Method Statement for removal & Installation

of
Crude Transfer Pump
at
ISPRL Padur

KGSGLOBAL E&C SOLUTIONS PVT. LTD.

Corporate Office:

1037, 10th Floor, Tower-B, Plot No-A-40, The-I-Thum, Sector-62, Noida-201 301

CIN: U74999UP2018PTC103656
Email: contact@kgsglobal.in, rakeshpathak@kgsglobal.in, rajanvaish@kgsglobal.in
Contact: +91 120 412 4879

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

1. Procedure for removal of submersible pump-Crude oil transfer pump:

1.1 We are using one crane of 180 MT, a transportation cradle / transportation box and the
required installation tools (mounting flange, horse shoe etc.).

1.2 Disconnect the power and signal cables in the junction boxes and pull them to the
installation area beside the casing pipe, where the pump-motor-unit should be removed.

1.3 Remove both cable glands including the flanges for cables glands from the top side of
the cover plate (untighten the glands, remove the screws of the flanges and push them over
the cables to the ends of the cables).

1.4 Drain the oil cooling unit / header tank. Remove the cooling pipes / oil tube to the cooling
unit / header tank.

1.5 Remove the discharge pipes above ground and the elbow, which are connected to the
well head.

1.6 Mount the mounting flange to the top flange of the well head

1.7 Hoist the power cable by crane (Refer Fig. 1: Typical installation arrangement).

1.8 Remove the bolts of the cover plate and casing flange.

1.9 Hook the crane by sling or chain and shackle to the mounting flange. Fit a second sling
to the hook and install a chain block to the sling, for later use (Refer Fig. 3: Preparation of
wellhead)

1.10 Hoist the well head assembly including riser pipes and pump-motor-unit (approx. 1 to
1.5 m).

1.11 Pull out the whole signal cable from the bottom side of the cover plate. Lead and push
the signal cable simultaneously from the top side of the cover plate so that the alignment to
the hole in the cover plate is as best as it can be.

1.12 Lay the signal cable on ground.

1.13 Disassemble the flanges of the cooling pipes / oil tube connection from the bottom side
of the cover plate

1.14 Hoist the well head assembly including riser pipes and pump-motor-unit. Remove the
fixation of the cables from the upper cable clamp. Disassemble the upper cable clamp

1.15 Hoist the well head assembly including riser pipes and pump-motor-unit till the first
cooling pipe / oil tube connection is on the same level as the flange of casing.

1.16 Remove the upper cooling pipes / oil tube.

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

1.17 Hoist the well head assembly including riser pipes and pump-motor-unit to the next
cooling pipe / oil tube connection. Disassemble the cooling pipe / oil tube.

1.18 Hoist the well head assembly including riser pipes and pump-motor-unit to the next
centralizer. Disassemble the centralizer.

1.19 Hoist the well head assembly including riser pipes and pump-motor-unit to the next
cable
or oil tube clamp. Disassemble the clip of the cable / oil tube and disassemble the clamp
from the riser pipe.

1.20 Hoist the well head assembly including riser pipes and pump-motor-unit till the first
flange
connection of the riser pipes is about 0.5 m above the flange of the casing pipe.

1.21 Put the horse shoe on the flange of the casing pipe. Move it in such a way, that the axle
journals of the horse shoe are on both sides of the riser pipe. After correct alignment, mark
this position of the horse shoe to the casing flange and lower down the wellhead assembly
including riser pipes and pump-motor-unit so that the lower flange of the riser pipe flange
connection bears on the horse shoe.

1.22 Disassemble the bolts from the flanges and the clamps of the riser pipe connection.

1.23 Hoist the well head assembly. Install a temporarily lifting point to the bottom flange of
the well head. Install the chain from chain block (refer to step 1.9) to the lifting point.

1.24 Rotate the well head assembly into horizontal position by using the chain block (Refer
Fig. 5: Erection of well head).

