5638 e1 1500 CA Pro 220 Rev.3_ Construction Procedure for Tank Hydrostatic Test

7/25/2019 5638 e1 1500 CA Pro 220 Rev.3_ Construction Procedure for Tank Hydrostatic Test

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OF OIL TERMINAL AT HFZ(EPC-1)

AGREEMENT NO. 10-5638-E-1

ABU DHABIOIL REFINING COMPANY PROJECT PROCEDURE

CONSTRUCTION PROCEDURE FOR

TANK HYDROSTATIC TESTDOC.NO.:5638-E1-1500-CA-PRO-220 Page

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Rev.3

PROCEDURE

FOR

TANK HYDROSTATIC TEST


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This page is a record of all revision of this document. All previous issues are hereby superseded

and are to be destroyed.

REV DATE DESCRIPTION PRPD CHKD REVD APPRD COMPANY

3 19/Dec/13Approved for

ConstructionLQL TCS ZHQ AJL

2 12/Dec/13Reissued for

Approval withAmendment

LQL TCS JHB AJL

1 26/Nov/13Reissued for

Approval withAmendment

LQL TCS JHB AJL

0 26/Apr/12Approved for

ConstructionLQL AGS JHB AJL

B 16/Mar/12

CommentsIncorporated and

Reissued ForApproval

LQL AGS JHB AJL

A 05/Mar/12For Approval/

CommentLQL AGS JHB AJL

SIGNED(Initials)

QA/QC manager


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PARAGRAPHS REVISED IN THIS ISSUE

Para. No. Para. No. Para. No. Para. No.


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TABLE OF CONTENTS

No. DESCRIPTION PAGE

1 INTRODUCTION ............................................................................................................... 5

1.1 General ......................................................................................................................... 5

1.2 Scope ............................................................................................................................ 5

2 DEFINITIONS .................................................................................................................... 5

3 REFERENCE CODES AND DOCUMENTS .................................................................... 6

4 RESPONSIBILITIES .......................................................................................................... 7

5 WATER TEST .................................................................................................................... 7

6 HYDROSTATIC TESTING REQUIREMENTS FROM CODE ....................................... 8

7 TANK FILLING ................................................................................................................. 9

7.1 Initial Filling: ............................................................................................................... 9

7.2 Water Filling: ............................................................................................................. 10

8 MONITORING AND SETTLEMENT LIMITS .............................................................. 11

9 TESTING OF THE ROOF ................................................................................................ 14

9.1 Fixed Dome roof ........................................................................................................ 14

9.2 Floating Roof (Single Deck Pontoon Type) ............................................................ 14

9.3 Roof Drains ................................................................................................................ 15


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1 INTRODUCTION

1.1 General

The purpose of this procedure is to establish the job instruction for hydrostatic testing of StorageTanks shall be tested in accordance with API standard 650 and compliance with the requirementsof the project specification.

This job instruction in conjunction with job safety is intended to describe the sequence of activitiesto be carried out to ensure hydrostatic and pneumatic testing is conducted in a safe andcontrolled manner.

1.2 Scope

The scope of this procedure covers all types of Storage Tanks like external floating roof, internalfloating roof with fixed dome roof and fixed dome roof. The test of each tank shall be carried outafter completion of all mechanical works with the mechanical completion check list witnessed byCONTRACTOR and the COMPANY.

For hydrostatic testing the method of filling, the fill rate and flow, static and pneumatic testing,emptying or transfer the water to other tank for testing. During testing we shall verify the tanks allweld seams for leaks, settlement of tank foundation, movement of floating roof, roof drain nozzleand all fixed roof nozzles shall be in open condition during filling and emptying, All shell openingsshall be closed with temporary blind flanges and gaskets with proper size of fasteners for bolting.

For hydrotesting of storage tanks, clean water will be used.CONTRACTOR should follow theapplicable rules and regulations and obtain the approval from HFZA , Sharjah Port Authority

SPA. and Sharjah Municipality.

