1.0 PURPOSE:
1.1 This method statement shall provide minimum guidelines in accordance with international codes, standards, project drawings and specification to erect Reformer Furnace in plants and Refinery.
2.0 SCOPE:
2.1 This specification covers the minimum requirements for erection of reformer furnace to be applied in in plants and Refinery.
3.0 APPLICABLE DOCUMENTS:
3.1 Specification and Standards
3.1.1 S-000-1630-003 Material and Equipment Protection Program at work Site
3.1.2 S-000-1520-103 Handling Procedure
3.1.3 S-000-1640-005 Procedure for Work Release Between Disciplines
3.1.4 S-000-1520-102 Non-Conformity Control Procedure
3.1.5 S-000-1520-101 Field QC Procedure
3.1 .6 S-000-1650-001 Safety Execution plan
3.1.7 S-000-1351-002 Installation Marking Procedure
3.1.8 S-000-3150-001 Installation of Static Equipment
3.1.9 FWBS CODE (5000) Equipment Installation
3.2 ARAMCO Project Specifications and Standard
3.2.1 SAES-W-011 Welding Requirements for On-Plot Piping
3.2.2 SAES-F-001 Design Criteria of Fired Heaters
3.2.3 SAES-H-001 Coating Selection and Application Requirements for Industrial Plants and Equipment
3.2.4 SAES-N-100 Refractory Systems
3.2.5 SAES-N-110 Installation Requirements – Castable Refractories
3.2.6 SAES-N-130 Installation Requirements – Fireclay Bricks
3.2. 7 SAES-N-140 Installation Requirements – Refractory Ceramic Fiber
3.2.8 32-SAMSS-029 Manufacture of Fired Heaters
3.2.9 SAEP-302 Instruction for obtaining a waiver of a mandatory Saudi ARAMCO Engineering requirement.
3.2.10 Related Vendors Installation and maintenance manuals and /or specifications.
3.2.11 SAES-Q-005 Concrete foundation
3.2.12 SAES-Q-010 Cement Based Non-shrink Grout for Structural and Equipment Grouting.
3.2.13 SAES-L-350 Construction of Plant piping
3.2 .14 SAES-H-101V Approved Saudi Aramco Data Sheets – Paints and Coatings.
3.3 Industry Codes and Standards:
3.3.1 AWS D1.1 Structural Welding Codes
3.4 Inspection and Testing Plan/Method Statement
3.4.1 SATIP-D-001-01 Typical Inspection Plan Pressure Vessel Installation
3.4.2 SATIP-Q-010-01 Cement Based Non-Shrink Grouting
3.4.3 SATIP-M-001-01 Structural Steel-Piperack, Steel Supports & Miscellaneous* Steel Structures (* Incl. Piping Supports per Specification)
3.4.4 SATIP-W-011-01 Welding of On-Plot Piping
3.4.5 SATIP-F-001-01 Fired Heaters – Field Installation
3.4.6 SATIP-N-110-01 Castable Refractory Installation
3.4.7 SATIP-N-130-01 Refractory System- Fireclay Bricks & Tile Installation
3.4.8 SATI P-J-600-01 Safety Relief Valve Installation
3.5 Latest Revision of the following Documents shall be used.
3.5.1 Vendor Drawing
3.5.2 Foundation Drawing
3.5.3 Equipment Details
3.6 Saudi ARAMCO Safety, Health and Environmental Standard:
3.6.1 Construction safety manual – compliance with schedule D.
3.6.2 General Instructions (G.l’s) at the work site.
4.0 RESPONSIBILITY:
4.1 Construction Manager shall be responsible for implementing HSE, analyze and schedule all construction activities with his department to include manpower and equipment line up as well as other possible resources required for the successful implementation of the construction work activities. Study all aspects of work procedure as per Saudi Aramco Standards.
