Retail Outlet Construction

Nayara Energy Limited

Construction Execution Procedure

For
Tank & Product pipeline -Hydro Testing, Doping &
Installation
EOL-Engg-M-001_R1
Rev Date Description Prepared Reviewed Approved
00 17.07.2016 Issue for Use PSN RM RA
01 09.06.2020 Changes in tank hydro test pressure and doping procedure RK/PP/SM SM RA
Nayara Energy Limited CEP - Hydro Testing , Doping & Installation of Tank & Pipeline
Marketing Department EOL-Engg-M-001_R1
Retail Division
Rev. 1 – 9th June, 2020

TABLE OF CONTENTS

1.0 PURPOSE & SCOPE......................................................................................................................... 3

1.1 IMPORTANCE OF ANTI-CORROSIVE BITUMINOUS PAINT APPLICATION ................. 3
1.2 REFERENCES .................................................................................................................................. 3
1.2.1 GENERAL REQUIREMENT .................................................................................................................3
1.2.2 STANDARD REQUIREMENT .............................................................................................................3
1.2.3 PROJECT REFERENCE DRAWINGS ....................................................................................................3

2.0 CONSTRUCTION METHODOLOGY ............................................................................................. 3

2.1 HYDRO TESTING OF UNDERGROUND FUEL STORAGE TANK .....................................................3
2.2 HYDRO TESTING OF PRODUCT PIPELINE ....................................................................................4
2.3 WATER PROOFING PROCESS ..............................................................................................................4
2.4 TANK INSTALLATION ...........................................................................................................................5
2.5 PERMITS ..............................................................................................................................................6

3.0 ACTIVITY SCHEDULE / MILESTONES......................................................................................... 6

4.0 CONSTRUCTION RESOURCES ..................................................................................................... 6
4.1 PERSONNEL .........................................................................................................................................6
DIVISIONAL ENGINEER ..............................................................................................................................6
4.2 PLANT & EQUIPMENT .........................................................................................................................6
4.3 MATERIAL ...........................................................................................................................................6
4.4 SITE ACCESS .........................................................................................................................................6
4.5 TEMPORARY SERVICES .......................................................................................................................6

5.0 INSPECTION & TESTING ............................................................................................................... 7

6.0 REPORT AND RECORDS ................................................................................................................ 7
7.0 ATTACHMENT.................................................................................................................................. 7

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Nayara Energy Limited CEP - Hydro Testing , Doping & Installation of Tank & Pipeline
Marketing Department EOL-Engg-M-001_R1
Retail Division
Rev. 1 – 9th June, 2020

1.0 PURPOSE & SCOPE

The purpose of this Construction Execution Procedure (CEP) is to logically describe the activities involved
installation operations of underground storage tanks for MS & HSD being carried out at EOL Retail Outlet.

The overall objective of this document is to address the following:

a) Provide the level of construction complying with project specifications and quality requirements.
b) To conduct all the activities associated with the work in a safe and logical manner.
c) Identify potential safety issues to be considered and addressed.
d) Minimize impact on the environment.
e) Identify individual roles and responsibilities.
f) Identify plant and equipment necessary for the job.

1.1 IMPORTANCE OF ANTI-CORROSIVE BITUMINOUS PAINT APPLICATION

A portion in tank without paint is like cancerous part of the human body. It will spread exponentially when
it will be earthen without doing Doping. Rusting and hence damage in larger part of tank will take place the tank
within 2-3 years and will make way to leakage.

1.2 REFERENCES
1.2.1 GENERAL REQUIREMENT
All the service work will comply with project manual for construction of a retail outlet.
1.2.2 STANDARD REQUIREMENT
Tank fabrication shall conform IS 10987.1992: Practice for Design, Fabrication, Testing & Installation of
under-ground / above-ground horizontal Cylindrical Steel Storage Tanks for Petroleum Products.
1.2.3 PROJECT REFERENCE DRAWINGS
Reference Project Doc Number Description Rev
EOL-M/STD/M/CCOE/002 MS Tank Design (15 KL Capacity) 0
EOL-M/STD/M/CCOE/003 MS Tank Design (20 KL Capacity) 0
EOL-M/STD/M/CCOE/007 MS Tank Design (25 KL Capacity) 1
EOL-M/STD/M/CCOE/004 MS Tank Design (30 KL Capacity) 0
EOL-M/STD/M/CCOE/005 MS Tank Design (40 KL Capacity) 0

2.0 CONSTRUCTION METHODOLOGY

Divisional Engineer will take measures to plan, execute, monitor and control the safe installation of MS Tank. Time
spent studying and comprehending the project design and quality standards gives the installation team an
understanding of the project scope and design intent.