2 DEFINITIONS


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EPC = Detailed Engineering, Procurement, Construction andCommissioning

FEED = Front End Engineering and Design

IT = Information Technology

Licensor = Any firm or company contracted to provide theirproprietary licensed technology for this Project

Site = Hamriyah free Zone, Sharjah, UAE

Project = Construction of Oil Terminal at Hamriyah Free Zone

(EPC-1)

Subcontractor = Any person, form, or company employed byCONTRACTOR to perform any work or duty on theirbehalf

3 REFERENCE CODES AND DOCUMENTS

API 650 Welded steel Tanks for oil storage

ASME Section II, part-c Welding rods, Electrodes and Filler materials

ASME Section V Nondestructive Examination

ASME Section IX Welding and Bracing Qualifications

ASME Section VIII,Div-1 Pressure Vessels

5638-E1-1500-MEQ-DS-201-207 Data Sheet for Tanks

5638-E1-1500-MEQ-DWG-201-231

5638-E1-1500-MEQ-DWG-251-281

5638-E1-1500-MEQ-DWG-301-331


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5638-E1-1500-SA-PRO-001 Project HSE plan

5638-E1-1500-SA-PRO-006 Permit To Work Procedure

5638-E1-1500-SA-PRO-009 Fall Prevention And Protection Procedure5638-E1-1500-SA-PRO-011 Confined Space Entry Procedure

DGS-MF-001 Design Basis Tanks

DGS-MF-002 Field Erected Welded Steel Storage Tanks

DGS-MW-003 Welding of Storage Tanks

DGS-MX-001 Painting

STD-MF-00024 Methods of Tank Erection

DGS-PU-009 Flange bolting

DGS-MX-002 Galvanising

DGS-MX-004 Lining

Hamriyah Free Zone Authority Guidelines

Sharjah Municipality Guidelines

SEWA - Sharjah Electricity and Water Authority

4 RESPONSIBILITIES

The hydrotesting of Storage Tanks shall be headed by Project Manager of the CONTRACTOR

supported by overall project safety, quality, and tech service departmental heads. Eachdepartment shall provide designates for this work for proper control. Construction Managerreporting to Project Manager shall be responsible for related construction activities.

Competent persons shall be assigned for the hydrotesting work. Since the hydrotesting shall beon 24 hrs basis, for proper coverage to oversee the operation, The competent personnel shall bed l d i i h hif ll Ad li h i h ll b d k f d i


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Water drainage from the storage tank will be disposed to HFZA approved area or disposal ofhydrotest water shall be drained through approved agency as per the rules and regulationsof HFZA.

6 HYDROSTATIC TESTING REQUIREMENTS

Here are the hydrostatic testing requirements from Project codes and specifications ,Detailedplan refer to section 9 Site Tank Hydrostatic Testing Water Execution Plan subject to sitecondition.

Tank shall be hydrotested on completion of all construction work directly associated with the

tank and its welded attachments and on completion of all non destructive testingrequirementsexcept painting activities.

No project connections are to be made between the tank and any product line until the tankand all mountings have been satisfactorily tested.

No welding is to be carried out on the shell when the tank is full of water. Any leaks foundshall be repaired with the water level at least 300 mm below the point being repaired to anagreed welding procedure and retest.

Internal bottom elevation measurements shall be made before and after hydrostatic testing.measurements shall be made at maximum intervals of 3m measured on diametrical linesacross the tank. The diametrical lines shall be spaced at equal angles, with a maximumseparation measured at the tank circumference of 10m. A minimum of four diametrical linesshall be used.

All dimensional tolerances required in accordance to API Std 650.

For fixed roof tanks, testing shall be done by filling the tanks with fresh water to the level ofthe top leg of the top curb angle, and noting any leaks over a period of at least 24 hours.

For open top tanks and floating roof tanks the maximum test water level is approximately 150mm below the top of the shell.