1.25 Push and pull the power cable horizontal out of the hole (Refer Fig. 4: Feeding the
power supply cable through the wellhead cover plate). Coil the power cable to the power
cable drum located on top of the frame work for power cable drum.

1.26 Lower down the well head assembly and deposit it beside the casing.

1.27 Remove the mounting flange from the well head assembly and mount it to the top
flange of riser pipe, which is fixed in the casing.

1.28 Hoist the riser pipe with pump-motor-unit up to the next cable clamp. Disassemble the
cable clips and remove the cable clamp from the riser pipe.

1.29 Hoist the riser pipe with pump-motor-unit up to the next cooling pipe connection.
Remove both upper cooling pipes.

1.30 Hoist the riser pipe with pump-motor-unit up to the next centralizer. Disassemble the
centralizer and remove it from the riser pipe.

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

1.31 Hoist the riser pipe with pump-motor-unit up to the next cable clamp. Disassemble the
cable clips and remove the cable clamp from the riser pipe. Repeat this step one more time.

1.32 Hoist the riser pipe with pump-motor-unit up to the next cooling pipe connection.
Remove both upper cooling pipes.

1.33 Hoist the riser pipe with pump-motor-unit up to the next centralizer. Disassemble the
centralizer and remove it from the riser pipe.

1.34 Hoist the riser pipe with pump-motor-unit up to the next cable clamp. Disassemble the
cable clips and remove the cable clamp from the riser pipe.

1.35 Hoist the riser pipes and pump-motor-unit till the next flange connection of the riser
pipes
is about 0.5 m above the flange of the casing pipe.

1.36 Put the horse shoe on the flange of the casing pipe according to the marked position at
the casing flange done in step 29. Lower down the riser pipes and pump-motor-unit so that
the lower flange of the riser pipe flange connection bears on the horse shoe.

1.37 Disassemble the bolts from the flanges and the clamps of the riser pipe connection.

1.38 Hoist the upper riser pipe and deposit it beside the casing.

1.39 Remove the mounting flange from the laid down riser pipe and mount it to the top
flange of riser pipe, which is fixed in the casing.

1.40 Repeat step 1.27 to 1.39 for removal of the riser pipes.

1.41 Install the mounting flange to the top flange of the adapter 18”, which is fixed in the
casing.

1.42 Hoist the pump-motor-unit up including adapter 18” to the next cooling pipe connection.
Remove both upper cooling pipes from the pump-motor-unit. Fit the stored transportation
caps (Refer step 2.42 of installation procedure) to the cooling pipes of the pump-motor unit.

1.43 Hoist the pump-motor-unit including the adapter 18” up to the plug of the power cable
and signal cable connection. Disassemble the plug and the signal cable connection.

1.44 Lay the power cable and the signal cable on the ground.

1.45 Hoist the pump-motor-unit including adapter 18” out of the casing. Install a sling (choke
hitch) around the motor (position of the sling see step 7 of installation procedure) and hook
the sling to the hydra.

1.46 Rotate the pump-motor-unit including adapter 18” in vertical position by hoisting the
hydra which is fixed at the sling around the motor. Lower simultaneously the crane fixed at
the mounting flange.

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

1.47 Deposit the pump-motor-unit on the transportation cradle / transportation box.

2. Installation Procedure of submersible pump- Crude oil transfer pump:

2.1 Align the transportation box / cradle with the pump-motor-units to the casing where the
unit shall be installed. (Length of crude oil transfer pump: 6.272 m). Alignment means, that
the position of the transportation box / cradle is beside the caisson with enough space for
mounting the required parts according to step 2.2 to 2.5 and adequate space for crane and
hydra to solve the task according to this procedure (Refer Fig. 1: typical installation
arrangement). Use chain pulley block of 3 tons capacity without trolley, adequately
supported at the crane hook. Keep the mounting flanges and the other installation tools
beside the casing pipe, in which the pump-motor-unit should be installed. Temporary
anchoring of the tools shall be done if needed. This means, the tools should be temporary
secured by rope or chain to avoid falling down into the casing pipe during installation.

