Method Statement For Construction of LPG Mounded Storage Bullets

METHOD STATEMENT FOR CONSTRUCTION OF LPG
MOUNDED STORAGE BULLETS.

Doc No: 2023-24/PID-40/AMUNRA/EIPL/MB/MS-01, R.0
CLIENT EAST INDIA PETROLEUM PVT LTD
GLOBE GAS EQUIPMENT AND INDUSTRIAL

CONSULTANT
CONTRACTOR AMUNRA INFRATECH AND AGRITECH PVT LTD
LPG STORAGE CAPACITY EXPANSION PROJECT BY CONSTRUCTING

PROJECT
LPG MOUNDED STORAGE BULLETS (3*1650 MT)
JOB NUMBER
XXXX
METHOD STATEMENT FOR CONSTRUCTION OF LPG MOUNDED

SUBJECT
STORAGE BULLETS
00 01.03.2024 For Approval
Prepared By Reviewed By Approved By

Rev Date Description
(AIAPL) () (TPI) (EIPL)
Pages 1 of 21
Contents
1.0 PURPOSE .................................................................................................................................................................. 4
2.0 SCOPE ........................................................................................................................................................................ 4
3.0 TERMS & DEFINITION ......................................................................................................................................... 4
4.0 REFERENCE CODES AND STANDARDS. ......................................................................................................... 4
5.0 SITE SAFETY ARRANGEMENTS ......................................................................................................................... 5
6.0 RESPONSIBILITIES .............................................................................................................................................. 5

 PROJECT HOD ............................................................................................................................................................ 5
 MANAGER ................................................................................................................................................................... 6
 ENGINEER IN CHARGE ............................................................................................................................................. 6
 QA/QC MANAGER ...................................................................................................................................................... 6
 QC ENGINEER/INSPECTOR ...................................................................................................................................... 6
 FIELD ENGINEER/SUPERVISOR .............................................................................................................................. 7
 ADMIN INCHARGE ..................................................................................................................................................... 7
 STORES INCHARGE ................................................................................................................................................... 7
 EQUIPMENT OPERATOR ........................................................................................................................................... 7
 QUALIFIED WELDER /WELDERS HELPER .............................................................................................................. 8
 QUALIFIED RIGGER. ................................................................................................................................................. 8
 LEAD SAFETY ENGINEER: ........................................................................................................................................ 8
7.0 CONSTRUCTION DRAWINGS:........................................................................................................................... 8
8.0 METHODOLOGY ..................................................................................................................................................... 9

8.1 MOBILIZATION OF MATERIALS, SITE SETUP AND MOVEMENT OF VEHICLES, EQUIPMENTS AND
MACHINES.......................................................................................................................................................................... 9
8.2 RECEIPT AND STORING OF MATERIALS ............................................................................................................ 9
8.3 MATERIAL TESTS ................................................................................................................................................ 10
8.4 CIVIL WORKS ....................................................................................................................................................... 10
8.4.1 SOP for Boring, Piling and Operation Of Tripod...................................................................................... 10
8.4.2 Sop for Bar Cutting, Bending, Fixing, Welding And Gas Cutting. ......................................................... 11
8.4.3 Sop for Placing and Handling of Reinforcement Cage and Liner. ........................................................ 12
8.5 MECHANICAL WORKS ......................................................................................................................................... 13
8.5.1 Material Inspection, approval & Traceability ........................................................................................... 13
8.5.2 Steel marking and surface preparation .................................................................................................... 13
8.5.3 Cutting& Marking: ....................................................................................................................................... 14
8.5.4 Fit Out of assembly/sub-assemblies. ........................................................................................................ 14
8.5.5 Established Welding Area ........................................................................................................................... 15
8.5.6 Welding Steel Pipe ...................................................................................................................................... 15
8.5.7 Pre-heating ................................................................................................................................................... 15
8.5.8 Inspection & Testing: ................................................................................................................................. 16
8.5.9 Transportation ............................................................................................................................................. 16

Pages 2 of 21
8.5.10 BULLET ERECTION ...................................................................................................................................... 16

8.5.11 Inspection and Testing of Welds ............................................................................................................... 17
8.5.12 Water filling and hydro test of the Bullets. .............................................................................................. 18
8.5.13 Surface Preparation and painting of Bullets ............................................................................................ 18
8.6 CONSTRUCTION OF RETAINING WALLS AROUND THE MOUND .................................................................. 20
8.7 MOUND FILLING .................................................................................................................................................. 20
9.0 FINISHING AND TIDYING UP ........................................................................................................................ 21
10.0 QUALITY ASSURANCE & CONTROL ........................................................................................................... 21
11.0 INSPECTION AND TEST DOCUMENTS ...................................................................................................... 21
12.0 CHECK LIST ....................................................................................................................................................... 21
13.0 HEALTH SAFETY AND ENVIORNMENT. .................................................................................................... 22
14.0 DOCUMENTATION AND RECORDS ............................................................................................................ 22