Any tank showing evidence of leakage from the bottom during test must be emptied


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After completion of the hydrotest only non-structural small attachments may be welded to thetank in accordance with 7.2.1.11. Any welded joints above the test-water level shall beexamined for leakage by one of the following methods.

1. Coating all of the joints on the inside with a high penetrating oil, such as automobile springoil, and carefully examining the outside of the joints for leakage.

2. Applying vacuum to either side of the joints or applying internal air pressure as specifiedfor the roof test in 7.3.7 and carefully examining the joints for leakage.

3. Using any combination of the methods stipulated in subitems 1 and 2.

The CONTRACTOR shall be responsible for preparing the tank for testing. This shall includeremoval of all trash, debris, grease, oil, weld scale, weld spatter, and any other foreign matterfrom the interior and the roofs of the tank.

The CONTRACTOR shall be responsible for furnishing, laying, and removing all pipe linesfrom the clean water source tie-in locations and to the water disposal point. To obtain requiredpermission for taking clean water for filling and then after testing disposal of water with priorapproval from the COMPANY and the concerned authority of HFZA and Sharjah Municipality.

During emptying the tank or after hydrotest CONTRACTOR shall be responsible for cleaningthe tank with clean water, which is kept outside the tank on the ground with jet pump.

The CONTRACTOR shall be responsible for monitoring the settlement measurements inaccordance to code.

The CONTRACTOR shall be responsible for furnishing all other test materials and facilities,including blinds, bolting, and gaskets.

The CONTRACTOR shall be responsible for checking the wind girders for proper drainageduring or following the hydrotest . If water is retained, additional drainage shall be providedsubject to the COMPANY approval.


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with API 653, Appendix B. The CONTRACTOR shall take jacking and leveling into considerationfor the tank design.

Uneven settlement of the tank on its foundation shall be reported immediately to the COMPANYand filling shall be stopped at any signs of excessive settlement pending a decision by theCONTRACTOR and the COMPANY on the action to be taken.

In the case of excessive soil settlement, the situation shall be reported to the soil mechanicsspecialist and his recommendations considered.

The temperature of the test water shall be not lower than that specified by API 650 for the

conditions concerned.

7.2 Water Filling:

The CONTRACTOR and COMPANY representative shall witness the tank filling operations.

The tank shall have all shell in-out connections blanked off except a nozzle used to allow asteady inflow or outflow of hydrotest water. Isolating and check valves shall be fitted to thisnozzle in case of filling failure and shall be served by mean of a manifold from the temporaryline.

Appropriate roof connections (manholes) must be open to allow free venting of air duringfilling.

For floating roof tanks, the maximum and minimum annular space between the shell and theroof rim plate prior to initial floatation and at the maximum test fill height shall be measuredand recorded.

If settlement measurements are specified by the COMPANY, any differential settlementgreater than 13mm per 10m of circumference or a uniform settlement over 50mm shall bereported to the COMPANY for evaluation. Filling of the tank shall be stopped until cleared bythe COMPANY.


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One day for settlement reading at 50%One day for settlement reading at 75%One day for settlement reading at 100%

Total four days for settlement observation

The tank shall be observed for signs of leakage. Careful inspection of all welded seams in theshell, including shell to bottom and all welds around openings and pipe joints, shall be carriedout. Besides shall be ensured there is no evidence of water seeping from beneath the tank.

8 MONITORING AND SETTLEMENT LIMITS

Monitoring shall be consist in the measurement of settlements along the tank circumference byoptical level instrument reading.