2.2 Put the horse shoe on the top flange of the casing pipe and align it to the center line of
the casing pipe by measuring the distance from each side of the horse shoe to the flange of
the casing. After this alignment, mark this centered position to the top flange of the casing
pipe and to the horse shoe.

2.3 Mark the riser pipes with numbers of the correct sequence of installation. First riser pipe
length is 2 m (duplex stainless steel), second riser pipe (duplex stainless steel), length is
12.320 m. Six riser pipes (carbon steel) with a length of 12.320 m, last riser pipe (carbon
steel) is 2.278 m long. Mark the position of the cable clamps and centralizer to the riser
pipes made of carbon steel. Per pipe length of 12.320 m, there are needed 4 cable clamps
and 2 centralizers. Per pipe length of 2 m, there is needed one cable clamp. Per pipe length
of 2.278 m, there is needed one cable clamp and one centralizer.

2.4 Adapter 18” is factory fitted to the top case of the pump-motor-unit.

2.5 Install the mounting flange to the top flange of the first riser pipe / adapter 18”.

2.6 Disassemble the transportation locks (belts) of the pump-motor-unit.

2.7 Lift the pump-motor-unit including the adapter 18” horizontal out of the transportation
cradle by using crane and hydra. Crane is hooked by sling or chain and shackle to the
mounting flange, hydra is hooked by sling (choke hitch) to the motor. The distance between
both lifting points is approximately 4.900 m (sling around the motor is located 1.700 m
±0.050 m from the bottom of the motor). See Fig. 2: lifting of pump motor- unit.

2.8 Rotate pump-motor-unit including adapter 18” / first riser pipe in vertical position by
hoisting the crane which is fixed at the mounting flange. Lower simultaneously the hydra,
which is fixed at the other lifting point of the pump-motor-unit.

2.9 When the pump-motor-unit is rotated in vertical position, disassemble the sling around
the

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

motor / cooling shroud from the hydra and remove the hydra.

2.10 Align pump-motor-unit including the adapter 18” / first riser pipe with the center line of
casing pipe by adjusting with the crane. Marking was done on horse shoe and flange of
casing pipe. Precautions shall be taken for alignment of bottom centralizer with casing pipe.

2.11 Lower the pump-motor-unit in casing pipe until the top case of the motor is on the same
level with the flange of the casing pipe.

2.12 Disassemble the shipping caps of the power cable plug and signal cable connection at
the top case of the motor.

2.13 Install the cable plug for power cable and mount the signal cable connection. After
draining back the oil into the motor, disassemble the oil expansion bag from one of the
transportation caps of the piping for the cooling fluid. Then remove the transportation caps
from the inlet- and outlet pipe of the pump-motor-unit. Fit the 2 transportation caps to the
upper ends of the two cooling pipes which should be installed in next step.

2.14 Install the first cooling pipes with caps at the cooling inlet and cooling outlet of the
pump-motor-unit.

2.15 Lower down the pump-motor-unit in casing pipe until the adapter 18” is on the same
level with the flange of the casing pipe.

2.16 Put the horse shoe on the flange of the casing pipe. Move it in such a way, that the axle
journals of the horse shoe are on each side of the adapter 18”. If necessary, position the
pump-motor-unit by crane so that the horse shoe can be aligned to the marked position
which had been done in step 2.2. After correct alignment, lower down the pump-motor-unit
so that the upper flange of the adapter 18” bears on the horse shoe.

2.17 Disassemble the mounting flange from the adapter 18” and mount it to the first riser
pipe (length of 2 m, according to the marked number of the correct installation sequence
(see step 2.3)). Hoist the first riser pipe in vertical position and align it to the center line of the
adapter 18” by adjusting the crane. Lower down the first riser pipe to the flange of the
adapter 18”. Put the gasket between the flanges and install two clamps for cooling pipes.
Bolt the flanges and the clamps, fix the cooling pipes to the clamps.

2.18 Hoist the pump-motor-unit with the first riser pipe. Remove the horse shoe from the top
flange of the casing. Fit and tighten the remaining bolts, which weren’t accessible because of
the horse shoe.