Pages 3 of 21
1.0 PURPOSE
The purpose of this document is to follow proper procedure to describe the Execution of Civil,
Mechanical, Electrical and other associated works for construction of LPG mounded storage
Bullets. This procedure covers the detailed civil works, Fabrication, Erection of Steel tanks for
LPG Storage Capacity Expansion Project, EIPL Terminal, Visakhapatnam.
2.0 SCOPE
This documents cover the methodology to be followed during Civil Foundation works,
Fabrication and Erection of all Steel structures and Tanks, Pipe Racks, Technological
Structure, Paving, Platforms including Gratings/Handrails etc. at Site Works Area pertaining
to Contract and Project Approved Drawings/Specification.
3.0 TERMS & DEFINITION
For the purpose of this document, the term “Shall” indicates a mandatory requirement and
“Should” indicates a recommended practice.
4.0 REFERENCE CODES AND STANDARDS.
In preparation of this procedure, the following documents in totality or in part shall from the
reference document:
a) IS 5121 (1969) Safety Code for Piling & other deep foundations.
b) IS: 7293-1974 (Safety code for working with construction machineries)
c) IS 3764 -1992 Code of safety for excavation work
d) IS 4014-2-1962 Code of Practice for Steel Tubular Scaffolding, Part II: Safety
Regulations for Scaffolding
e) IS 7293- 1974 Safety code for working with construction machinery
f) IS 7969- 19974 Safety code for handling and storage of building materials
g) IS 13416-Part-1- 1992 Recommendations for preventive measures against

hazards at workplaces, Part 1: Falling material hazards prevention
h) BIS CODES: IS: 2062, 800, 801, 802, 816, 818, 819, 822, 919, and 1024,
1261, 1323, 1477, 1852, 2074, 7205, 7215, 7307, 7310, 7318, 9595 & other
relevant IS Codes.

Pages 4 of 21
i) Other Standards and Codes of Practice.
5.0 SITE SAFETY ARRANGEMENTS
Amunra Infratech and Agritech Pvt Ltd is dedicated to ensure that the safety, health, and
environmental aspects are respected. To begin with, every personnel is compelled to attend
safety meetings and tool box talks which take place every morning on site before the
commencement of any activity. Secondly, all tools and equipment shall be regularly maintained
and properly calibrated to ensure the quality of the work results. Moreover, Personal Protective
Equipment (PPE) must be worn on site by all personnel at all time.
6.0 RESPONSIBILITIES
Following are the responsibilities and reporting structure of Personnel involved in the scope
of this Procedure:
 PROJECT HOD
a) Shall be responsible for providing resources for the implementation of the method
statement.
b) Maintain good communication with all employees involved in this process.
c) To ensure that all the equipment, tools and tackles required to execute the works
according to approved construction Schedule are available in good condition and
provide any additional equipment as required.
d) To ensure all the equipment/vehicles are handled by licensed/ skilled operators.
e) To provide all necessary support to his construction team and ensure that the works
are carried out as per the approved Method Statements/procedures.

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f) Co-ordinate with site engineer, Surveyors, Safety Engineer, Quality Engineer, and
frontline supervisors for safe & proper execution of the works.
g) To ensure that, checked levels shall be entered in level books as per the approved
formats & requirements on daily basis.
h) To ensure that levels are jointly being signed by the contractor and Client
representative.
i) To continuously check the progress of works as per schedule/ programs.
j) To ensure Client approval on all checklists / permission as and when required.
 MANAGER
a) Shall be responsible for providing resources for the Implementation of the MS

b) Ensure Compliance to Project Specification Fulfill all Required Safety Measures.
 ENGINEER IN CHARGE
a) Shall Report to RCM.

b) Shall be responsible for the implementation of this MS Compliance to Project
Specification.
c) Provide adequate resources for Execution of Work.
 QA/QC MANAGER
a) Shall Report to RCM.

b) Shall be responsible for Job carried out as per this MS & ITP.
c) It shall be the responsibility of the QC Engineer/Inspector to carry out patrol.
d) Inspection to ensure that all Construction work is being carried out as per the
Requirements of the relevant Code/Specification, applicable WPS and all Quality
MS/Procedure & ITPs to be adhered to.
e) Communicating with all site staff about the Quality requirements as per QMS.
f) Shall ensure all inspections and tests are conducted as per approved Inspection and
Test Plan.
g) Shall ensure only approved materials incorporated in works.
h) Closure of Non-conformance, if any.
 QC ENGINEER/INSPECTOR
a) Ensure that Raw Material is as per approved make and traceability maintained.
b) Ensure required training and induction provided to all workers/supervisors.
c) Ensure fabrication procedure is as per approved Fabrication Method Statement.
d) Ensure all testing performed, witnessed and verified by Inspection agency.

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 FIELD ENGINEER/SUPERVISOR
a) Understanding the drawings prior to start of work and all details are provided to execute
the work. If not, then take clarification from Client.
b) Compliance to EHS and QA/QC requirements prior to commencement of work.
c) Engaging workmen in work according to plan.
d) Cross checking the activities intermittently during day’s work and ensuring the activity is
done within tolerance limits.
e) Mobilizing the materials required for work prior to start of work.
f) Giving Instructions to workmen working under him highlighting the risk involved in the
task.
g) To ensure safety of workmen working in his area. To ensure proper working platform
with access to keep materials.
h) To ensure all working and checking tools are available at site with working team before
start of work.
i) To ensure proper housekeeping at site at the end of day’s work.
j) Understanding EHS requirements of project from EHS plan, EHS management systems,
EHS Manual & following the same in execution of work.
k) Marking legibly grid reference/ Date of construction.
l) Ensuring implementation of proper work methodology for all activities.
m) Preparation of all checklists and certification of works from Client.
 ADMIN INCHARGE
a) Ensure availability of all statutory documents related to safe use of all construction
equipment and vehicles such as dumpers, excavators, and passenger vehicles (if any).
b) To facilitate site team for all enabling work to carry out works safely without any
interruption.
 STORES INCHARGE
a) EPCC store personal will collect invoices and MTCs of all material received at Fabricator’s
end.
b) Maintain the record of incoming materials from Fabricators and dispatch record.
 EQUIPMENT OPERATOR
a) Participate in Safety Tool Box meeting and JSA.

b) Understand the scope of work and the hazards involved in his/her specific job duty.
c) Maintain good communication with the Equipment Operator and supporting personnel
at all times.
d) Ensure that the buffer zone is free of any unauthorized equipment or personnel at all
times.