Level measurement on tank circumference

The tank shall be provided with reference points, equally spaced along the circumference andmade of steel elements welded to the shell approx. one meter above the edge of the bottomcourse. A set of level reading on all reference points shall be performed at the following times:

a) After tank complete construction, before start of filling for hydrastatic testb) With the water level at 25% of max. levelc) With the water level at 50% of max. leveld) With the water level at 75% of max. levele) With the water level at 100% levelf) 24 hours after reaching max. level of water in the tankg) In empty tank without waterh) 24 hours after emptying of the tank

Level measurements shall be referred to a permanent bench mark, both the bench mark and therequired permanent station joints shall be located at least 0.75 tank diameter from the tank edgeto avoid ground settlements that may influence the reading. The level instrument shall be set upat least 1 times tank diameter away from the tank when tank elevation readings are taken.


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9.1.4 Water vendor will use 15-20nos water tanks of 5000 gallons each to transport water fromtheir factory to Contractor site. The sufficient water will be stored in waste water Sumpbefore hydro test start.

9.1.5 Manpower

Description Quant.

Mechanical engineer 2

QA/QC engineer 1

Safety officer 2

Surveyor 2

Site supervisor 2

Welder 4

Fitter 2

Rigger 4

Driver /Operator 5Labours 6

9.2 Water filling & drains arrangement

9.2.1 Contractor to use T901 waste water sump as buffering pool for water filling operation.Contractor shall Clean the waste water Sump (WWS) thoroughly before using it .Sample ofwater should be taken from WWS for testing.

9.2.2 The total 16 tanks farm site will be divided into two areas for hydrostatic testing gradually :

(1)The first tank area testing sequence is as follows:

T201, T202T203T204T101, T103T102, T205T211, T212


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9.2.4 Official hydrostatic testing water filling

This official hydrostatic testing water filling should be followed only after all the tank fittingsand structure were completed and inspected. The water filling shall strictly comply with tankhydrostatic testing requirements and contractor to keep good water filling and settlementrecords.

9.3 Official Tank Hydrostatic Testing Water Filling Schedule

Categ.In.

Dia.TankShell

Height

Total

FillingHeight(HLL)

1stStage(25%)

Settle.Observ.

2ndStage(50%)

Settl.Observ

3rdStage(75%)

Settle.Observ.

4thStage(100%)

Settle.Observ.

JET A1TANK

41m 22m 19.81m 4.95m 24hr. 9.9m 24hr. 14.86m 24hr. 19.81m 24hr.

ULG &GAS OIL

TANK

36m 22.7m 21.25m 5.31m 24hr. 10.63m 24hr. 15.94m 24hr. 21.25m 24hr.

Note:

(1) The total filling height is from Data Sheet for Tanks Rev.0 .HLL--- High liquid level(2) The balance tank T205, fire water tanks and slop tanks will apply to this schedule either.

(3) Take the I.D.36m tank for calculation , using 260m/hr. pump and spend 10hr.each day to fill

water, It will take approx. 15 days to complete High liquid level hydrostatic test (excluding waterdraining).

10 TESTING OF THE ROOF

10.1 Fixed Dome roof (If Required)


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It is essential for a floating roof to be liquid-tight for it to function safely and well. To ensure thatweld seams and joints, which are required to be liquid-tight fulfill this requirement, they shall beinspected and tested carefully. The following procedure shall be adhered to.

Center Deck of Pontoon-Type Roofs:

The weld seams of the single center deck plates shall be checked for liquid-tightness by thevacuum box method or by the penetration oil/chalk method.

Pontoon of pontoon-type roofs:

Before the top plates of the pontoons are installed the following seams in particular, shall betested for tightness, using liquid penetrates or any other test method:

a) The single-fillet welds on the upper surface of the pontoon bottom plates.b) The single-fillet welds between the bottom and the side walls of the pontoon.c) The single-fillet welds between the bulk heads and the bottom and side walls of the pontoon.d) The welds at the bottom corners of the bulk heads. These should be tested with particular

care, since the bulk heads are mostly shaped at these points to clear the longitudinal weldbetween the bottom and the side walls. The gaps so formed in the corners shall be closed

thoroughly, as leaks in one compartment will allow oil to penetrate into the adjacentcompartments.

e) The longitudinal welds joining the center deck to the pontoon.

