MS for water filling test of storage tank

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B 03-Sep-19 L.K.Quang S.I.Yoon I.S.Jeon REVISED FOLLOWING THE OWNER’S COMMENT

A 29-Jul-19 L.K.Quang S.I.Yoon I.S.Jeon FOR APPROVAL

Rev Date Prepared Checked Approved Details of Revision

1 PURPOSE 3

2 SCOPE 3

3 GENERAL 4

4 ORGANIZATION CHART 4

5 REFERENCES CODES AND STANDARD 5

6 TESTING METHOD 5

6.1 PREPARATION 5

6.2 FILLING TEST PROVISION 6

6.3 FILLING OPERATION 7

6.4 AFTER FILLING TEST 8

6.5 MANPOWER 9

6.6 EQUIPMENT & TOOLS 10

7 ENVIRONMENT, HEALTH AND SAFETY 10

7.1 SAFETY REGULATIONS FOR EXECUTION VEHICLES: 10

7.2 FOR PARTICIPANTS: 11

7.3 ELECTRICAL SAFETY: 11

7.4 CONFINE SPACE WORK: 12

7.5 SAFETY FOR WORKING AT THE HIGH LOCATIONS: 12

7.6 SAFE USE OF LIFTING EQUIPMENT IN ASSEMBLY & PREPARATION WORK FOR TESTING: 13 7.7 TRANSPORTING MATERIALS AND EQUIPMENT: 14

7.8 SAFETY PRECAUTIONS ON USING EXECUTION EQUIPMENT AND TOOLS: 15

7.9 INDUSTRIAL HYGIENE, ENVIRONMENTAL PROTECTION: 16

8 RISK ASSESSMENT AND JSA (JOB SAFETY ANALYSIS) 17

8.1 RISK ASSESSMENT 17

8.2 JSA (JOB SAFETY ANALYSIS) 26

RECORD OF REVISION

1 PURPOSE

The purpose of this method statement is to control and measure any changes on the body andfoundation level and to prove the integrity of the storage tank body of Storage in Nghi Son 2BOT Thermal Power Plant with safety, quality and consistently The procedures brieflydescribes the general method in performing the water filling test after completing all therequirements needed on the specification and applicable code & standards

This method is made for following storage Tank installation guidance:

a Potable water storage tank

b Demi water storage tanks

c Plant & Fire Water Storage Tanks

d Condensate water storage tanks

e Light diesel oil storage tanks

f Absorber towers for FGD system

g Makeup water tank for FGD system

h Limestone storage tanks for FGD system

i Emergency storage tank for FGD system

j Gypsum slurry storage tank for FGD system

k Filtrate tank for FGD system

l Any Tank where is construction in the site would be applied in this MS

B

3 GENERAL

This method statement is applied for water filling test of Field tank only If there are anymatters not mentioned in this procedure, then that will be carried out according to relativedrawings and standards

 Project: Nghi Son 2 BOT Thermal Power Plant uses

technology of coal firing with capacity 2x600 MW

 Country: Socialist Republic of Viet Nam

 Plant type: Coal Fired Thermal Power Plant

 Fuel: Imported Coal

 Site: Thanh Hoa Province

 Owner: NS2PC

 Main Contractor: Doosan Heavy Industries Viet Nam

 Subcontractor: Lilama Corporation

Organization Chart of LILAMA Corporation

5 REFERENCES CODES AND STANDARD

Project Specification requirement;

 For Construction Drawings

 Contract Quality Plan

 Project EHSS Management Plan

- In preparing the Tank for testing, all temporary attachments welded to the exterior ofthe tank shall be removed such as alignment clips, fitting equipment, stabilizers &lifting lugs and any noticeable projections of weld metal shall be ground smooth withthe surface of the plate

- All temporary attachment welded to the interior of the tank, including the shell, roof,tank bottom, roof columns and other internal structures shall be removed and anynoticeable projections of weld metal shall ground smooth