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e) Maintain a safe working distance away from any mobile equipment while work is in
progress.
f) Be aware of traffic and pedestrians and make sure the equipment operator knows
when equipment or a vehicle is approaching
 QUALIFIED WELDER /WELDERS HELPER
a) Participate in Safety Tool box meeting meeting and JSA.

b) Inspect all welding equipment used for welding operations.
c) Scan out work area to ensure any flammable material is not present.
d) Understand the scope of work prior to beginning task.
e) Maintain good communication with the spotter and supporting personnel during
operations.
f) Commence work and maintain safe operations (Able to locate fire extinguisher and
fire blankets as required).
 QUALIFIED RIGGER.
a) Participate in tailgate meeting and JSEA.

b) Inspect all lifting devices and make certain of capacities.
c) Maintain a safe working distance away from any mobile equipment while work is in
progress.
d) Understand the scope of work prior to beginning task.
e) Use proper rigging techniques.
 LEAD SAFETY ENGINEER:
a) Shall inspect in maintaining safe working environment & conditions and compliance to
Project EHS Plan. Shall facilitate in EHS Risk analysis and ensure required preventative
measures.
b) Identify potentially unsafe acts, areas and practice and educate people.
c) Monitor EHS practices, persuade to minimize non compliance
d) Report incidents beyond control and unsafe occurrences.
e) Issue stop work notice for unsafe work.
f) Investigate unsafe occurrences and initiate preventive steps.
g) Discuss near miss accidents with staff and workmen
h) Conduct safety training programs and celebrations
i) Review Health & Environment related aspects as per the norms.
7.0 CONSTRUCTION DRAWINGS:
Construction drawings shall be prepared by AIAPL & thoroughly checked, stamped

“Approved for Construction” and signed by AIAPL/EIPL’s own responsible engineer, to
ensure the accuracy and correctness of the drawings. AIPAL shall prepare the shop

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fabrication drawings and submit to TPI/EIPL for approval. Only based on approved for
construction drawings, work will be executed.
8.0 METHODOLOGY
8.1 MOBILIZATION OF MATERIALS, SITE SETUP AND MOVEMENT OF VEHICLES,

EQUIPMENTS AND MACHINES.
a) Access of transportation of materials should be checked prior to commencement of work.

b) Traffic movement should be considered.
c) Space required for movement of vehicles, machines and equipment should be considered.
d) Loading and unloading should be done on levelled ground.
e) All the drivers and operators should carry their valid license& should be free of any
alcohol/drugs intake. Regular random checks shall be done to ensure this.
f) Speed limit should be restricted to 10KMPH in EIPL Terminal inside plant area.
g) All the reversing activity of vehicles equipment and machines should be done under the
supervision of dedicated helper/flagman.
h) All the machineries, equipment and vehicles should be checked before operation&
Fitness tag should be displayed for easy identification.
i) Before operating vehicles, operators should ensure that nobody is under the vehicle.
j) All the vehicle should have valid documents like Registration Certificate, insurance,
fitness certificate etc.
8.2 RECEIPT AND STORING OF MATERIALS
Each section shall be marked for identification and each lot should be accompanied by
manufacturer's quality certificate, conforming the specifications, for mechanical items
chemical analysis and mechanical characteristics. All sections shall be checked, sorted out,
straightened, and arranged by grades and qualities in stores. Any instruction given by
Safety Officer in this respect shall be strictly followed.
Structural steel with surface defects such as pitting, cracks, laminations etc. shall be
rejected if the defects exceed the allowable tolerances specified in relevant standards. All
such rejected material shall be kept in designated quarantine area & subsequently
removed from store/site.
a) One dedicated unloading area or platforms should be arranged.

b) Rigid barricading should be provided around the area. Only authorized people relating

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to loading and unloading operation should enter the area.

c) Dedicated worker/flagman should be deployed to prevent unauthorized entry.
d) Banners and posters relating to loading and unloading work should be displayed.
e) Equipment, lifting machines, lifting gears involved in loading and unloading operation
should have TPI (third party inspection certificate) or EIPL client certification.
f) Only authorized operator should operate the machine & must be free of alcohol/drugs
intake. No operator shall be engaged whose age is below 58 yrs.
g) Loading and unloading should be done under the supervision of authorized signaler.
h) All the relevant PPEs should be used.
i) All the supervisors looking after the job should maintain good housekeeping to prevent
slip and trip hazard..
j) Tag line shall be used to guide suspended loads.
k) No person should be allowed to move under suspended load.
l) Cement shall not be stacked for more than 6 feet.
m) Support pads shall be provided while stacking similar items to avoid finger crush press
in between while handling.
8.3 MATERIAL TESTS