4.2 Mechanical Superintendent/ Supervisor shall study and review all necessary documents for the Erection works in his area to include, technical scope of work, specification, bill of quantities, planned milestone dates and construction procedure in support to his Mechanical Foreman. He shall monitor the availability of materials in accordance with the schedules and construction analysis. He shall be directly reporting to the Construction Manager. He shall coordinate with other discipline to visualize possible conflicts in the drawings as well as in the schedules to provide other options in preventing unnecessary delays and obstructions.
4.3 The Welding Supervisor and/or Foreman are solely responsible to ensure that all welding works are in conformance with applicable codes, standards, specifications and approved procedures.
4.4 Mechanical Foreman shall be responsible for the direct work supervision at site and ensured that the work is performed in accordance with Saudi Aramco Standards and latest approved for construction drawings. He shall monitor the availability of materials in line with his required schedule.
4.5 QC Inspector shall be responsible in monitoring and inspection of the work and ensured that the work is performed and properly documented in accordance with Saudi Aramco Standards.
4.6 Safety Officer/Supervisor shall be responsible in monitoring safety aspects and ensuring that the work is done in accordance with Saudi Aramco Safety Standard Procedure He shall discuss to the workers the characteristics of related materials and Status of work area giving reminders as an additional point to work safely.
5.0 MANPOWER
5.1 The Mechanical Supervisor shall control the overall activity of Fitter and pipe support machine Erection . The basic manpower under him shall consist but not limited to the following:
5.1 .1 Supervisor Mechanical
5.1.2 Foreman mechanical
5.1 .3 Rigger 1 (certified)
5.1.4 Rigger ( certified)
5.1.5 Welder
5.1.6 Millwright
5.1.7 Mechanical Fitter
5.1.8 Masons/Carpenters
5.1.9 Crane Operator (certified)
5.1.10 Safety Engineer/supervisor
5.1.11 Truck driver
5.1 .12 QC Inspector
5.1.13 Surveyor
5.1.14 Helper/ Fire watcher
5.1.15 Structural Worker
6.0 TOOLS AND EQUIPMENT;
6.1 Tools and equipment needed should be in good condition and must be checked by Mechanical Supervisor/Safety Officer prior to use in the construction area. These Includes but not limited to:
6.1.1 Calibrated engineering level with calibration certificate.
6.1.2 Corrective wrenches all required range.
6.1.3 Certified sling and hoists.
6.1.4 Rigging accessories.
6.1.5 Spreader Beam (approved by ARAMCO).
6.1.6 Concrete drill.
6.1.7 Millwright Precision meter.
6.1.8 Theodolite.
6.1.9 Auto level.
6.1.10 Crawler crane
6.1.11 Tag line nylon rope
6.1.12 Welding Machine.
7.0 ERECTION OF REFORMER FURNACE PROCEDURE | METHOD STATEMENT:
General Requirements – Seal welding activity shall be done for all radiant and convection connection flanges.
7.1 Job site Receiving and Inspection:
7.1.1 Upon withdrawal and receipt of equipment from warehouse, receiving inspection shall be conducted immediately to verify compliance with the latest revision of vendors drawing, project requirements & SAEP-302.
7.1.2 Record of Material Receiving Inspection shall be documented. Findings, deviations shall be documented in Quality control Inspection Report (QCIR) and Non Conformance Report (NCR).
7.2 Equipment Preservation/Protection:
7.2.1 Vendor’s/Manufacturer’s recommendation for equipment preservation shall be followed, also comply with project requirements and standard.
7.2.2 When the equipment arrived at site, shop preservation shall be checked. Where necessary damage to preservation shall be rectified without delay.
7.3 Preparatory Works:
7.3.1 Secure work permit prior to work commence.
7.3.2 Tools and equipment shall be made operational and available for use. Ensure tools are color-coded accordingly. Calibration certification where required shall be in valid dates.
7.3.3 Prior to the arrival of equipment on site, must review the manufacturer’s requirement and the requirements of this Project Specification regarding site storage of the equipment. These requirements shall be incorporated with the preservation plan in all respects.
