Ref No : MS/TANKFAB /001

Rev : 0

METHOD STATEMENT
For
HSD DIESEL TANK
At Volvo India Private Limited, Hosakote
Bangalore

Prepared Reviewed Approved

Name Name Name
Sign Sign Sign

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 TABLE OF CONTENTS
1) Scope
2) Purpose
3) Reference Standard
4) Responsibility
5) Method of Construction
a) Identification of Materials
b) Fabrication Work
i) Annular & Bottom Plate Fabrication
ii) Shell Plate Fabrication
iii) Roof Plate Fabrication
iv) Appurtenances
v) Stairway, Hand Railing
c) Erection Work
i) Sequences activities
ii) Activity at specific location
iii) Tank details
6) Design and Technical Specification
7) Plant /Equipment /Tools / Tackles
8) Man Power
9) Quality Assurance & Quality Control
10) Safety
11) Records
12) Conclusion

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 1. Scope:

This procedure covers detailed activities for fabrication, erection and testing of the
Diesel storage tanks, and also equipment & manpower required for the same. All the
tasks / activities need to be carried out with at most care with good workmanship and
in accordance with the specifications to achieve satisfactory completion of the whole
activities.

2. Purpose:

The purpose of this document is to follow proper methodology to carry out the activities
in a proper sequence for fabrication, Erection and Testing of the Diesel storage tanks.

3. Reference Standard:

IS 803

4. Responsibilities

a. Project Head.

 Ensure all the requirements are met, to complete the project in timely manner.
 Coordinate with client/consultant with respect to accessible site clearance
 Over all supervision of operation and ensuring that and all necessary safety
measure are taken.

b. Project Engineer.

 To implement the method of statement.

 To make sure that required inspection and tests are carried out according to
project specification.
 Plan and supervise all the activities on time

c. Safety Engineer

 To propose the safety requirements at site as per authority requirements.

 To ensure that the safe working practice are implemented as per rules and
regulation.
 Ensure the approved method of statement as per as client

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 5. Method Of Construction:

a. Identification Of Materials

Each Piece of Plates, fittings or any other component of tankage system shall be clearly
identified by marking heat no. on the using hard punching. Each weld joint shall be
marked with joint Number with Welder Number.

b. Fabrication Work

All fabrication work involving material identification, marking, cutting, rolling and
welding shall be done in accordance with this job procedure with reference standard IS
803.. The workmanship shall be good in every respect meeting all safety, QC & NDT
requirements, with the coordination of Engineer and Manager-In-Charge. Lay all the
plates, Structural & pipes in such a way prior to fabrication to facilitate proper checking
of dimensions & heat no mark the components as per the drawings

i. Annular & Bottom Plate Fabrication:

 Mark the plates as per drawing

 Carry out the cutting operation after proper inspection.
 All the cutting operation shall be carried out by Gas Cutting.
 Grind the cut edges smooth to remove burrs and slag.
 Stack the plates at designated place in the fabrication yard in proper sequence.
 Backing – Strip shall be fitted and tacked with annular plate as per drawing
 After completion of the fabrication under side of annular and bottom plates shall
be cleaned and painted to the external with one coat of primer and two coats of
Enamel Paint.
 Check the Joint Position, Root gap for welding after welding Inspection by weld
visual 10% Radiography.

ii. Shell Plate Fabrication

 Lay all the plates in the open area such a way easy for marking and cutting.
 Mark the plates as per drawing and to the satisfaction of Engineer and Manager-
in-charge.
 The cutting operation includes bevelling shall be carried out by gas cutting
method on all the four sides.
 Grind the cut edges smooth to remove slag and burr.
 The edge prepared plates shall be shifted by hydra crane to the rolling area.

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 The plates shall be fed to rolling machine by means of hydra crane & proper
lifting tools and tackles.
 The plate shall be rolled as per drawing details and the radius shall be checked
using Template.
 Proper care shall be taken for the smooth curvature.
 The Template shall be checked and cleared by inspection authority.
 Final profile and dimensions check shall be carried out before sent for reaction

iii. Roof Plate Fabrication

 Mark the roof plate as per drawing

 All the cutting operation as per requirement shall be carried out after getting the
clearance from the in charge.
 All the cutting operation shall be carried out by gas cutting method on all the
four side.
 Grind the cut edges smooth to remove burrs &slag.
 Structural item of the roof shall be fabricated as per drawing.
 These roof plates shall be shifted to Painting Yard to carry out the painting.

iv. Appurtenances

 Mark the required items of the Appurtenances as per the drawing.

 All the cutting operation as per requirement shall be carried out after getting the
clearance from in charge.
 All the cutting operation shall be carried out by gas cutting method.
 Grind the cut edges smooth to remove burrs & slag.
 Flanges face to be covered with a suitable cover to protect from damage during
handling, fabrication and transportation.
 The entire shell nozzle, roof appurtenance, i.e. flanges, flanges to pipe joint and
other requirements etc. Shall be fabricated as per approved drawings.
 All the fabrication and welding activities shall be carried out after the stage wise
inspection wherever required.

v. Stairway, Hand Railing

 All the structural items shall be straightened before marking and cutting.
 Mark the components as per drawing.
 All the cutting operation, as per requirement shall be carried out after getting the
clearance from in charge.
 All the cutting operation shall be carried out by gas cutting method.
 Grind the cut edges smooth to remove burrs & slag.