AIPAL shall submit manufacturer's quality certificate for the material supplied. Wherever
quality certificates are missing or incomplete or when material quality differs from
standard specifications, Materials shall be procure from approved vendors AIAPL/OWNER
shall conduct all appropriate tests as directed by TPI at approved test houses and submit
to TPI/Owner for approval. Materials for which test certificates are not available or for
which results do not tally with relevant standard specification, shall not be used and shall
be removed from stores/site.
8.4 CIVIL WORKS
8.4.1 SOP for Boring, Piling and Operation Of Tripod
a) Boring and piling zone should have barricading to prevent unauthorized access/entry.
b) 5 m. Exclusion zone around the rig should be done.
c) Piling rig should be tract into position under the supervision of competent person.
d) Unauthorized entry should be restricted into hazardous zone.
e) One dedicated person should be deployed to prevent unauthorized entry.
f) In an interruption of piling occurred the chisel needs to be removed, it should

Pages 10 of 21
be done under the supervision of competent person.

g) Piling rig should have third party inspection certificate or EIPL . Pile driving equipment
in use shall be inspected by a competent engineer at regular intervals not exceeding
three months. Also a register shall be maintained at the site of work for recording the
results of such inspections. Pile lines and pulley blocks shall be inspected by the
foreman before the beginning of each shift. For any excess wear or any other defect.
h) Where electricity is used as power for piling rig, only armored cable conforming to the
relevant Indian Standard shall be used and the cable shall be thoroughly
waterproofed.
i) Piles being hoisted in the rig should be so slung that they do not have to be swung
round, and may not inadvertently, swing or whip round. A hand rope shall be fastened
to a pile that is being hoisted to control its movement. While a pile is being guided into
position in the leads, workers shall not put their hands or arms between the pile and the
inside guide or on top of the pile, but shall use a rope for guiding.
j) If two pile drivers are erected at one place these shall be separated by a-distance
at least equal to the longest leg in either rig.
k) The frame of any rig shall be structurally safe for all anticipated dead, live or wind
loads. Whenever there is any doubt about the structural strength, suitable test shall
be Carrie out by the foreman and the results of the test recorded. Test pile or other
working pile-driving equipment shall be taken into use until it has been inspected and
found to be safe.
l) Pile drivers shall be firmly supported on heavy timber sills, concrete beds or other
secure foundation. If necessary to prevent danger, pile drivers shall be adequately
guyed.
m) Adequate precautions shall be taken to prevent a pile driver from overturning if a wheel
breaks.
n) Adequate precautions shall be taken by providing stirrups or by other effective
means, to prevent the rope from coming out of the top pulley or wheel.
o) When the rig is not in use, extra precautionary measures for stability, such as securing
them with minimum four guys, shall be adopted to prevent any accidents due to wind,
storm, gales, and earthquake. When not in use the hammer shall be in dropped position
and shall be held in place by a cleat, timber or any other suitable means.
8.4.2 Sop for Bar Cutting, Bending, Fixing, Welding And Gas Cutting.
a) The area should be rigidly barricaded.

b) Security/dedicated worker should be deployed to prevent unauthorized entry.
c) All the activity in the fabrication yard should be done under competent supervision.

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d) The yard should be proper house kept to prevent hazards like falling, slipping, tripping.
e) Welding activity should be done by the competent person and earthing should be
done for welding machines.
f) The electrical connection should be routed through 30mA sensitivity RCCB. Bare cable
insertion is strictly banned. Only industrial purpose plug sockets shall be used. Only
double insulated cable shall be used.
g) Gas cutting should be done under the competent supervision; IS standard flash back
arrester should be used to prevent accident like fire and explosion. Pressure gauge
shall be in working condition.
h) Gas cylinder should be handled safely & always stored in upright position. Oxygen & DA
cylinders shall be stored separately at least 6m away. Never roll cylinders on ground.
i) Fire extinguishers & sand & water buckets shall be kept nearby hot work area.
j) Poster should be displayed relating to the relevant hazards.
k) Everyone inside the yard should wear relevant PPEs like safety shoe, safety helmet,
face shield, ear plugs, and shoulder pads.
l) Mechanical handling inside the yard should be done under competent supervision.
m) Bar bending & cutting equipment’s shall have emergency stop button & adequate
guarding for rotating parts?
n) Only IS certified & tested cutting blades shall be used for bar cutting.
o) Gas cutters/ welders, bar benders/cutters shall be provided with ID cards to
prevent unauthorized operation.
8.4.3 Sop for Placing and Handling of Reinforcement Cage and Liner.
a) Placing and handling of reinforcement cage and liner should be done

under competent supervision/Lifting Supervisor/Rigger.
b) All the lifting machines and gears involved in mechanical handling must have TPI
certificate, or EIPL.
c) Only authorized operators should operate the equipment.
d) Load shall be properly secured to crane hook by a competent Rigger/Khalasi/Lifting
supervisor.
e) During the activity nobody should stand around the activity zone.
f) During operation nobody stand under the suspended load.
g) Tag line should be used for controlling accidental swing.
h) Safe working load of the equipments should not be exceeded. Crane’s operational Safety
devices shall be in working condition & not bypassed.
i) Suitable Hand gloves should be used while handling reinforcement cage & liner.