- Permanent attachment are items welded to the shell that will remain while the tank is inits service This include items such as wind girders, stairs, gauging system, davits,walkways, tank anchor, supports for internal items such as heating coils and otherpiping supports, ladders, supports welded to the shell, exterior piping support,grounding clips, insulation rings and electrical conduit and fixtures

- Un-floating material as scaffolding frame for painting work would be kept during waterfilling test

- Furnishing, laying and removing all lines from the water source tie-in location and tothe water disposal point as prescribed

- Checking the wind girders for proper drainage during or following the water filling test

If water is retained, additional drainage shall be provided and subject for approval

- Hydrostatic test package shall be submitted for approval before water filling work.

- The water used for the filling test shall be fresh water as recommended The watertemperature may be at less than ambient temperature

- Interior of the tanks shall be cleaned

- Roof manhole (as vent) shall be open during filling and emptying operation (VeryImportant)

- All nozzle below the maximum filling level will be blinded with blanks able to standthe pressure in the respective point - in case there are no isolation valves

- Welding joint will not be painted and cleaned to shining metal condition before the test

- Appurtenances inside of the tanks such as coils or pipe supports shall have beeninstalled

- Settlement monitoring devices shall be provided prior to filling water

- Permanent or temporary tank level gauges shall be provided to monitor the water level

- Cleaning surfaces (internal/external) completely and pipe and fittings should becarefully cleaned before assembly and any loose jointing material should be removed

- Installing of valves and fittings

- Temporary water piping and pumps for filling and discharging shall be installed fromthe tank to water supply point and disposal point

- Water filling test shall be commenced and finished during day lights hours And thewater temperature should be ambient temperature

- Test chart (time & levels) shall be provided

B

B

DRAINAGE TO DISPOSAL AREA

LEVEL METER

WATER TANK

(Supply water by water truck)

DRAINAGE TO DISPOSAL AREA

Plan for Water Filling Test of Storage Tank

a Filling may continue while the elevation measurements are being made as long as thechange in water elevation for a set of readings does not exceed 300mm (12in) Unlesswaived on the data sheet, below paragraph shall make shell elevation measurements inaccordance with the API 650 standard as following:

- Shell elevation measurements shall be made at equally-spaced intervals around thetank circumference not exceeding 10 m (32 ft) The minimum number of shellmeasurement points shall be eight

- Observed elevations shall be referred to a permanent benchmark The level

instrument shall be set up at least 1 ½ times tank diameter away from the tankwhen tank elevation readings are taken Six sets of settlement reading arerequired:

 Before start of the water filling test

 With tank filled to 1/4 test height (+/- 600mm {2 ft} )

 With tank filled to 1/2 test height (+/- 600mm {2 ft} )

 With tank filled to 3/4 test height (+/- 600mm {2 ft} )

(Test height is the maximum design liquid level)

 At least 24 hrs after the tank has been filled to the test height, Owner/OE will

be invited for inspection and access will be provided for visual examination ofall welds This 24 hrs period may be increased to duration specified on the data

B

sheet if it only requires for condition such as:

o The tank is the first one in the area

o The tank has a larger capacity than any other existing tank in the area

o The tank has a higher unit bearing load than any other existing tank inthe area

o There is a question regarding the rate or magnitude of settlement thatwill take place

 After tank has been emptied of test water

b If settlement measurements are specified, any differential settlement greater than 13

mm per 10 m (1/2 in per 32 ft) of circumference or a uniform settlement over 50mm(2 in.) shall be reported for evaluation

c Internal bottom elevation measurements shall be made before and after water fillingtesting Measurement shall be made at maximum intervals of 3 m (10 ft) measured ondiametrical lines across the tank The diametrical lines shall be spaced at equal angles,with a maximum separation measured at the tank circumference of 10 m (32 ft) Aminimum of four diametrical lines shall be used

d All elevation measurements shall be included in document package

a Gauge measurement and visual inspection shall be assessed and reported together with

measurement records, including gauge plots relative to water levels The measurementrecords shall be issued to the engineering manager and company and the engineeringmanager shall review and interpret measurement records if anomalies are happened, theengineering manager shall instruct the site immediately to stop the water filling, and shalldiscuss with Company.