2.19 Lower down the pump-motor-unit with first riser pipe to the marked position of the cable
clamp, which had been done in step 2.3. Install the cable clamp and fix the cables

2.20 Lower down the pump-motor-unit with first riser pipe in the casing pipe until the
mounting
flange is about 0.5 m above the flange of the casing pipe.

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

2.21 Put the horse shoe on the flange of the casing pipe. Move it in such a way, that the axle
journals of the horse shoe are on both sides of the riser pipe. If necessary, position the
pump-motor-unit by crane so that the horse shoe can be aligned to the marked position
which had been done in step 2.2. After correct alignment, lower down the pump-motor-unit
with riser pipe so that the upper flange of the riser pipe bears on the horse shoe.

2.22 Disassemble the mounting flange from the riser pipe.

2.23 Install the mounting flange to the next riser pipe (according to the marked number of the
correct installation sequence (see step 2.5)).

2.24 Hoist the next riser pipe in vertical position and align it to the center line of the riser
pipe,
which is fixed in the casing by adjusting with the crane.

2.25 Lower down the riser pipe to the flange of the fixed pipe in the casing. Put the gasket
between both flanges and install two clamps for cooling pipes. Bolt the flanges and the
clamps, fix the cooling pipes to the clamps

2.26 Hoist the pump-motor-unit with the riser pipe (approximately 0.3 m). Remove the horse
shoe from the top flange of the casing. Fit and tighten the remaining bolts, which weren’t
accessible because of the horse shoe.

2.27 Lower down the pump-motor-unit with riser pipe till the first marked position of cable
clamp (see step 2.3). Install the first cable clamp to the riser pipe. Fix the cables to the
clamp.

2.28 Remove both transportation caps from the cooling pipes of the pump-motor-unit. Fit the
2 transportation caps to the upper ends of the two cooling pipes which should be installed in
next step. Install the next cooling pipes with caps to the cooling inlet and cooling outlet.

2.29 Lower down the pump-motor-unit with riser pipe till the next marked position (first
position of centralizer) (see step 2.3). Install the first centralizer to the riser pipe.

2.30 Lower down the pump-motor-unit with riser pipe till the next marked position (second
position of cable clamp) (see step 2.3). Install the second cable clamp to the riser pipe and
fix the cables to the clamp. Lower down the pump-motor-unit with riser pipe till the ends of
cooling pipes are on the same level with the flange of the casing pipe. Remove both
transportation caps from the cooling pipes of the pump-motor-unit. Fit the 2 transportation
caps to the upper ends of the two cooling pipes which should be installed in next step. Install
the next cooling pipes with caps to the cooling inlet and cooling outlet.

2.31 Lower down the pump-motor-unit with riser pipe till the next marked position (third
position of cable clamp) (see step 2.3). Install the third cable clamp and fix the cables to the
clamp.

2.32 Lower down the pump-motor-unit with riser pipe till the next marked position (second
position of centralizer) (see step 2.3). Install the second centralizer to the riser pipe.

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

2.33 Lower down the pump-motor-unit with riser pipe till the next marked position (fourth
position of cable clamp) (see step 2.3). Install the fourth cable clamp and fix the cables to the
clamp.

2.34 Repeat step 2.20 to 2.33 for each riser pipe. When the last riser pipe is installed, lower
down the crane till the whole assembly rests on the horse shoe, which is placed on the top
flange of the casing pipe. Remove the mounting flange.

2.35 Put the cables U-shaped on the ground so that the end of the cables is beside the
casing.

2.36 Install the mounting flange to the well head assembly (cover plate including pipes,
flanges, ribs and top flange for elbow). Fix the gasket for the casing pipe temporarily to the
bottom side of the cover plate. Install a second lifting point to the lower flange of well head
assembly. Use chain pulley block of 3 tons capacity without trolley, adequately supported at
the crane hook. (referFig. 3: Preparation of well head)

2.37 Lift the well head assembly in horizontal position next to the casing pipe. Insert the end
of the power cable from bottom side of the cover plate into the hole in the cover plate. Push
and pull the power cable horizontal through the hole (Refer Fig. 4: Feeding the power supply
cable through the wellhead cover plate). Bead the gaskets, flange for cable gland and the
cable gland itself to the power cable and push them along the cable to the top side of the
cover plate.

