1500 MTPD Phosphoric Acid plant 4500 MTPD Sulphuric Acid plant METHOD STATEMENT

Project

1500 MTPD Phosphoric Acid plant 4500 MTPD Sulphuric Acid plant

Method Statement No CIVIL ELECTRICAL MECHANICAL INSTRUMENTATION

Prepared by Section Engineer Site Manager

Reviewed by Construction Manager

Safety Release Safety manager

QA/QC Approval QA / QC Manager

Approved by Project Manager

Date Name Date Name

METHOD STATEMENT FOR ERECTION AND INSTALLATION OF AGITATORS Rev-0

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1500 MTPD Phosphoric Acid plant 4500 MTPD Sulphuric Acid plant METHOD STATEMENT

1. INTRODUCTION The purpose of this Method statement is to explain the erection, installation of Agitator for tanks and vessels in Phosphoric acid plant. 2. Function and location, General Description, Scope of Work a) Function and Location The function of the agitator is to maintain homogeneity in the fluid by creating turbulence. b) General Description Generally Agitator consists of a big size shaft with a blade which was installed vertically over the tanks, and it will be coupled to a motor through a gearbox. c) Scope of work Installation of agitator over the tank and erection, alignment, coupling of gearbox with motor. Erection of blades by BOLTING / WELDING For the following items 1. 223-A-01AB ------ FILTER CAKE WASH TANK AGITATOR 2. 223-A-02 --- ------FILTARATION SUMP AGITATOR 3. 225-A-01 --------- CONCENTRATION SUMP AGITATOR 4. 225-A-02ABCD ---FLOURINE SCRUBBER 1 SEAL TANK AGITATOR 5. 225-A-03ABCD ---FLOURINE SCRUBBER 2 SEAL TANK AGITATOR 6. 227-A-01---------- ACID SUMP AGITATOR 7. 231-A-01---------- WEAK ACID MATURATION TANK AGITATOR 8. 231-A-03AB------- WEAK ACID STORAGE TANK AGITATOR 9. 231-A-04--------- -WEAK ACID SUMP AGITATOR 10. 232-A-01AB-------CONCENTRATED ACID MATURATION TANK AGITATOR 11. 232-A-04---------- CONCENTRATED ACID STORAGE SUMP AGITATOR 12. 232-A-05---------- POST PRECIPITATE SLUDGE SUMP AGITATOR 13. 233-A-01---------- EFFLUENT TANK AGITATOR 14. 233-A-03---------- WASHING STATION SUMP AGITATOR 15. 234-A-01---------- FLOUSILICIC ACID STORAGE SUMP AGITATOR 3. Related Documents 1. Vendors manual for installation of agitator. 2. Release certificate for the agitator support structure.
METHOD STATEMENT FOR ERECTION AND INSTALLATION OF AGITATORS Rev-0

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1500 MTPD Phosphoric Acid plant 4500 MTPD Sulphuric Acid plant METHOD STATEMENT

3. Release certificate for the tank. 4. AFC Drawings. 5. I.T.P 4. Required Material Testing, during and before work 1. Checking the agitator parts for completeness as per vendor instruction. 5. Environmental and Safety 1. All the persons involved in this activity will be with proper PPEs. 2. Proper scaffolding will be provided if working at height more than 1.5 meter. 3. TOOL BOX talk will be conducted daily at the starting of activities. 4. Proper crane selection for erection purpose with 70-80% efficiency. 5. Proper disposal of Oil/grease waste after applying lubrication. 6. All the lifting tools are of certified.

6. Detail of work supported with sketches and with special highlight for details 1. Erection and welding of Agitator support Plate. 2. Inspection of welding. 3. Preparation of Agitator shaft for erection. 4. Alignment and coupling of gear box to the Agitator shaft. 5. Surface preparation of Agitator support plate i.e. grinding, finishing etc. 6. Positioning of Agitator shaft near to the tank. 7. Positioning of crane for erection purpose. 8. Erection of Agitator shaft over the support plate. 9. Tightening of bolts. 10. Installation of anti vibration elements if applicable 11. Checking the verticality of the shaft. 12. Tightening of the bolts to the required torque. 13. Check for free rotation of shaft. 14. Check the verticality of the shaft. 15. Erection of Motor and coupling with the gear box. 16. Alignment of motor with gear box. 17. Check the free rotation of shaft. 18. Erection of scaffolding inside the tank.