With this knowledge, the following work method will be the basic steps taken to complete installation of MS Tank
with interconnecting infrastructure post hydro testing and water proofing process.

2.1 HYDRO TESTING OF UNDERGROUND FUEL STORAGE TANK

Ensure following points during Hydro Testing process;

1. MS Tank unloaded, kept on levelled ground and proper supports from both sides are provided.
2. Tank dimensions, Fittings and Accessories received from MS Tank Vendor; are as per drawing.
At the time of tank dispatch clearance following documents are reviewed and sent for reference to
DE/ZE
a) Complete TPI report.
b) Hydro test report and photograph with witness. Tank Primer – Shali Prime PW CT.
c) Packing list of fittings.
d) Loaded truck with tank and dispatch details such as LR copy with truck number.
3. Any deviations found, has to be corrected by tank manufacturer prior to commencing hydro testing process.
4. Vendor supplied gasket has to be used only during hydro testing process.

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Nayara Energy Limited CEP - Hydro Testing , Doping & Installation of Tank & Pipeline
Marketing Department EOL-Engg-M-001_R1
Retail Division
Rev. 1 – 9th June, 2020

5. Hydro test to be carried out preferably in the early morning or afternoon hours. Constant pressure of 0.5
kg/cm2 has to be kept and observed for one hour.
6. Pressure gauges used for testing must have valid calibration certificate with traceability. PG should be of the
range 0-1 Kg/cm2 with least count of 0.1 kg/cm2. Once desired pressure attained then please mark the position
of the pointer with marker pen on the glass of the PG.
7. If any pressure drop found during this process, leakage points has to identified and rectified as per procedure
with the help of tank vendor immediately. For leakages observed through weld joints, tank has to be returned
back to vendor with REJECTED stamp.
8. Hydro testing process has to be repeated again after attending the leakages through flange/threaded joints.
9. If there is no any pressure drops during an observation period of one hour, release the water pressure
and empty the tank.
10. MS Tank has to be cleaned thoroughly with the help of dry cloth from inside after hydro testing process.

2.2 HYDRO TESTING AND CLEANING OF PRODUCT PIPELINE

Ensure following points during Hydro Testing process;

1. Mild Steel Pipes confirms to IS:1239, Class ‘C’ should be laid of 50 mm NB for both suction and vent and 80mm
NB for fill pipe which is used for Product unloading at Retail Outlet.
2. All fittings such as Tees, Elbows, reducers, couplings and unions etc. except valves should be of Carbon Steel,
Black screwed ends.
3. Gasket should be made of CAF with thickness 3mm.
4. Suction pipe should be laid with 1 cm per meter slope towards tanks.
5. Vent and Fill line should have 2 cm per meter towards tanks.
6. Angle Check Valve of Leader or GG make as per IS 778 should be provided on the top of the tank manhole, one
each for each suction pipeline.
7. Swing joints / universal joints should be provided just below the dispensing units.
8. Pipe lines should be laid at min 300 below finished drive level and the same is to be taken through half cut
inverted Hume pipe of 150mm with one or two pipe lines and 200mm to 300mm Hume pipe for 3-4 and more
pipe lines. Bottom of the half inverted Hume pipe would be with 80mm PCC and 50mm sand above PCC.
9. Hydraulics test pressure of 1.5 kg/cm2 to be kept up to one hour with the help of hydraulic pump in case of
suction type dispenser. In case of pressure type dispenser, hydraulic test pressure should be 1.5 times,
Submersible turbine pump design discharge pressure.
10. After hydro test, flush the pipeline with same water by applying air pressure from the tank end and releasing
the water from DU connection so that all unwanted material, if any in the pipeline will get flushed out. All field
fabricated piping shall also be cleaned at the completion of the fabrication. All burrs shall be removed by any
suitable means (Mechanical tools, wire brush, etc.).
Suction/Pressure, Fill Pipeline can be further cleaned and oiled internally with the help of cotton bulb
of size bigger than pipe diameter tied to the TMT bar/bamboo, dipped in diesel/oil must be pushed inside the
pipe to clean and oil the internals of the pipe. This process is to be repeated till the internal is completely free
of foreign particle. After completion the open ends of the pipes can be covered with polythene bags till the
final connection/fitment.
It is the responsibility of contractor to ensure and FE/DE to witness that there is no foreign material left in
the pipe e.g. stone particle, weld particles, mud etc.
The contractor shall employ adequate skilled fitters and helpers to complete all work according to schedule.
Skilled workers shall possess the minimum qualifications and experience required to complete the job.