Pages 12 of 21
8.5 MECHANICAL WORKS
Fabrication shall be in accordance with IS 800:2007 Section 17. Fabrication shall be done
as per “Approved for Construction” fabrication drawings adhering strictly to work points
and work lines on the AIAPL same. The connections shall be welded or bolted as per
design drawings. Work shall also include fabricating built up sections. Prior to
commencement of structural fabrication, undulations in the fabrication yard, if any shall
be removed and area levelled and paved by AIAPL. Any defective materials used shall be
replaced by AIAPL at his own expense, care being taken to prevent any damage to the
structure during removal. Any faulty fabrication pointed out at any stage of work by
TPI/TPI/EIPL/Owner, shall be made good or replaced by AIAPL. Tolerance for fabrication
of steel structures shall be as per IS: 7215. Frequency of NDE shall be as per applicable
Coad &specifications.
Demarcate Bullet Fabrication area and clear the jungle by cutting off Trees & Bushes and
Fence by Temporary Barricading up to 3 Mtrs height all around.
8.5.1 Material Inspection, approval & Traceability
a) Raw Material (Structural Steel), welding electrodes/ consumables has to be inspected by

EPCC.
b) Invoice and respective MTCs has to be collected and verified by EPCC.
c) After inspection of EPCC the same shall be offered to Employer’s/Engineer’s
Representative/Inspector for approval.
d) Physical condition of material and dimensions will be verified randomly by EPCC,
Employer’s representative/Inspector.
e) Traceability of Raw Material with invoice and MTC has to be verified.
f) Heat/Batch no. written/embossed/stenciled/stickered over Raw Material shall be
matched with MTC.
g) Reference of MTC shall be mentioned in respective invoice or vice versa.
Documents of the parts being delivered shall comprise of following information.

 Quality documents
 Quantity of structure members.
 Position of member in the structure.
 Particulars of structures.
 Identification number etc.
8.5.2 Steel marking and surface preparation

a) Suitable platform is required for assembly and Welding.

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b) Due to higher thickness of plates, Distortion will take place while continuous welding
process will going on to arrest all the distortion it is very essential to make suitable
heavy support platform has to be placed at 1meter distance to prevent distortion due to
weld heat inputs so as to keep plates in perfect level and sequence shall be carried out
before start the welding.
c) Before start of welding, the entire member is locked properly by using extra support to
avoid distortion. After completion of welding, when the welded members cool down in
normal/room temperature the extra support will be removed.
d) For fit up of every new member, cutting edges of the web will be removed and the
fabrication platform needs to be cleaned properly by removing all the
spatters/slag/previous welding spot.
8.5.3 Cutting& Marking:

a) Raw materials shall be marked and cut to size by shearing, saw cutting, flame or plasma
cutting and include the allowances such as cutting, grinding, Cutting Allowances shall be
as follows-
1) Up to 6 mm: 2 mm
2) For 6-25 mm: 3 mm
3) For 25-63 mm: 4 mm
4) For 75-150 mm: 6-8 mm
b) Flame cut edges shall be cleaned to remove slag. Uneven edges shall be dressed by
grinding.
c) Gas cuts shall be smooth and regular in contour.
d) Cutting of plates by pug machine needs skilled and experienced operators to maintain
proper cutting edge. Also after one cut the next cut will be started in other side of the
plate to avoid distortion in cutting zone.
e) Marking on steel shall be done in accordance of shop drawing and cutting plan.
f) Code of marking over fabricated member shall be as follows-
Drg. No. / Mark No. / Part No. / Weight / Heat No.
This marking on members shall be done by hard punch.
g) Every separate member shall be plainly and permanently marked with paint to show
position and direction as necessary for each identification and correct placing.
h) Loose pieces of connection shall be attached to their respective members.
8.5.4 Fit Out of assembly/sub-assemblies.

a) Fitting shall be carried out after ensuring removal of burrs, notches, grinding of edges
wherever required.
b) Identification markings for mark no., drawing no. and other shall be carried out as per
the drawing/specification/approved QAP.
c) After completion of the fit out, Production shall check the job/assy./subassembly for
completeness, physical condition to ensure absence of surface defects. Production will

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also record the name of the fitter(s) for feedback, improvement and skill level
assessment.
d) IQC-Fit Up shall carry out inspection as per the drawing (drawing should have good for
manufacturing stamping by PPC/PMG- to ensure that that it is pertinent issue of the
drawing).
e) IQC shall prepare dimensional report and record dimensions, orientation of the child
parts, correct weld preparation etc.
f) After completion of rectification, assembly/sub-assembly shall be cleared/moved to
welding section.
g) Welding supervisor shall carry out welding using qualified welders and the procedures
which are appropriate to achieve desired welding quality.
8.5.5 Established Welding Area

Area is designated based upon minimum traffic from personnel, vehicles, and mobile
equipment. Area also has to be safe distance (based on client requirements) from
existing hazardous heads. Area also has to be safe distance from vegetation and any
other flammable material
8.5.6 Welding Steel Pipe

(Personnel Involved: Equipment Operator, Spotter, Welder, Welders Helper, and
Qualified Rigger)
a) Before work can commence, properly complete all Checks, work permits, safety tool
box meetings.
b) Equipment inspections will be completed by qualified personnel.
c) Establish the scope of work, and ensure everyone knows their specific job duty.
d) Spotter will maintain a safe buffer zone and inform the operator that it is safe for
work to commence.
e) Using proper lifting devices, supporting personnel will begin to rig up to the joint of
steel pipe.
f) The joint of steel pipe will be transported to established welding area.
g) Welder and helper will adjust pipe to make sure it is level and square.
h) Welders will begin to make their welding passes steel pipes. After each pass the
Welder’s Helper will grind and dress out the weld as needed. Once the last welding
pass is completed, the Welders Helper will use a buffing wheel to buff down the
weld.
8.5.7 Pre-heating
a) Fit-ups of members will be carried out by qualified fitters under the supervision of Fit-up
supervisors as per ITP/QAP/TS/Dwg.