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  Fabrication such as fitting, welding, drilling, etc. shall be carried out as per
drawing and after the clearance from in charge.
 After all the works completed, the leak test will be carried out .
 After completion of leak test the surface preparation and painting will be
carriedout.

c. Erection:

Shifting & Unloading of Tank in Sequences

i. Sequences activities:

 Prior to start material shifting work, specific area shall be inspected for access
and barricade the working zone, to carry out the task.
 Check for adequate tools, tackles and hardware’s at point of unloading.

ii. Activity at specific location:

 Safety Induction & information of Site rules & regulation should be provided prior
to enter work site.
 Tool Box talk should be conducted before starting Activity.
 PPE’S like FBSH with shock absorbing double lanyard, cotton hand gloves, Helmet,
Safety shoes and reflected Jacket will be provided to workers
 Prior to the installation height work permit and hot work permit will be received
from concern authorities.
 Informing to the client will be clearing the area where installation carried out. (In
case any other materials are stored nearby which are hindrance to the work
place).
 Required tools & tackles and materials will be mobilized at the work place.

iii. Tank details

 Tank Height is 5.7 Mtrs, Tank Diameter is 3.8 Mtrs and Tank Capacity is 60 Cu.M.
 Skilled and competent person to be deployed for erection.
 Confirm the availability of enough manpower required for the particular job.
 Hydra Crane will be used for erection purpose, before entering into the site we
will comply the Volvo Inspection checklist for the crane.
 Two cranes is used to erect the Tank.
 The crane that is used for lifting the Tank will be operated by trained operator.
 Set the level for bottom of the tank on pedestal.

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 Ensure unloading and placing the Tank at correct location nearby the working
areas, which are not hindrances for the area where labours are standing for and
Tank positioning and lifting.
 Shift the Tank to the working place by using Hydra crane.
 The lifting equipment will be shifted to the work place.
 Web sling used will be tested and in good condition without damage.
 The people who are doing work at height will be worn proper safety harness and
which is ensured by the Safety Officer.
 Prior to lifting the fabricated Tank, pre-inspection will be done for checking of
dimension and other parameters.
 Barricade the working area erection work signage will be placed.
 Lifting the Tank by using the Hydra crane and ensure the lifted Tank is not slipping
back down.
 Supervisor and safety officer will be present during erection.
 Rope used for holding Tank at position shall be tested.
 Lifted Tank will be positioned properly nearby the support.
 The installation area will be barricade by the caution tape and the safety officer
will monitor the same.
 After the erection area will be cleaned and permit will be closed.

6. Design and Technical Specification

 Tank Diameter – 3.8 Mtr

 Tank Height – 5.7 Mtr
 Tank Capacity – 60 Cu.M
 Bottom Plate – 4.1 Mtr Dia and 10mm Thick
 Shell Plate Thickness (up to 4.5 Mtr height) – 8mm Thick
 Shell Plate Thickness (4.5 to 5.7 Mtr height) – 6mm Thick
 Top Plate Thickness – 6mm Thick
 Hand Rail Size – 25 NB Pipe
 Ladder Size Vertical Pipe – 40 NB Pipe
 Ladder Size Horizontal Pipe – 25 NB Pipe
 Man Hole Size – 500 mm Dia
 Design Pressure – Atmospheric
 Working Pressure – Atmospheric
 Design Temperature – 50 °C
 Working Temperature- Ambient
 Fluid Operating – Diesel

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7. Material of Construction:

 Shell Roof – IS 2062 Gr.’A’.

 Nozzle Flanges – IS 2062 Gr.’A’.
 Nozzle Pipe – IS 1239 Heavy Class.
 Bolt and Nut – IS 1367 CL.4.6/4 (Gal)
 Gasket – 3mm Thick Rubber

8. Plant /Equipment /Tools / Tackles

 Hydra 12 T Capacity.
 Hammer,
 Water level tube,
 Adjustable spanner,
 Ring spanner (25/28,30/32,34/36),
 Double spanner (25/28,30/32,34/36),
 Belts and sling(6T),
 Rope
 Sprit level, etc.
 Welding Machine – 3 Phase.
 Hydraulic Jack 12 MT [with power pack & accessories] and other required
equipment.
 Grinding machine [AG - 7, AG - 5]
 Hand cutting m/c
 All Measuring Tape (30M, 5M)
 Aluminium Ladder -4 Nos.
 Hand lamp set.
 Exhaust fan for tanks.
 Panel board separately for welding Rectifiers and Grinding.

9. Man Power

Fabrication
 Manager – 1 No
 Engineer – 1No
 Safety officer – 1 No
 Supervisor – 1No
 Labour – 10 No

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 Erection
 Manager – 1 No
 Engineer – 1No
 Safety officer – 1 No
 Supervisor – 1No
 Labour – 5 No

10. Quality Assurance & Quality Control

This shall be followed and maintained with the compliance / adherence to the drawings,
procedure and code specification. Records shall be kept in the relevant check sheet and
formats duly signed by all the concerned departments

11. Safety

 Tested & certified Lifting equipment’s should be used for lifting and shifting
purpose.
 Safety Precautions should be followed during fabrication and erection as per
specification.
 Welding cables and power cables to be laid properly.
 Proper housekeeping and clean condition shall be maintained in the fabrication
shop and site as per requirement

 Personal Protective Equipment (PPE):

The workers working on job site must be equipped with minimum PPE as below:

 Safety Helmet
 Safety shoes , Soft shoes when working on the roof otherwise safety shoe all the
time
 Full body safety harness with 01 or 02 hooks
 High visibility vest
 Safety gloves

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12. Records

 Material Inspection Records

 Welding Inspection report
 Radiography reports
 Test reports
 Handing Over Certificate
 Commissioning Certificate
 Operation and Maintenance manual

13. Conclusion

 Thus the Fabrication and erection of Diesel Tank is underlined. The various tasks
involved in fabrication are discussed.
 The joints, which are important components in plates, shell, and Roof Plate are
explained, with a special emphasis on welded joints.
 Thus an overall view of the fabrication and erection of Tank is covered in this
Method of Statement.

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