1. PURPOSE
2. SCOPE
3. APPLICABLE DOCUMENTS
4. RESPONSIBILITIES
5. MANPOWER
6. TOOLS AND EQUIPMENT
7. METHODS / PROCEDURES
8. QUALITY CONTROL
9. SAFETY PRECAUTION
10. ATTACHMENTS
AIR FIN COOLERS AFC FINAL NOZZLE CLOSURE WORK PROCEDURE | METHOD STATEMENT
1. PURPOSE
1.1 This method statement shall provide a minimum and general guideline to implement final nozzle closures of Air Fin Coolers (AFC)Tube Bundles during pre-commissioning works at Site of plants and refineries to ensure that the work is implemented safely and in accordance with Project Specifications and Drawings.
2. SCOPE
2.1 This method statement shall apply to final nozzle closure works for all tube bundle nozzles for Air Fin Coolers at Site of plants and refineries.
3. APPLICABLE DOCUMENTS
3.1 Saudi ARAMCO Project Specifications and Standard
3.1.1 G.I. 2.710 Mechanical Completion and Performance Acceptance of Facilities.
3.1.2 CSM Saudi ARAMCO Construction Safety Manual
3.1.3 SAEP-351 Bolted Flange Joints Assembly
3.2 Inspection and Testing Plan/ Method Statement
3.2.1 SATIP-E-007-01 Air Cooled Heat Exchanger (Fin Fan Cooler)
3.2.2 SAIC-E-2009 Internal Cleanliness Inspection of Heat Exchangers
3.2.3 SATR-D-2003 Vessel Closure Inspection Certificate
3.2.4 SATIP-L-350-01 On-Plot Metallic Piping Installation
3.2.5 SAIC-L-2014 Inspection of Bolted Flange Joint Assembly
3.3 Contractor’s/ Subcontractor’s Procedure and Method Statement
3.3.1 PIP-MS-008 Procedure for Gasket Installation
3.3.2 1770-MS-MECH-002 Method Statement for Erection of AFC Installation (ARCC)
3.4 Contractor’s HSE Procedure
3.4.1 S-000-1650-001 Contractor Site Safety Program
3.4.2 S-000-1650-029 Work at Heights Procedure
4. RESPONSIBILITIES
4.1 Pre-commissioning Manager
Ensure that all works are carried out according to this procedure and secure that all work areas are in safe working condition and monitor properly from time to time the implementation of safe procedure, requirements.
4.2 Pre-commissioning Mechanical Manager
Make planning and Implementation including preparation of AFC nozzle closure work schedule complying with the approved project standards and safety requirements. Prepare material requisition and assign competent supervisors to AFC nozzle closure work.
4.3 Pre-commissioning Mechanical Supervisor
Direct and control the AFC nozzle closure work schedules complying with the approved standards and safe guidelines. Supervise all related activities on site and prepare the inspection request to QA/QC section. Ensure competent workers are assigned to execute the activities. Confirm all necessary work permits are in proper places and the availability of all the materials, tools, and equipment required to AFC nozzle closure work.
4.4 Quality Control Manager
Ensure full implementation of the required quality control procedures and maintain the required documentation as per applicable Saudi ARAMCO Inspection and Test Plan for the final acceptance and handover of the systems. Guide and inform QC inspectors to maintain the quality level of inspection for the scheduled inspection activities.
4.5 Safety Supervisor/ Officer
Ensure that relevant safety precautions/ procedures are in operation and work permits have been obtained. Also, ensure that proper working platform, safety barriers and warning signs are prepared where necessary. Verify all workers are using required Personal Protective Equipment (PPE).
5. MANPOWER
5.1 Superintendent/ Supervisor
5.2 Foreman
5.3 Mechanical Workers
5.4 Pipe Fitter (for Nozzle Closure)
5.5 Crane Operator (if required)
5.6 Rigger (if required)
5.7 Helper
6. TOOLS AND EQUIPMENT
6.1 Tools and equipment should be in good condition and must be checked by supervisor and/or foreman prior to use at site.