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b) There will be inspection by QC team as per ITP/QAP/TS/Dwg and after clearance

welding will be started.
c) Preheat and Interpass Temperatures: Parts to be welded shall be preheated by means
of gas flames, or other means to bring to the specified preheat temperature the full
thickness of the base metal for a distance equal to the thickness of the part being
welded, but not less than 75mm from the point of welding.
d) Welding preheat temperatures shall be in accordance with AWS D1.1 and checked by
thermal chalk or Temperature Gun. The root run will be made by GMAW/FCAW for full
fusion and checked soundness of weld by NDT make sure that there is no defect in the
root. After that, SAW will be used for filling the groove in multi-layer. In multilayer
welding slags, spatter, other impurities etc. on each completed weld shall be removed
prior to the start of next layer.
e) For pre heating of long section, series of burners fitted in a suitable frame shall be
used to maintain regular heating in total area at a time. LPG will be used as fuel for
heating burner.
f) Thermal chalk or temperature Gun will be used to check the required temperature
when heating process is going on.
g) 13.6 WPS and PQR will be submitted for approval for following welding process-
SMAW, GMAW, 3. SMAW + SAW
8.5.8 Inspection & Testing:

a) The stage inspection shall be carried out as per approved ITP.
b) The dimensions of weld structural members shall be within the project specification
(AWS D1.1M)
8.5.9 Transportation
a) After final shop acceptance and marking, the item shall be loaded for
transportation. Fabricated items must be protect during loading and unloading.
Proper lifting devices shall be used for loading, in order to protect items. Loading
and transportation shall be done in compliance with transportation rules.
b) The small parts such as fin-plates, gussets etc. shall be securely tied with wire to
their respective parts. Bolts, nuts and washers shall be packed and transported in
crates, marked in at least 2 places with water resistant paint.
8.5.10 BULLET ERECTION

(Personnel Involved: Equipment Operator, Fitter, Grinder, Welder, Welders Helper,
and Qualified Rigger)
a) Before start of erection all crane & Hydra & other lifting equipment's shall be ensured
of having proper test certificates/Checklist so that it can work safely for the required
load of the member.

Pages 16 of 21
b) Checklist must be filled by operator regular basis. Operating area of Crane shall be
barricading.
c) Storing & Handling of bullet shall courses shall be done in a controlled manner to
avoid excessive stress & any damage.
d) Proper safety precautions shall be taken before & during the erection work each
worker shall be trained for precaution taken for erection jobs.
e) The framework must be sufficiently braced to prevent wind damage.
f) Steelwork shall be hoisted and erected in position carefully, without any damage to
itself, other works and injury to workmen.
g) During erection, the steelwork shall be securely bolted or fastened. Wherever
necessary temporarily braces shall be provided for all loads to be carried by the shell
during erection, including those due to erection equipment and its operation.
h) All field assembly and welding shall be executed in accordance with the requirement
for shop assembly and welding.
i) A “Fit for Use” notice will be present on the scaffold. Damaged scaffolding is not to be
used.
j) Scaffolding higher than 2 meters must be bonded/ fixed to the building.
k) Scaffolding must have bottom stand plates. Scaffolding higher than 2 meters must
have handrails around.
l) All scaffolding material shall be stored in an orderly manner and the storage area
shall be properly house kept.
m) The handrails will be at least 900mm high and Guard rails must be installed to
prevent workers from falling if it is not reasonably practical to use Personal Protective
Equipment.
n) Toe plates of at least 100mm high must be installed if scaffolding is higher than 2
meters.
o) Cross support must be used on scaffolding. No tools or equipment is allowed to be
thrown/passed from one level to the next.
p) A safe barricade must be put up if scaffold is higher than 3 meters.
q) Scaffolding shall be erected on the request for erection from the contractor and shall
be kept in place for the entire duration of works and shall be dismantled after request
for dismantle from the contractor.
r) All scaffolding must be inspected before use and after rain.
s) The Construction Manager or his nominated sub ordinate will conduct weekly
inspections on scaffolding.
8.5.11 Inspection and Testing of Welds
The method of inspection shall be according to the relevant applicable codes & standards
and to be carried out during all stages of fabrication & erection, to check the conformity
with the relevant specifications and IS codes / standards. Defects & faults occurring at the
surface such as blow holes, exposed porosity, unused welds, surface cracks in the weld
metal etc, profile defects like excessive convexity or concavity, overlapping, incomplete

Pages 17 of 21
filled grooves, excessive penetration heads, root grooves etc. Distortion due to welding
i.e. local shrinkage, camber, bowing, twisting, rotation etc. & other dimensional errors,
eccentric angular & rotational miss.
8.5.12 Water filling and hydro test of the Bullets.
a) After completion of the erection, welding and NDT the following points shall be
checked before testing.
b) All the mechanical activities completion in respect of the drawing, Specification and
code requirements.
c) Finally mechanical clearance from the Engineer-In-Charge shall be taken before Hydro
test in approved format.
a) Clearance of QC In charge also shall be taken in the approved format.
b) Each bullets shall be hydro tested as per the hydro test procedure, the testing medium
shall be clean water.
c) During testing, inspection report shall be filled and TPI/EIPL signatures shall be taken.
d) After completion of test water shall be emptied out as per the hydro test procedure.
8.5.13 Surface Preparation and painting of Bullets
 Storage of Paints
a) Paints shall be stored in accordance with any local laws or regulations, or both. In
principle, paints shall be stored in an independent warehouse/container. However, only a
short period of outdoor storage may be allowed when provisions for weather protection
and provisions for cover from direct sun light are made.
b) Paint shall not be stored together with other dangerous and inflammable materials.
c) All paints shall be stored in a tightly sealed condition, and never stored in, or exposed to
the open air.
d) The oldest paints shall be used first after they have been delivered from the
manufacturer’s warehouse.
e) Material Safety Data Sheets shall be kept in “MSDS” Box available with the paint container.
Paints and Thinners shall be stored in well ventilated building at storage temperature as
recommended in manufacturer’s data sheet.
f) Temperature of inside the Paint container must be maintained as per MSDS.
g) A paint storage container shall be with good ventilation, air conditions, temperature
reading device and its log sheet/book, fire extinguisher, warning signs such as “ No
Smoking”, “No Open Flames” and “Storage of Flammable Materials”, etc.
h) Storage condition of paint materials should be monthly jointly inspected with client.