2.3 WATER PROOFING PROCESS

2.3.1 Surface Preparation: - The surface should be thoroughly cleaned to remove loose dust, foreign particles, rust,
laitance, oil and other contaminants.

2.3.2 Application: - Apply primer (min. thickness of 60 micron) using Brush or Spray Gun in two coats. Never apply
primer on Wet Surface or when it is raining. Allow the primer to dry completely and then proceed for application
of anti-corrosive bituminous paint.
Each container should be agitated for at least 3 minutes with a mechanical mixer in order to produce a
homogenous solution before application of anti-corrosive bituminous paint. Anti -corrosive bituminous paint is
cold, applied by using steel plate in two - three layers with thickness in each layer between 1-1.5mm max., to
achieve 3 mm thickness. Each new layer is applied in a criss-cross pattern with respect to the previous one, when
the latter is dry, in order to avoid solvent vapour inclusion between the layers. For the same reason one thick layer
should be avoided.
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Nayara Energy Limited CEP - Hydro Testing , Doping & Installation of Tank & Pipeline
Marketing Department EOL-Engg-M-001_R1
Retail Division
Rev. 1 – 9th June, 2020

Coating needs to be started from the base of the Tank so after emptying the tank, it can be rolled such that
manhole touches the ground. Put gunny bags as wedges for support to tank.
Please apply first Coat of Shalimar Tar Plastic Paint to 1/3rd of the Tank bottom area and allow it to dry for
sufficient time. Once the Paint is dried then apply second coat of the Paint and allow it to dry.
Application of the Paint to be done uniformly using Steel Plate from top to bottom so that the thickness of 3
mm Paint is available on the entire Tank body. Once the bottom coating is done please ensure gunny bag cushion
is provided while rolling back for other side coating and then back to straight upright position to avoid damage to
the coating. Take photographs of this painted area from all sides.
Once the Painting is done please check the thickness of the Paint by either removing 50mmx50mm area or
measuring the same with tape or with Elcometer without removing any Painted part. If the thickness is found
sufficient then Paint the area from where the sample was extracted. . If found sufficient, allow the Paint to dry.
Please ensure that the Tank pit area is cleaned and ladder is available for the skilled Manpower to go inside
the Pit. In case the Earth Pit wall needs to be made, please ensure it is of max. 1.2 mtr height only. Tank should be
lifted with Crane having Proper sling and hook and to be kept inside the Tank Pit. Use gunny bags to avoid scratches
to painted portion while tank is being lifted from current position with crane. Tank should be properly levelled,
aligned with the help of water level so that the Tank is straight and upright inside the Pit and Manhole cover is in
the Centre of the Tank.
Tank should be anchored properly from both the sides. Now fill the sand in alternate layers (of height not
more than 300mm) along the length of the tank. Sand back filling can be done upto the height of the earlier painted
bottom portion, leaving 50mm painted portion. Now paint the other balance and top portion of the tank as
explained above.
In case of rainy season please fill the Tank with water once it is placed properly inside the Pit so that the Tank
should not float if the Painting work is taking long time during the rains. Painting of the balance area of the Tank to
be done as per the process followed earlier. Once all the Painting work is completed please check the thickness of
the Paint again. If found sufficient, allow the Paint to dry. The ideal setting time for drying 3mm thick tar plastic is
72 hours (minimum).
Once the Painting is completely done as per process and verified that required thickness is available the start
filling the sand next to the Tanks in alternate layers to avoid differential Pressure on the wall from both the sides
simultaneously till the top of the Tank.