6.2 Torque wrenches shall have valid calibration certificates.
6.3 Tools and equipment must be color-coded.
6.4 Required tools and equipment are as follows but not limited to:
6.4.1 Wrenches
6.4.2 Torque Wrenches
6.4.3 Boroscope and/or Inspection Mirror for Visual Inspection
6.4.4 Air Compressor and/or Vacuum Cleaner for Cleaning.
7. METHODS/ PROCEDURES
7.1 Preparation
7.1.1 Confirm that all AFC tube bundles have been correctly installed and inspected.
7.1.2 Confirm that all external pipes connected to the tube bundles have been aligned and hydro-tested. Also, confirm that required lay-up has been completed.
7.1.3 Confirm proper access and/or platforms are available for bolt tightening for nozzles of AFC tube bundles.
7.1.4 Confirm that all tube bundle nozzles have spectacle blind plates with closed position and inside tube bundles have been preserved by nitrogen.
7.1.5 Confirm the upper nozzles of tube bundle end side have temporary blind flanges with pressure gauges and the gauges indicate positive pressure.
7.1.6 Prepare and obtain the required work permit.
7.2 Final Nozzle Closure Works
7.2.1 Final nozzle closure work of AFC ( Air Fin Coolers) tube bundles shall be implemented as per the following steps.
Step-1: Release the nitrogen from inside tube bundles.
Step-2: Loosen all bolts of nozzles and remove blind plates and gaskets.
Step-3: Perform visual internal inspection in accordance with SAIC-E-2009 Sec. C as follows:
a. Through the openings at the flange nozzles
b. Opening low point drains or nozzles
c. Opening header plugs for internal inspection of tube sheets by random selection, which shall be concurred to by Proponent’s Engineering / Inspection Group.
Step-4:Â If any debris or foreign materials were found inside tube bundle, they shall be removed by air blowing or vacuum cleaning.
Step-5: After visual inspection was accepted, immediately start installation of spectacle blind plates with open position. Always new permanent gaskets shall be used for those installations. At the end side of tube bundles, start replacing temporary blind flanges to permanent ones with new permanent gasket as well.
Step-6: After setting the permanent bolts and nuts correctly, start tightening all bolts and nuts in accordance with SAEP-351.
7.2.2 After completing the nozzle closure work, all temporary materials, equipment and tools used for this works shall be removed from the site.
8. QUALITY CONTROL
8.1 Ensure that required inspections for AFC structure and tube bundle installation work have been completed and accepted in accordance with SATIP-E-007-01 prior to the final nozzle closure inspection.
8.2 The inspection of final nozzle closure shall be conducted in accordance with SAIC-E-2009 and SAIC-L-2014.
8.3 Contractor’s and Subcontractors’ QC inspectors shall attend all inspections of the final nozzle closure works on site to ensure that all applicable requirements, codes and standards are complied with.
8.4 Preservation of tube bundles after the final nozzle closure works shall be conducted as a part of the system lay-up together with related piping which are connected to the tube bundles.
9. SAFETY PRECAUTION
9.1 Ensure that proper work permit has been prepared and approved prior to the work.
9.2 Conduct Safety Tool Box and TSTI every morning prior to the nozzle closure works.
9.3 When the work starts, ensure that nitrogen gas inside tube bundle for preservation has been released and confirm no more remained during the work, especially for the visual inspection of inside tube bundles.
9.4 Ensure that proper working access and platforms have been provided for bolt tightening work.
9.5 Ensure that all supervisors and workers have taken “working at heights” training and always use the proper PPE.
9.6 Ensure that barricades and warning signs are properly installed.
9.7 All power/hand tools must be secured with tool lanyard or string.
10. ATTACHMENTS
ATTACHMENT-1 Job Safety Analysis for AFC Nozzle Closure Works.
ATTACHMENT-2 SAIC-E-2009: Internal Cleanliness Inspection of Heat Exchangers.