7.3.4 Mobilize all manpower, tools and equipment needed for the job.
7.3.5 Check the availability of material according to the erection sequence.
7.3.6 Compliance with GI 7.025 for Heavy Equipment Operator Testing and Certification.
7.3.7 Install barricades to confine the area for authorized personnel only.
7.4 Foundation Preparation for Reformer Furnace:
7.4.1 Confirm acceptances & turnover of civil works foundation/pedestals with a signed copy of works release notice prior to installation of equipment / structure.
7.4.2 Verify the equipment/ structure seating area requirements.
7.4.3 When the foundation released the following points shall be checked with the latest relevant drawing:
7.4.3.1 Distinct position (centre) marking and height (level) marking on the foundation, It will be referred for alignment work of level and position.
7.4.3.2 Size and number of anchor bolt and nuts, position of anchor bolts with projection.
7.4.3.3 Existence of damages and rust of threaded of buried anchor bolts with projection.
7.4.3.4 Trace centerlines of foundation bolt holes with reference to gridlines. Check Verticality/plumbness of anchor bolt.
7.4.3.5 Clean the surface thoroughly by blowing with oil-free from air compressor.
7.4.3.6 Centerlines lost due to chipping operations will retrace anew.
7.4.4 Anchor bolts shall be protected properly to avoid damages during chipping/padding work and keep it up to the structure & equipment installation.
7.4.5 The elevation of the chipped top foundations shall be set to consider the required grout thickness under the base plate as per the design drawings.
7.4.6 The bottom of the bases shall be cleaned and free of laitance, oil or grease.
7.4.7 Laitance shall be removed from the surface of the foundation and boxes by chipping to ensure good adherences of padding and grout materials to the surface preparation.
7.5 Dimensional Inspection and Checking of Foundation:
7.5.1 Using Work Transfer Sheet, following shall be done;
• Establish centerlines (Northing and Easting) of columns reference to applicable foundation/civil drawings.
• Using an auto level, confirm Top of Concrete (T.O.C.) elevation.
7.5.2 Compare data with reference drawings and Survey Data Record. Note the discrepancies and unacceptable tolerances and report through QCIR.
7.6 Padding
7.6.1 Pads and liners shall be machined flat parallel and larger than the foot of base frame.
7.6.2 Pads material shall be in accordance with ASTM A283 Gr. C,D or equivalent.
7.6.3 Pad shall be hot dip galvanized in accordance with ASTM A123 or coated with zinc rich epoxy primer in APCS-1C of SAES-H-101Vas applicable.
7.6.4 In general, the distance between pads shall not exceed 800 mm. If the distance becomes more than 800 mm, an additional pad shall be added in between.
7.6.5 Pad size shall be selected as per the anchor bolt size as follows:
7.6.5.1 Bolt diameter M 24 or 1 inch and below Pad width 50 mm
7.6.5.2 Bolt diameter M 30-M 48 or 1-1/4 to 2 inches Pad width 75 mm.
7.6.5.3 Bolts diameter M 56 or 2-1/4 inches and above Pad width 100 mm.
7.6.6 Number of pads shall be determined so the load pressure will be less than 30 kg/cm².
• The supporting load can be calculated as per following formula.
L=W/NxAxB
L: Load supported by liner (kg/cm2)
W: Lifting load of equipment (kg)
N: Number of pads
A: Width of base plate for equipment (cm)
B: Width of liner (cm).
7.6.7 The length of pad shall be 20 mm to 30 mm longer than the width of the equipment bases.
7.6.8 The thickness of the both taper and straight liners shall be at least 10 mm and the minimum thickness of the tapered ends shall be 2 mm. Adjustment allowance shall be 4 to 6 mm.
7.6.9 The wedge liners may be applied to tower and vertical vessel, if necessary. The gradient of the wedge liners shall be generally less than 1/30, and two wedge liners shall be used in back to back so as to make their top and bottom faces in parallel.
