METHOD STATEMENT FOR INSTALLTION OF AGITATORS

7/30/2019 METHOD STATEMENT FOR INSTALLTION OF AGITATORS

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1500 MTPD Phosphoric Acid plant

4500 MTPD Sulphuric Acid plant

METHOD STATEMENT

Prepared by Reviewed by Safety Release QA/QC

Approval

Approved by

Date

Name

SectionEngineer

ConstructionManager

Safetymanager

QA / QCManager

ProjectManager

Date

Name

Site Manager

Project 1500 MTPD Phosphoric Acid plant


Method Statement No

CIVIL

ELECTRICAL

MECHANICAL

INSTRUMENTATION


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METHOD STATEMENT

1. INTRODUCTIONThe 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 Worka) Function and Location

The function of the agitator is to maintain homogeneity in the fluid by creating

turbulence.

b) General DescriptionGenerally 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 workInstallation 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 AGITATOR2. 223-A-02 --- ------FILTARATION SUMP AGITATOR3. 225-A-01 --------- CONCENTRATION SUMP AGITATOR4. 225-A-02ABCD ---FLOURINE SCRUBBER 1 SEAL TANK AGITATOR5. 225-A-03ABCD ---FLOURINE SCRUBBER 2 SEAL TANK AGITATOR6. 227-A-01---------- ACID SUMP AGITATOR7. 231-A-01---------- WEAK ACID MATURATION TANK AGITATOR8. 231-A-03AB------- WEAK ACID STORAGE TANK AGITATOR9. 231-A-04--------- -WEAK ACID SUMP AGITATOR10.232-A-01AB-------CONCENTRATED ACID MATURATION TANK AGITATOR11.232-A-04---------- CONCENTRATED ACID STORAGE SUMP AGITATOR12.232-A-05---------- POST PRECIPITATE SLUDGE SUMP AGITATOR13.233-A-01---------- EFFLUENT TANK AGITATOR


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METHOD STATEMENT

3. Release certificate for the tank.4. AFC Drawings.5. I.T.P

4. Required Material Testing, during and before work1. Checking the agitator parts for completeness as per vendor instruction.

5. Environmental and Safety1. 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 details1. 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 applicable11.Checking the verticality of the shaft.12.Tightening of the bolts to the required torque.13.Check for free rotation of shaft.


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METHOD STATEMENT

19.Erection and bolting of Agitator Blades to the shaft (WLEDED / BOLTED TO BECOFIRMED).

20.Alignment of Blades21.Bolt tightening to the required torque.22.Electrical and instrumentation cabling.23.Check for the direction of rotation.24.Grease and lubrication applications25.Release for commissioning.

7. Curing and Weather Protection1. 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 onproducts.

1. Refer to I.T.P9. Construction Equipment to be used , including standby Arrangement

1. Mobile crane for erection purpose and arcane with equivalent or more capacity craneare 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 the3 Riggers: - These will involve in handling the plates for erection alignment etc


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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 Team1. 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.


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AGITATOR SUPPORT STRUCTURE


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TANK SHELL



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AGITATOR SUPPORT PLATE



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AGITATOR SHAFT

AGITATOR BASE PLATE


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AGITATOR BASE PLATE

AGITATOR SHAFT


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AGITATOR BLADES

AGITATOR SHAFT


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AGITATOR BLADES

AGITATOR SHAFT


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AGITATOR BLADES

AGITATOR SHAFT

AGITATOR GEARBOX & MOTOR

METHOD STATEMENT FOR INSTALLTION OF AGITATORS

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