2.38 Hoist the well head assembly in vertical position and align it to the center line of the
casing (Refer Fig. 5: Erection of well head into vertical position).

2.39 Lower down the well head assembly to the flange of riser pipe which is fixed in the
horse shoe.

2.40 Put the gasket between both flanges and install two clamps for cooling pipes. Bolt the
flanges and the clamps.

2.41 Hoist the well head assembly including riser pipes and pump-motor-unit (approximately
0.3 m). Remove the horse shoe from the top flange of the casing. Fit and tighten the
remaining bolts, which weren’t accessible because of the horse shoe.

2.42 Hoist the well head assembly including riser pipes and pump-motor-unit (approximately
1 m) until the upper ends of the cooling pipes are on the same level as the casing flange.
Remove the transportation caps from the cooling pipes and store them. Mount both upper
compensating elements to the cooling pipes.

2.43 Lower down the well head assembly including riser pipes and pump-motor-unit till the
flange connection of the riser pipes is on the same level as the flange of casing. Fix the
cooling pipes to the clamps located at the upper flange of riser pipe.

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

2.44 Lower down the well head assembly including riser pipes and pump-motor-unit till the
cover plate as about 0.5 m above the flange of casing. Install the upper flanges of the
compensation elements of the cooling pipes including the gaskets to the bottom side of the
cover plate.

2.45 Insert the end of signal cable from bottom side of the cover plate into the hole in the
cover plate. Pull out the signal cable from the top side of the cover plate. Lead and push the
signal cable simultaneously from the bottom side of the cover plate so that the alignment to
the hole in the cover plate is as best as it can be.

2.46 Hoist the well head assembly including riser pipes and pump-motor-unit till the middle
of the upper riser pipe of the well head assembly is on the same level as the casing flange.
Install the cable clamp to the upper riser pipe of the well head assembly and fix the cables to
the clamps. Install the centralizer to the upper riser pipe of the well head assembly.

2.47 Hoist the well head assembly including riser pipes and pump-motor-unit till the flange
connection of both riser pipes of the well head assembly is on the same level as the casing
flange. Install both clamps for cooling pipes to the upper flange and fix the pipes to the
clamps.

2.48 Hoist the well head assembly including riser pipes and pump-motor-unit till the middle
of the lower riser pipe of the well head assembly is on the same level as the casing flange.
Install the cable clamp to the lower riser pipe of the well head assembly and fix the cables to
the clamps.

2.49 Remove the temporarily fixture of the gasket from the cover plate and put it to the
flange of the casing pipe. Lower down the well head assembly including riser pipes and
pump-motor-unit to the flange of the casing pipe. Bolt flange of cover plate to casing flange.

2.50 Bead the gaskets, flange for cable gland and the cable gland itself to the signal cable
and push them along the cable to the top side of the cover plate.

2.51 Bolt the flanges for cable glands of the signal- and power cable to the cover plate.
Mount the cable glands to the flanges for cable glands and tighten them.

2.52 Connect the flanges of the cooling pipes on the top side of the cover plate to the
cooling unit.

2.53 Connect the power and signal cables to the junction boxes.

2.54 Install the elbow and the discharge pipes above ground.

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

Fig. 1: Typical installation arrangement

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

Fig. 2: Lifting of pump-motor-unit

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

Fig. 3: Preparation of wellhead

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

Fig. 4: Feeding the power supply cable through the wellhead cover plate

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

Fig. 5: Erection of well head into vertical position

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 Method Statement for removal & Installation of
Crude Transfer Pump at ISPRL Padur

Fig. 6: Removing of Power supply and signal cables

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