Before all weld seams mentioned above are tested for tightness, they shall be thoroughlycleaned of slag and dirt.

10.3 Roof Drains

Drain pipe systems of storm water drains shall be tested with water to a pressure of 3.6kg/cm2(g).

During the flotation test, the roof drains shall be kept open and observed for leakage of tankcontents into the drain lines.


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For the hydrotest water below valve level, suction pumps shall be utilized to remove theremaining water from the bottom sump.

The tank shall be completely drained and free from standing water.

15 CLEANING OF INTERNAL TANK AFTER DRAINING

After the completion of draining of clean water from the tank, blinds covering the manholes ornozzle openings shall be removed prior to the cleaning activity. The operators and relativepersonnel will go up to the top of tank from outside spiral stair and go into tank inside floating

deck ,which acts as the work cleaning platform , from tank inside floating stairway. PTW andconfine space entry procedure shall be always followed before work start.

A temporary storage tank filled with potable water is to be kept outside the tank on theground and connected to a jet pump.

The jet pump shall be positioned near the movable working platform with adequate length ofhose and spray nozzle at the end. Minimum pressure at nozzle and is approximately 30 bargauge and output is 290/600 litres/hour.

Cleaning of the shell plates shall be start from the highest course downward by standing onthe floating deck ,using the spray nozzle from the jet pump.

16 CALIBRATION OF TANK

Tank shall be calibrated in the presence of Third Party Inspection approved Agency by

COMPANY. After obtaining Third party Inspection procedure for Tank calibration and same shall

be submitted to COMPANY for further approval.


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Refer to 5638-E1-1500-QA-ITP-MEQ-01 Inspection and Test Plan for Storage Tank and ProjectQuality Plan 5638-E1-1500-QA-PRO-001. Hydro test report shall be well prepared as per sitetesting course.


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OIL TERMINAL CONSTRUCTION PROJECT (EPC-1), HFZ, SHARJAH

RISK ASSESSMENT (Page 2 of 11)

2 Transportatio

n and Lifting

of HydroTesting

Materials

* Collide with

other vehicle or

adjacent objectsduring lifting/

swinging

* Clash with

adjacent operations

*Nip points

*Sharp edges of

materials

*Under load*Overload/over turn*Load failure

*Roll over

*Fatality

*Injury

*PropertyDamage*Workstoppage

*Crane and all the lifting accessories

shall be 3rd

party certified and the

serial numbers of slings shall bematched with the certificates

*Crane operator, rigger shall be withvalid 3

rdparty Certificate.

*Valid PTW* Lift plan if required

*Pipe clamps shall be appropriate tothe pipe size.

*All the slings, clamps shall beinspected by rigger before each lift

*Only trained and authorizedpersonnel be allowed

*Barricades and caution sign boardsbe displayed

*Proper supervision and pre plan oneach activity

*Other adjacent activities are to be

restricted during the work*Riggers must be instructed well todecide the slinging points depends tolength and weight of pipes/materials

*Slinging techniques shall be

implemented correctly*Wind speed must be considered*Load chart must displayed visible in

the operator cabin.

*Radius and angle of boom and slingsmust be planned and monitored.*SWL of slings and cranes must be

considered and planned well.

*Spreader shall be used always ifrequired.* Minimum two tag lines are required

(Tag line not less than

3m)

4 C H *Allocation of safelocation for positioning

of Trailer and crane,materials stacking,

Flagman and riggers*Proper plan required

for material handling,sequential operation

always*Mandatory PPEs and

accoutrements shall bedonned

*All the equipmentsand tools shall be

inspected as perchecklist daily and

periodically and colourcoded.

*Weight of each load

shall be calculatedbefore slinging.*Fork lift shall not be

used to lift any size ofpipe.

*Dimension of piperacks shall beconsidered and planed

well the lifting path

*Man positioning,working platform shallbe planed and explained

to the work force.