Pages 18 of 21
 Surface Blasting
a) Abrasive blast cleaning method shall be used for preparation of surface.

b) The surface shall not be blasted when the surface temperature is less than 30 °C above
the dew point, when relative humidity is greater than 85%, or when there is possibility that
the blasted surface will be subject to wetting.
c) Oil, Grease and other contaminants shall be removed from the steel surfaces by solvent
cleaning (SSPC-SP1) prior to blasting of steel surface. Compressed dry air will only be used
to blow-off or de-dust the blasted or primed or intermediate applied surfaces prior to any
coating application. All cleaned surfaces shall be primed with in 4 hours to avoid
contamination. If the prime coat cannot be applied with in 4 hours, the surface
preparation work for the surfaces shall be repeated, before Priming.
 Application of Paint
a) Application equipment such as spray equipment shall be adjusted and controlled to

produce a smooth, uniform without orange peel or dry overspray at all times.
b) The application can be made by one or a combination of the methods such as brushing
and airless spraying. Written company approval should first be secured prior to usage of
brush or roller if needed to be substituted for spray application.
c) Each coat shall be applied at the dry film thickness required range in the coating system as
described procedure. The maximum dry film thickness shall be in accordance with the paint
manufacturer’s recommendations.
d) Application personnel shall have sufficient working experience in coating works.
e) The distance between spray gun and the surface is usually 300mm to 400mm; however
the distance can be adjusted in reference to be requirement of the paint material and or
manufacturer’s instructions. The trigger of the gun shall be pulled fully open during
spraying and be kept on right angle.
f) Re-coating intervals and temperatures specified on the paint Manufacturer in the Data
Sheets should be strictly followed.
g) Paint finishes should have no sags, runs, or defects and should have uniform appearance.
h) Coating Material shall be used as per company approval in engineering specification for
blasting and painting. The paint shall be contained in a tightly sealed container.
i) The coating material shall be mixed and applied in accordance to the coating
manufacturer’s latest published data sheet. These data sheet shall be present at the job
site during blasting and coating activity.
j) Blasted weld joints and shell surface and damaged area may be painted by airless spray.
k) Power tool cleaned weld joints and damaged area shall be painted by brush or roller. Care
shall be used to achieve required and specified film thickness.
l) Final DFT shall be checked and inspection report shall be prepared by field QC Engineer.

Pages 19 of 21
8.6 CONSTRUCTION OF RETAINING WALLS AROUND THE MOUND

a) Engineer In charge shall verify all the mechanical and electrical works pertaining to bullets
and provide Clarence to construct the retaining walls as per the approved construction
drawings.
b) Bar bending and fixing shall be done as per the approved drawings. Necessary scaffoldings
shall be used to fix the reinforcement steel.
c) Field Engineer shall ensure the fixing of reinforcement steel shall be in accordance with the
project specifications and general standard procedures.
d) All formwork material in site shall be visually inspected for straightness, finish and defects
prior to use.
e) Setting out shall be done by the Surveyor or Site-Engr. Prior to proceeding with formworks.
f) Each type of the form work for the retaining wall slab shall be erected as per approved shop
drawings.
g) Material shall be protected as necessary from the elements during storage and transportation.
h) Care shall be taken to ensure that any formwork system is installed and supported correctly
when applied on site, visual inspection shall be carried out by the Project Manager. Use for
each element to ensure support provided is adequate for actual site condition.
i) Inspection shall be raised for the Consultant inspection and approvals before proceeding to
concrete pouring
j) Ensure provision of appropriate cover to new rebar.
k) Placement of concrete into appropriate locations will be aided by an assembling shooter to the
actual pour location.
l) Concrete vibration will be achieved with the aid a poker vibrator.
m) Prior to casting of structural concrete, the temperature of concrete will be tested on site and
slump will be taken to check in accordance with design class of the concrete.
n) Concrete samples will also be taken of the replaced concrete as per Eng specification to
ensure design strength be achieved.
o) Concrete will not be placed in any section of the work until all preparations for that section
have been inspected and approved by EIPL/TPI.
p) AIAPL shall make available samples of concrete cubes for strength testing at 7 and 28 curing
days.
q) AIAPL will furnish Client with Material data sheet (MSDS/MTS) of all concrete additives.
r) Proper Curing shall be done as per the recommendation of Civil Structural Engineer.
8.7 MOUND FILLING
a) After completion of the mechanical works and retaining Wall the spaces left in the pits and
trenches shall be cleared of debris, brickbats, mortar droppings etc. prior to the start of
backfilling.
b) When directed by the engineer Incharge/Project Manager coarse river/crushed sand shall also
be used filling material. Soils such as black cotton soil, clay and mixtures having excessive
swelling characteristics shall not be used as filling material.