Take photographs of the painted portion of the tank inside the pit from all sides of the tank. Also take the count
and photographs of the emptied cans/drums of primer and paint to ensure the consumption of entire estimated
quantity of STP as per trailing table.

2.3.3 Recommended Material Make and minimum required quantity:-

Sr Material Recommended Make Paint

No Thickness
1 Primer Tiki Primer, Shalimar Zink Oxide 60 micron
2 Anti-corrosive bituminous paint Tiki tar plastic, Shalimar tar Plastic (STP) 3.00 mm

Requirement of STP
Sr. Tank Surface
No. Tank Capacity Approximate Qty of paint required (Kg) Area (Sq.M.)
1. 15 KL 130 41.01
2. 20 KL 160 50.57
3. 25 KL 180 56.97
4. 30 KL 195 63.34
5. 40 KL 235 72.39
Add 1-2 boxes in above quantity for suction, fill and vent pipeline coating.

2.4 TANK INSTALLATION

1. Ensure brick wall thickness 600 mm wherever future plan of adjacent tank installation, to avoid existing wall
collapse after excavation in future (Existing Tank May Tilt)
2. Ensure the burry depth is minimum 900 mm, but calculate this depth based on the pipe length, slope, fittings,
and manhole height and observe whichever is more.
3. Ensure that the front and back ends of MS Tank are at the same level and the central dip hatch is vertically up
100%, after lowering the tank.
4. After straightening the tank, the tank should be fastened/ tightened with turn buckle.
5. Remaining portion doping to be done by Tiki tar plastic or Shalimastic Anti Corrosive doping in the pit.
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Nayara Energy Limited CEP - Hydro Testing , Doping & Installation of Tank & Pipeline
Marketing Department EOL-Engg-M-001_R1
Retail Division
Rev. 1 – 9th June, 2020

6. Again tank inside should be cleaned with the help of dry clothes.
7. Use the new gaskets (CAF) for manhole and all flanges. Old gaskets will be wasted, once in contact with water.
CAF gasket should be fire fly or Champion make or approved brand.
8. The tank pit shall be back filled from inside and outside simultaneously to avoid differential pressure on the
wall.

2.5 PERMITS

Prepare work permit to carry out lifting work and confined space working as and when required. These permits
will be reviewed as conditions change and work type progresses from initial construction to cleaning, painting,
testing and commissioning.

3.0 ACTIVITY SCHEDULE / MILESTONES

Millstones are as per follows,

1. Receipt of Fabricated MS Tank at Retail Outlet.
2. Availability of duly signed hydro testing report by Vendor at his own fabrication yard.
3. Installation of walkways around the tank for access.
4. Hydro testing of MS Tank.
5. Water proofing process as mentioned in methodology;
a) Stage-1:- Bottom surface after tilting MS Tank upside down.
b) Stage-2 :- Top surface after lowering down the tank in pit with the help of crane, chain pulley
arrangement or any such mechanism
6. Installation of MS Tanks.

4.0 CONSTRUCTION RESOURCES

4.1 PERSONNEL

DIVISIONAL ENGINEER
1. Shall be responsible for supervising in coordination with Tank Vendor to ensure that all project design
specifications and standards are met.
2. Shall inspect all incoming materials for installation at site to ensure that all materials are in good condition.
3. Shall be responsible for arranging required materials for installation of MS Tanks.
4. Shall be responsible for monitoring all safety aspect during execution.
5. Shall be responsible for organizing necessary inspection and prepare documentation.

4.2 PLANT & EQUIPMENT

1. Crane 15 Ton capacity
2. Portable diesel generator- 5Kva or more
3. Hydro testing set up i.e. pump, dial gauge, hose pipes etc.
4. All basic tools like spanners, hammer, measuring tape, spray paint equipment etc.

4.3 MATERIAL
1. Primer
2. Bituminous anti corrosive paint

4.4 SITE ACCESS

1. Ensure hardstand & proper access for crane movement in the work area.
2. Work area will be barricaded and safety signs will be provided.
Example - "Authorized Person Entry Only" and Safety PPE instructions.

4.5 TEMPORARY SERVICES

1. Power supply from portable DG.
2. A supply of potable water for hydro testing and the eventual disposal of this water.