Performer 3 C M


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3 Fabrication,

Blinding/

Weldingbefore Hydro

testing

* Caught under

load

* Collide withother objects/

operation

*Sharp edges

*Electrocution

*UV/IR radiation

*Injury

*Property

Damage*Electric

burn/Bruise

*Arc eye

*All the equipments, electrical

and hand tools shall be inspected

prior to use, maintainedperiodically and colour coded

accordingly.

*Equipments shall be inspected

and certified by a 3rd party

(Depends on the equipment).

*All the operatives shall be

competent and trained.* All the DBs, sockets and cables

shall be of project standards and

with GFCI and inspected

monthly.

* All the Welding machines,

shall be calibrated & grounding

shall be ensured for all electrical

equipments (Oven, work-piece,welding machine).

* All the electrical tools shall be

with deadman switch.

* No material shall be placed by

creating hinder to any access, exit

or any fire extinguisher.

*Proper supervision shall beensured always.*PPEs for Welding-Welding shield

shall be attached to helmet, Welding

Gloves, shall be used apart from

project mandatory PPEs.

*All the electrical

cables shall be routed

UG/above minimum

2m height & away from road, sharp,

hot parts

3 C M * Scrap & used buts

shall be stored

seperately andemptied regularly.

*Proper housekeeping

shall be ensured

always.

*Proper aisle,

workspace shall be

planned and defined.

*Material movementshall be planned &

executed sequentially

*Proper lighting,

ventilation shall be

ensured always.

*External ventilation,

mechanical exaustion

shall be provided ifrequired.

*Man positioning,

proper working

platform shall be

planed, provided and

explained to the work

force.

Performer 2 B L


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4. Laying andfixation of

hose, clamps,couplings,

pressuregauges and

other hydrotest materials

*Falling of

material

*Slip, Trip Fall

*Injury

*Falatlity

*Flood

*Rooting of hose, and fixing/clamp

points shall be planned well

considering the integrity of structureand weight of hydro test material

including the water volume and

pressure.

*Vertical and horizontal routing of

hoses shall be routed safe duly

ensured the tighness to avoid any

move and burst.

*Tightness of Hose connectors shallbe ensured.

*All the hose, connector/couplings

shall be rated to the required bar

pressure and back water thrust.

*proper ramps shall be installed at

road crossingss and routed safely to

avoid slip trip fall.

*Pressure gauges shall be installedat easily monitoring height levels.

3 C M *Personnel shall be

trained and issued

with proper PPE*Grounding/earthing

shall be ensured on

the routings.

*Hose, Clamps,

couplings, gauges

shall be international

standards towithstand the

pressure and be

inspected before

installation.*Callibrated Pressure

gauges be installed at

each section

*Proper access to allvalves, gauges shall

be provided

Performer 2 A L


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5 Water

Filling , Leak

TestingDrain, and

Settlement

Observation

*High pressured

liquid

*Structurecollapse

*Failure of

flanges

*Burst

*Buckling

*Fatality

*Injury

*Assetdamage

*Project delay

*PTW be obtained. Watter be filled

stage by stage duly monitoring

leake, pressure etc.*Involved area to be barricaded with

Warning signs.

*Continuous supervision

*Project Testing procedure shall be

followed

* Ensure that the test pack has been

signed and released for test to

proceed*A complete walk through

inspection shall be done always at

pressured.

*Ensure that adequate number of

spotters are in place at works

location and boundaries

*Ensure assigned test personnel are

in safe position prior to start test

*Hoses to be monitored, secured and

kept in a tidy nad no accumulation

of debris/sharp/hot objects.

*Ensure all flange bolts are secure

before test, Valves only to be

operated by authorised personnel

*Ensure inlet/outlet & safety valves,

pressure gauges are functional.

* Other personnel be removed fromthe testing area

*Nobody will be permitted to climb

up the roof/top portion of tank.