b The tanks shall be completely drained and thoroughly dried immediately after waterfilling test If necessary during discharging the test water, put the inflatable boat on thetest water and brushing the wall by using the boat as water level goes down

c After the tanks were emptied, surfaces of the bottom plates shall be cleaned All sand,sludge and rubbish shall be removed from the tanks bottom

d After final draining and drying, brushing, broom or vacuum cleaner shall clean surface ofthe tank bottoms

e Furnishing and disposing of the water for testing the tank from the water source tie-inlocation as designated

Base on the progress and manpower for water filling test of tanks will arrange as follow:

5 Scaffolding men 4

6.6 Equipment & tools.

Equipment and instrument table for testing work

7.1 Safety regulations for execution vehicles:

- All connection details for elevation, combination and installation before, during andafter production must be accepted in accordance with regulations on ISO qualitymanagement system

- Execution and combination equipment at the site must be checked, maintained, tested in accordance with regulations on elevation equipment safety, the inspectioncertificate must be still effective

load-7.2 For participants:

- Site leader decides the list of team leaders and staff involved in the work and onlythose persons are entitled to involve in lifting and installation of equipment (mainbeam, steam drum ) and must comply the following regulations:

o Being trained in execution process, safety measures and being tested, issued

safety cards by competent agencies

o Being medically examined by competent medical agencies and issued certificate

of good health before working

o Being provided with a full range of equipment and personal protective equipment

in line with the working conditions (shoes, protective clothing, hard hats, gloves,anti-dust masks, seat belts) and bring all of them when working

o Being strictly forbidden to use alcohol, beer and other drugs before and during

working hours as well as at the site

o Being only traveled in their working area, prohibited to travel to other areas

outside their execution premises when they have yet been permitted

- The equipment and supplies have strict requirements on safety when put to use in thefield, such as cranes, electric hoists, oxygen bottle, gas cylinders, pneumatic cylinders

in the construction process must be licensed to use issued by the competent State

- The equipment and materials on the site must be collected and fully protected whenthe working hours finishes

- Preparing enough drinking water for workers in the working process

- Necessary barricades, plates at the execution site must be arranged and guarded toprevent people from entering into dangerous areas

- In the working process, workers frequently expose to the power source through themachinery, equipment and tools for production Therefore, it is highly required thatpeople must comply with strict regulations on power as follows:

o Only related persons are allowed to use and operate electrical-run equipment and

machinery

o Cabinets and appliances are certainly earthed.

o The power distribution cabinet must have intermediate switches, lid and full

safety equipment such as circuit breaker, fuses, arc devices.

o All power cable system and wires for execution must be good insulated, wiring

positions must be arranged neatly so that travel, material and equipmenttransportation cannot be prevented

o While working in the dungeon and cellar, only using the device with the voltage

 36V

o When the machinery and equipment is stopped working or stopped for repairs, it

is vital cut off all power source to the machine While repairing, it is necessary tohang signal "No opening power source, it is in repair."

o When electricity-related work is conducted, it is vita to appoint those having

power expertise Each team must have 02 or more

o The circuit breakers for supplying power for execution are placed in a covered

box to protect against rain and on the stand > 0.7 m above the ground underconstruction

- Specific detail safe work method for confine space works (inside the pipe andassociated with hot work) shall be provided and added

- MSDS of any chemical shall be provided and added

- For emergency rescuing before working must be sure all of workers who take part intask must be known and training about Confined space work and method for rescuing

in case emergency and ERT persons should be available during workers are workinginside confined space And must be installed tripod and pulley and rope for rescuing incase emergency All worker must be worn safety harness with D ring 02 watchmanmust be available inside and outside of coal silo and communication in/out by walkie –talkie