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Nayara Energy Limited CEP - Hydro Testing , Doping & Installation of Tank & Pipeline
Marketing Department EOL-Engg-M-001_R1
Retail Division
Rev. 1 – 9th June, 2020

5.0 INSPECTION & TESTING

1. Test all components for leaks and functional operation in the fuel systems and rectify before the system is
handed over for the water proofing process. This will certify that the system has been properly constructed
and will perform to the specifications outlined in the design data.
2. Hydro testing, water proofing and installation work to be carried out strictly under the supervision of
technical personnel.

6.0 REPORT AND RECORDS

The results of each test shall be recorded on following completion check sheets approved by company vide
document number EOL-RM-RO-CHECKLIST-TANK-001_0

7.0 ATTACHMENT
 Appendix A : Construction Manual
 Appendix B : Drawing & BOM – MS Tank (15 KL Capacity)
 Appendix C : Drawing & BOM – MS Tank (20 KL Capacity)
 Appendix D : Drawing & BOM – MS Tank (25 KL Capacity)
 Appendix E : Drawing & BOM – MS Tank (30 KL Capacity)
 Appendix F : Drawing & BOM – MS Tank (40 KL Capacity)
 Appendix G : Hydro Testing Report format to be filled at Retail Outlet.

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 Annexure G

Nayara Energy Limited

ON SITE TANK INSPECTION REPORT
Name of the Fabricator

Date of Inspection

Name of the Franchise outlet for which tank is

fabricated
Registration No. (franchisee) Zone / Division

Advice letter No. and Date

Tankage as per Advice letter

LR No.

PART - I GENERAL INSPECTION

Materials Requirements as per Specification Documents Required Remark

Visual Check Rust free , cleaned surface Predispatch Inspection report

Complete TPI Report TPI Report

Factory Hydro test report and photograph with TPI Report with photographs
witness
Packing list of fittings Packing List

PART II - MATERIAL CHECK LIST AND TANK HYDRO TEST

Dimensional & Quantity Accuracy Requirements ss per Drawing As per actual

Outside Diameter (OD), Outside length (OL)

Circumference of tanks ( at three points along

lenght of tank)
Position of long seam weld All long seam weld in upper half of tank and
staggered at 90 Deg.
Stiffners 3 Nos- angles 100 x 100 x 10 mm thick

Additional Fit-ments with accessories

Manhole Diameter

Thickness

Neck Length

Fill pipe (80 NB) 1 No - 100 mm above the bottom of tank.

Suction Pipes (50 NB) 4 no's - 100 mm above the bottom of tank.

Dip pipe & dip pipe nozzle (50 NB) 1 No- with perforatations

Vent opening (40 NB) 1 No

Gaskets 3 mm thick CAF

Level gauge Opening nozzle Blind flange- A-105 Material
Flange- A-105 Material
Nuts and Bolts 24 Nos set

C' Bracket for Holding down bolts 8 Nos- 4 on either side

Anchor bolts with turn buckling 8 Nos

Diameter & length

Turn Buckle Length

Earthing Boss 2 Nos on either side

Lifting lugs 2 Nos on either side

Anti corrossive paint Red oxide Zinc chromate pimer- 30 Microns

DFT
Al. Dip caps with Chain and locking arrangment 1 No

Al. Fill caps with Chain and locking arrangment 1 No

Al. Dip rod of 12 mm x 12 mm 1 No

Length- Tank Dia + 1.5 Mts (with

graduation at 2mm)
Hydraulic test
Hydro test upto 0.5Kg/Cm2 for 1 hour.
Weld joints shall be Inspected visually & Tank 1 Tank 2 Tank 3
also hammered if required with a wooden
hammer.
Hydraulic Test carried out on

Test Start time

Test End time

Pressure Gauge:No. of Gauges, Measuring

Range, Least Count, Calibration due date,
Calibration Report No.
Photograph of pressure testing taken Yes / No Yes / No Yes / No
Hydro test passed Yes / No Yes / No Yes / No
Tanks accepted Yes / No Yes / No Yes / No

Remark:

Name & Signature: Name & Signatrue:

(Fabrication Contractor Representative) (Divisional Engineer)
 Rajesh. B. Sumbaly
ccC
PESO Competent Person
P3(9)-241/CPP302856
M.S. TANK DESIGN
(30 KL CAPACITY)
M.S. TANK DESIGN
(40 KL CAPACITY)