*Leak repair is not permited during

pressure test

* The rate of draining flow shall be

controled slowly and smooth duly

considering the integrity of tankwalls to avoid buckling damages.

4 C H *Medical aids and

rescue shall be

available foremergency

situations.*Pressurise & De

pressurise shall be in

steps and as per

specifications

*work and water filling

will be stoppedimmediately if sudden

increase/decrease/leak

monitored and be

alarmed.

*The whole system

(DG, Hose routing,

motor pump, valves,

test tank etc) shall bemonitored for 24

hours. Good

communication system

be provided and

ensured between

monitor, pump

operator etc.

*Alarm system/ overpressure valve shall be

installed & set to

required pressure.

*Test pieces shall not

be detached, repaired,

loosen or tighten until

clear depressurisation

after double checked.

*Hose be burried

properly

Performer 2 A L


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6 PneumaticTesting (if

required)

*High pressured

air

*Structurecollapse

*Failure of

flanges

*Fatality

*Injury

*Assetdamage

*Combustible gas are not allowed

to be used for pnenmatic test.

*Involved area to be barricadedwith Warning signs.

*Continuous supervision

*Project Testing procedure shall

be followed

* Ensure that the test pack has

been signed and released for test to

proceed

*A complete walk throughinspection on every non-welding

connection jont shall be done

always at pressured.

*Ensure assigned test personnel

are in safe position prior to start

test

*Hoses to be monitored,

securedwith whip lash arrestor, and

kept in a tidy no accumulation of

debris/sharp/hot objects.

*Ensure all flange bolts are tighten

before test, Valves be operated by

authorised personnel only.

*Ensure inlet/outlet & safety

valves, pressure gauges are fixed

properly and functional.

* Other personnel be removed fromthe testing area, near any valces or

blinds.

*Nobody will be permitted to climb

up the roof/top portion of tank.

*Leak repair is not permited during

pressure test.

4 C H *First aids and

rescue shall be

available foremergency

situations.*Pressurise & De

pressurise shall be in

steps as per

specifications

*Testing will be

stopped immediately ifsudden increase/

decrease/leak

monitored and be

alarmed.

*The whole system

(DG, Hose routing,

motor pump, valves,

test tank etc) shall bemonitored for 24

hours. Good

communication system

be established and

ensured between

monitor, pump

operator etc.

*Alarm system/ overpressure valve shall be

installed & set to

required pressure.

*Test pieces shall not

be detached, repaired,

loosen or tighten until

clear depressurisation

after double checked.

Performer 2 A L


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*Work plat form shall be robust to

withstand weight of test piece,

testors and helpers. Proper access,fall arrestors be worn by the testors

if required.


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7 Cleaning/

Flushing the

Tank WithHigh Pressure

Pump (If

required)

*Asphyxiation

*Hazardous Gas

*Fall from height

*Fatality

*Injury

*Propertydamage

*Only competent and project CSE

trained workers shall be involed in

the work. Alone worker is notpermitted.

*Safety supervisor, work supervisor,

Hole watch, Pressure pump &

compressor operator must be

available always

*Gas testing be done before

personnel entry

*All Equipment must be inspectedfor proper function.

*Required PPEs : high pressure

water jet protective clothing,

Helmet, Safety goggle & Gum Boot,

FBH .

*Safety and warning signs and

emergency rescue equipments be

made available ready.

*On/off switches of jet system be

out side of the tank and be

monitored always.

*Third party certified Manbasket

duly written clearly the SWL be

used by personnel going inside the

tank. Manbasket will remain inside

the tank until last person come out

from the tank. Manbasket shall notbe detached from the crane until

final removal of person from the

tank.

*3 Riggers will be used. 1 inside the

tank, 1 at the curb ring and 1 at the

vicinity of crane operator (Outside

the tank) and manbasket be moved

by relay the signals by the riggers.