7.5 Safety for Working at the high locations:

- When working at a height of 1.8 meters or more or less than 1.8 m but havingobstacles below, everyone should strictly comply with the following rules:

o Only allow people having enough health to climb (listed in the certificate ofhealth issued by competent authorities) for working

o If anyone is found using alcohol, beer and other stimulants, they are prohibited

from working and taken away from the working area immediately

o Workers wear tidy clothes (protective clothing, hats with straps, protective shoes).

o All equipment and operation location of workers must be absolutely insulated.

o Wearing seat belts, which are checked by functional departments and load-tested

before putting into use

o Seat belts are definitely hooked, reliability (Lifeline as shown in the figure),

position for hooking belts must be higher than or equal to 2/3 the height of theperson to ensure convenience in working

o Electric welder and oxyacetylene welder use leather belts.

o Tools for the execution must be neatly placed in boxes, free from dropping down.

o Do not throw materials and tools from bottom to top and vice versa.

o Around the working location, it is necessary to stretch wire and hang signboard

“Prohibit people to travel” in a radius of 5m

o When travelling in the operation floor with high danger, it is vital to stretch wire

or cable to hook safely

o It is vital to cover the working platform to prevent waste materials from falling in

the working process and industrial hygiene

7.6 Safe use of lifting equipment in assembly & preparation work for testing:

- Operator of lifting equipment must be expertise, skilled and granted training certificate

by legal training establishments

- Be trained in the safe operation of the lifting equipment and issued card by thecompetent authorities

- Must have been fully equipped with personal protective equipment in line with thework

- Complying with shift hand-over process, before they control machines, they mustcheck whether safe equipment (such as brakes, brake ratchet ), control structure aresafe or not

- During operation, they must pay attention to the alarm clock: load (bearing andallowed) and flip torque of lifting equipment If the alarm clock shows 80% load ormore, they must report to the direct leader to assign observers to see balance of liftingequipment, materials and they must perform each operation only, not combine them toavoid instability of lifting equipment and materials

- When lifting or lowering, moving the lifting device or load, they must show signal toinform everyone around

- When operating, they must observe the cables (chains, cylinder - lift tables) movingthrough the pulley (gear), to prevent it from being twisted, disordered or trapped.

- Only using lifting equipment to lift and lower volumes of materials in the verticalposition, prohibiting using it in oblique direction or drag volumes of materials on thefloor

- When lifting equipment is operated near power transmission lines, it is necessary tofollow safe distance under the power sector standards

- Prohibiting moving below, or stand on the volume of materials when it is lifted,moved

- Signal between the turn signal and the operator of lifting equipment must beconsistent, prohibiting letting beak hook deviate from the focus of the material volumewhen lifting, lowering and assembling it

- Cable hook points, muffle hook, anchor winch must be solid and appropriate, cranecable must be in accordance with the current regulation

- The direct leader at the site must understand the exact weight, size of each volume ofmaterials, clearly writing these parameters on at least 2 sides (deviation of 900) of thevolume of materials before assembly and removal, and understand the loadcharacteristics of the lifting device to be used at the construction site

- The important volume of materials (transformers, generators, control cabinet, pump,technology machine clusters, valve matrix, tanks .) must necessarily use a cablesystem with safety coefficient> 5, and only allows the load <80% of allowed load oflifting equipment for use in situations

- Prohibit using volumes of materials, architectural structures without permission of theinvestor as the hole or holding hoist, pulley

- Prohibit using lifting equipment for lifting people during construction

- The premises must be cleared, the moving path must be flat without having anyequipment or obstacles

- Check vehicles before shipment

- When materials are loaded onto carts, its shaft must be chocked tightly and loadedwith correct volume of materials

- When two porters or more involve in loading materials, their signal must beconsistent, and their height must be around equal They must carry materials on the