METHOD STATEMENT FOR ERECTION AND INSTALLATION OF AGITATORS Rev-0

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1500 MTPD Phosphoric Acid plant 4500 MTPD Sulphuric Acid plant METHOD STATEMENT

19. Erection and bolting of Agitator Blades to the shaft (WLEDED / BOLTED TO BE COFIRMED). 20. Alignment of Blades 21. Bolt tightening to the required torque. 22. Electrical and instrumentation cabling. 23. Check for the direction of rotation. 24. Grease and lubrication applications 25. Release for commissioning. 7. Curing and Weather Protection 1. The motor gear box may be covered properly for to protect from dust and moisture. 8. Show hold points for internal and external required inspection including specified tests on products. 1. Refer to I.T.P 9. Construction Equipment to be used , including standby Arrangement 1. Mobile crane for erection purpose and arcane with equivalent or more capacity crane are available at site. 10. Lifting equipment, involved (where applicable, crash, tower cranetest and location). 11. Tools and associated other contractors Apparatus involved in this NOT APPLICABLE 12. Manpower involved and Trades, who does what and when. 1. Supervisor for Tanks: - He monitors all the activities associated in erection and installation of Agitator. 2. Supervisor for Equipment erection:-He takes the 3. Riggers: - These will involve in handling the plates for erection, alignment etc. 4. Millwright Fitter: - He takes the fit up of nozzles and other pipe supports and structural items. 5. Welders: - These will do all the welding operations. 6. Grinders: - These will do grinding operation for the tank. 7. Helpers: - These are the general helpers to skilled workers involving in job. 8. Crane operator: - These will operate the crane.
METHOD STATEMENT FOR ERECTION AND INSTALLATION OF AGITATORS Rev-0 Page

1500 MTPD Phosphoric Acid plant 4500 MTPD Sulphuric Acid plant METHOD STATEMENT

9. QA/QC Team: - These will guide the job for required QA/QC levels.

13. Work Schedule Requirements and Timing for This work. 1. For this job the daily regular work hours will be 10 hrs excluding lunch time. 2. From 7-00Am to 6-00PM. 3. On weekly halfs required core skilled workers like welders will be engaged if necessary. 14. Training and Orientation for the Team 1. For all the team members TOOL BOX TALK will be conducted at the beginning of activity on daily basis. 2. The scaffolding team will be of trained and certified. 3. The crane operator will be of trained and certified. 4. The riggers involved will be of trained and certified. 5. Regular monitor of welders and if necessary training will be given regularly. 15. Tests on Systems (QA /QC ) 1. Checking the verticality of the agitator shaft. 2. Check the alignment of Agitator base plate. 3. Check the alignment of the coupling as per required tolerances. 4. Tightening the Nuts and Bolts with the proper torque. 5. Refer I.T.P 16. Logistics involved if work is expected to extend beyond normal working hours. 1. Lighting while working at night. 2. Shade protection while the wind velocity is very high.

17.

Annexes and sketches lists.

METHOD STATEMENT FOR ERECTION AND INSTALLATION OF AGITATORS Rev-0

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AGITATOR SUPPORT STRUCTURE

AGITATOR SUPPORT STRUCTURE

TANK SHELL

AGITATOR SUPPORT PLATE

AGITATOR SUPPORT STRUCTURE

AGITATOR SUPPORT PLATE AGITATOR SUPPORT STRUCTURE

AGITATOR SUPPORT PLATE

AGITATOR BASE PLATE

AGITATOR SHAFT

AGITATOR BASE PLATE AGITATOR SHAFT

AGITATOR SHAFT

AGITATOR BLADES

AGITATOR SHAFT

AGITATOR BLADES

AGITATOR GEARBOX & MOTOR

AGITATOR SHAFT

AGITATOR BLADES