3 C M *Emergency rescue

equipment, stretcher be

made available readily.*Job rotation be done

*Proper illumination,

ventilation be ensured

*all the entrant be

worn FBH and all PPE

* Nobody will enter

under the floating roof,

if water reside under it.*Bottom plate cleaning

will be done only if the

Bottom shell manhole

flange is opened fully

and possible dust

sedimentation is

removed.

*Proper

communication device,

emergency alarm be

provided to the

entrants.

*Self breathing

apparatus will be

available inside the

tank always for

emergency purpose

Performer 1 B L


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8 Confined

Space Entry

*Gas

*Lack of O2

*Supervisionmissed

*Poor

illumination

*Falling objects

*Fall from height

*Toxication

*Asphyxiation

*ElectricalBurn/Shock

*Fire

*Tumble*Injury

*Entry restriction Only well

trained & nominated person.

*Verify that the ventilation andlighting equipment & service are

well prepared and in good status

*Verify that rescue services such

(rope)life ladders & life line are

available and that the means for

summoning them are operable on

every ingress ,egress and

evacuation outlet*All Attendant Hole watch will be

adequately qualified via DEC Hole

watch training and follow up

supervisor directed training on the

job.

*Frequent breaks or change of

crews

*Prevent unauthorized individuals

to enter or attempt to enter the

confined space during entry

operations

*Adequate warning sign board

shall be placed.

*Clear communication and

coordination among crews

*Provision of attender.

*Verify the fitness of workers priorto entry into the tank

*Readiness of recovery equipments,

First aid & Respiratory apparatus.

*Provision of fire extinguishers

*No resting position works inside

the tank

*Before start of each shift work

proper atmosphere test to be carriedout by competent persons (AGT)

4 C H *Recording of

personnel Entry &

Exit.*Emergency horn

& light to

communicate an

Emergency situation.

*Provision of FBH &

Respirator (as per

requirement)

*Strict Supervision*Proper illumination

(100lux minimum)

*Proper ventilation

and external

ventilation shall be

arranged if required.

Performer 2 C L

OIL TERMINAL CONSTRUCTION PROJECT (EPC 1) HFZ SHARJAH


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9 Work At

Height (Tank

Top Testingor Testing

Observation

and Survey)

*Trip and Fall

*Fall of materials

*Sharp edges

*Injuries to

personnel

* Fatality*Property

damage

*Trip and Fall

*proper Work platform with ladders,

handrail, mid rail be provided

*FBH be worn by the personnelalways

*Testing personnel shall not enter

into the tank without permission and

proper arrangements and training

3 C M *Project WAH

procedure shall be

implemented.

performer 2 C M

10 General Task

(Applicable

to all

activities)

*Machineries

operation

*Sound

*Dust*Temperature

*Debris

*Tools

*Extreme weather

*Slip, Trip Fall

* Injury

*Fatality

*Heat related

illness*Fire

*Property

damage

*Work

stoppage

*TBT to be conducted daily to brief

the hazards of the task

*All the workers must be

Experienced & trained*A trained banksman/signalman

with flourescent jacket shall be

provided with each equipment.

*Use Mandatory PPEs to protect

Head, Eye, Ear, Body, Hands &

Foot.

*Provision of Shelter and water

points*Fire Extinguishers

*PTW requirement as per procedure

*Proper housekeeing shall be

ensured each shift start and end

*All the activities should be stopped

at any extreme weather conditions

*Work shall be resumed after

inspection on back to normalweather.

*All tools should be inspected

before start of work and shall be

colour coded periodicaly.

3 C M *Strict supervision

*Use the right tools /

Equipment in correct

manner.*All project employees

must be aware of

emergency response

plan.

*Muster point must be

visible at all times.

*Job rotation and

periodic rests*Home made tools are

prohibited

Performer 2 B M


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Documents

5638 e1 1500 CA Pro 220 Rev.3_ Construction Procedure for Tank Hydrostatic Test