall be stored clean and in a dry place.

No Wet electrodes or coils shall be used and it shall be discarded.

SMAW /MIG/CO2 Welding process shall be used for this process.

All the welding consumables shall be suitably selected which will match the
mechanical properties of the base material reputed make-ESAB, ADOR, D&H
Electrode shall be used for welding work

11.3 Welding

All welding shall be carried out as per relevant IS code and approved WPS

Minimum Inter-pass temperature shall be ensured.

11.4 Back Gouging Inspection

Back gouged surfaces shall be visually inspected prior to welding to ensure

the root is cleared from defects.

11.5 Sequence of Welding

The sequence of welding shall be selected to ensure that the components assembled
by welding are free from distortion and large residual stresses are not developed.
Welds shall be made in flat position wherever practical.

The ends of butt welds shall have full throat thickness. This shall be obtained on all
main butt welds by the use of runoff and run on pieces adequately secured on either
side of main plates. Additional metal remaining after the removal of extension pieces
shall be removed by grinding or by gas cutting.
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Temporary supports shall be removed by grinding without damaging the base metal
and the damaged areas shall be ground smooth and flush. Temporary supports shall
be removed only by grinding.

If temporary supports are needed to avoid distortion while handling shall be

left as it is and shall be removed at site during erection.

11.6 TANK DIMENSION CHECKING

After complete weld jointing the final dimension to be ensured to comply with client
approved drawing.. The report of the same shall be prepared

11.7 INSPECTION:-

Visual Examination of Welds

Completed welds shall be inspected visually

The weld reinforcement of butt-welds & Fillet joints shall be within the requirements

11.8 Dimensional check and final visual inspection

The fabricated Tank shall be inspected in accordance with Shop drawing.

Visual inspection shall be carried out on the assemblies before releasing for Surface
cleaning and painting

11.9 Inspection & Test Requirements

Inspection and Test shall be carried out as per the submitted Inspection and Test
Plan.

Non-destructive examinations shall be performed as approved Inspection and Test

plan/approved fabrication drawing/BOQ or specifications.

12. Testing & Commissioning.

Pressure Gauges

Gauges shall be installed for each test. One placed in the highest part and the other in
the lowest part of the Test System. All Pressure Gauges shall be duly calibrated from
NABL laboratory

12.1 General Procedure

The Pressure Test will then be performed in accordance with the project specifications.
The client witness and approve the Test.

12.2 Pre Test Requirements

All welds and Non Destructive Testing shall have been completed.

The system shall be cleaned with dry air.

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URBAN INFRASTRUCTURE

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Hydro test diagram showing test limits with blinds and manifold and vents and
drains location shall be prepared and attached in this procedure.

Vent shall be open during filling so that all air is vented prior to applying pressure to the
system.

Test medium shall be sweet water for hydro test and with valid laboratory analysis
during the test.

12.3 Pneumatic Test

The testing shall comply with Client Spec.

The circuit shall be vented during filling and before any pressure is applied. The filling
of the System shall to be at lowest point.

Pressure shall be applied using suitable method

Pneumatic test sequence shall be in stepwise such that initially 50% of the Test
pressure has to be pressurized and then check for preliminary Check shall be done.
Then onwards test pressure shall be increased in Steps no greater than one-fifth of test
pressure shall be increased and finally 100% have to be pressurized and check for
leaks.

The applied test pressure shall be 1.5 times of working pressure

The test pressure shall be reached gradually and be maintained constant, for the time
enough to enable a visible inspection of the circuit, a time not less than 30 minutes or
the time required by the inspector.

Pumping or venting operations during inspection shall be allowed only as

consequence of the ambient temperature variation, in order to restore the test
pressure, otherwise the pump shall be isolated from the circuit.

All welds and flanged connections shall be visually inspected to ascertain possible
leakage.

Visual Inspection of Pressure Test shall be done.

12.4 Acceptance Criteria

No leak is permitted and the pressure should remain constant

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URBAN INFRASTRUCTURE

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13. Protocol-Records & Quality check list

13.1 STORAGE TANKS:

13.2 Status of tanks

13.3 No of HSD tanks provided with capacity

13.4 Total capacity of HSD Tank

13.5 Provision of drain cock in each storage tank with lock and seal

13.6 Whether Storage tank is provided with ladder/catwalk.

13.7 Whether any leakages observed in HSD valves, joints and pipelines & what action
taken by HSE in- charge.

13.8 Whether ground availability of HSD oil is measured by dip reading in each shift and
recorded while handing over and taking over

13.9 Whether calibration of storage tank is done after cleaning in case of physical
deformation of the tank is noticed

13.10 Total numbers of fuelling points

13.11 Locations of fuelling points: -

13.12 Provision of Remote control switches and its conditions

13.13 Leakage from valves/joints of fuelling pipe line

13.14 Number of fire buckets

13.15 Number of fire extinguishers, location & due date for testing/refilling.