Pages 20 of 21
c) Filling material shall be spread in layers of thickness approx. 200 mm and compacted by 4
passes of 10 T vibratory roller. Water shall be sprinkled intermittently.
d) Each layer shall be compacted before laying the succeeding layer. Surface voids in each layer
shall be filled by crusher dust/Sand.
e) When instructed by the Engineer-in –Charge, controlled backfilling shall be done. Material
shall be spread in un compacted layers of thickness approx. 200 mm and rolled by
adequate number of passes of a 10T vibratory roller so as to achieve 90% of the maximum
Proctor density of the fill material.
f) Each compacted layer under controlled backfilling shall be tested for degree of
compaction. One test per 100 sq. m of compacted area shall be done for determining field
dry density of the compacted layer. Alternate layers shall be tested as per Modified
Proctor Density Test and Sand Replacement Method respectively. Records of field density
test shall be maintained in the format approved by Engineer-in-charge.
g) Sand filling shall be continue up to top of bullets as specified in the construction drawings.
h) Once the Filling reaches to the desired height necessary HDPE/PVC, Geo textile sheets and
Drain Pipes shall be laid and further filling shall be done by following the steps given in
mound GA drawing.
i) Finally Paving shall be done through the surface of Mound as per the construction drawing.
9.0 FINISHING AND TIDYING UP
Whenever a section of the work is completed the area will be cleaned and all waste
immediately removed from site.
10.0 QUALITY ASSURANCE & CONTROL
a) Ensure necessary testing/checking is done as per approved ITP.

b) Daily records of quality checks shall be maintained.
11.0 INSPECTION AND TEST DOCUMENTS
Review test and Inspection documents
12.0 CHECK LIST
1. Preparation of checklist location & axis wise

2. All check list items shall be completed mentioning date of completion.
3. Check list incorporating Client comments are to be verified by TPI/Client.

Pages 21 of 21
13.0 HEALTH SAFETY AND ENVIORNMENT.
Proper PPE is to be used by the involved person. All measuring, lifting and test equipment
and materials used must be well maintained.
14.0 DOCUMENTATION AND RECORDS
a) JSA - Work Permits (If Required)

b) Equipment Inspection Forms
c) Client Required Formats

Pages 22 of 21

Method Statement For Construction of LPG Mounded Storage Bullets

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Method Statement For Construction of LPG Mounded Storage Bullets

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METHOD STATEMENT FOR CONSTRUCTION OF LPG

MOUNDED STORAGE BULLETS.

CLIENT EAST INDIA PETROLEUM PVT LTD

GLOBE GAS EQUIPMENT AND INDUSTRIAL

CONTRACTOR AMUNRA INFRATECH AND AGRITECH PVT LTD

LPG STORAGE CAPACITY EXPANSION PROJECT BY CONSTRUCTING

METHOD STATEMENT FOR CONSTRUCTION OF LPG MOUNDED

00 01.03.2024 For Approval

Prepared By Reviewed By Approved By

2.0 SCOPE ........................................................................................................................................................................ 4

3.0 TERMS & DEFINITION ......................................................................................................................................... 4

4.0 REFERENCE CODES AND STANDARDS. ......................................................................................................... 4

5.0 SITE SAFETY ARRANGEMENTS ......................................................................................................................... 5

6.0 RESPONSIBILITIES .............................................................................................................................................. 5

8.0 METHODOLOGY ..................................................................................................................................................... 9

00 01.03.2024 For Approval

Prepared By Reviewed By Approved By

8.5.10 BULLET ERECTION ...................................................................................................................................... 16

10.0 QUALITY ASSURANCE & CONTROL ........................................................................................................... 21

11.0 INSPECTION AND TEST DOCUMENTS ...................................................................................................... 21

12.0 CHECK LIST ....................................................................................................................................................... 21

13.0 HEALTH SAFETY AND ENVIORNMENT. .................................................................................................... 22

14.0 DOCUMENTATION AND RECORDS ............................................................................................................ 22

00 01.03.2024 For Approval

Prepared By Reviewed By Approved By

3.0 TERMS & DEFINITION

4.0 REFERENCE CODES AND STANDARDS.

b) IS: 7293-1974 (Safety code for working with construction machineries)

c) IS 3764 -1992 Code of safety for excavation work

e) IS 7293- 1974 Safety code for working with construction machinery

g) IS 13416-Part-1- 1992 Recommendations for preventive measures against

00 01.03.2024 For Approval

Prepared By Reviewed By Approved By

i) Other Standards and Codes of Practice.

5.0 SITE SAFETY ARRANGEMENTS

00 01.03.2024 For Approval

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a) Shall be responsible for providing resources for the Implementation of the MS

a) Shall Report to RCM.

a) Shall Report to RCM.

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a) Participate in Safety Tool Box meeting and JSA.

00 01.03.2024 For Approval

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 QUALIFIED WELDER /WELDERS HELPER

a) Participate in Safety Tool box meeting meeting and JSA.

a) Participate in tailgate meeting and JSEA.

 LEAD SAFETY ENGINEER:

7.0 CONSTRUCTION DRAWINGS:

Construction drawings shall be prepared by AIAPL & thoroughly checked, stamped

00 01.03.2024 For Approval

Prepared By Reviewed By Approved By

8.1 MOBILIZATION OF MATERIALS, SITE SETUP AND MOVEMENT OF VEHICLES,

a) Access of transportation of materials should be checked prior to commencement of work.

8.2 RECEIPT AND STORING OF MATERIALS

a) One dedicated unloading area or platforms should be arranged.

00 01.03.2024 For Approval

Prepared By Reviewed By Approved By