7.6.10 The wedge liners may be applied to tower and vertical vessel, if necessary. The gradient of the wedge liners shall be generally less than 1/30, and two wedge liners shall be used in back to back so as to make their top and bottom faces in parallel.
7.6.11 After finishing padding work, following points shall be checked
7.6.11.1 Position of center and elevation line of foundation
7.6.11.2 Elevation and position of pads
7.6.11.3 Cleanliness of concrete surface
7.6.11.4 Condition of anchor bolts
7.7 Erection of Reformer Furnace
7.7.1 Prepare lifting location where the crane will be located and positioned.
7.7.2 Prepare and set all rigging accessories according to arrangement.
7.7.3 Checked wind condition, lift shall not proceed when wind velocity is greater than required of crane.
7.7.4 Stabilized ground areas where crane will be located and positioned. Crane mats shall be provided in accordance to findings of soil bearing pressure.
7.7.5 Make sure that all rigging plans are approved prior to erect equipments/ structure.
7.7.6 Prior to erect radiant panels; verify if all studs anchors are in good condition or without damage. In case stud anchors has damage, provide site instruction to and proceed to repair work.
7.7.7 After arrival of 1st shipment (see attachment B for illustration)
7.7.7.1 Set of 90 deg. and 270 deg. sides main columns (A-1-3, E1-3)
7.7.7.2 Set of floor beam support stanchion (B-D-1, B-D-2, B-D-3).
7.7.7.3 Installation of 90 deg . and 270 deg. side beams (between A-1-3, E-1-3)
7.7.7.4 Installation of floor beam (line nos. 1-3)
7.7.7.5 Installation of Reinforcement column & beams of O deg. side
7.7.7.6 Installation of 90 deg. and 270 deg. sides Lower/Upper Panels (total: 24 panels) JO-F-0401, 0402. Lower panel: 12 panels and Upper Panel: 12 panels.
7.7.7.7 Installation of O deg. side lower panels (Total: 16 panels). Lower panel: 8 panels, Upper Panel: 8 panels.
7.7.8 After arrival of 2nd shipment. (see attachment B for illustration)
7.7.8.1 Set of main columns (A-4 & 5, E-4 & 5)
7.7.8.2 Set of floor beam support stanchion (B-D-4, B-D-5)
7.7.8.3 Installation of floor beam (Line Nos. 4 & 5)
7.7.8.4 Installation of reinforcement column and beams of 180 deg . side.
7.7.8.5 Installation of 90 deg. and 270 deg. sides Lower/Upper panels (total: 24 panels) for J10-F-0403, 0404. Lower panel: 12 panels, Upper Panel: 12 panels
7.7.8.6 Installation of 180 deg. Lower panels (total: 16 panels) Lower panel: 8 panels, Upper panel: 12 panels.
7.7.8.7 Installation of Header support (B’-11-26, D-11-26, F-11-26, G11-26, H-11-26, 1-11-26, J-1-26, K-11-26, L-11-26, M-11-26)
7.7.8.8 Place floor panels on temporary location (floor panels inside and outside section of rad. Coil).
7.7.9 After arrival of 3rd shipment (see attachment B for illustration)
7.7.9.1 Installation and adjustment of header with radiant coils for J1 O-F0401, 0402
7.7.9.2 Installation of remaining floor panels for J1 O-F-0401,0402
7. 7.10 After arrival of 4th shipment (see attachment B for illustration)
7.7.10.1 Installation and adjustment of Header with Radiant coils for J10-F0403,0404
7.7.10.2 Installation of remaining floor panels for J10-F-0403,0404
7.7.10.3 Installation of Radiant Arch truss frame with radiant arch beams for column line nos. 1-5
7.7.10.4 Installation of Radiant arch structure for column Line Nos. A&E.
7.7.10.5 Install radiant arch panel.
7.7.10.6 Installation of Transition duct block (Refractory lining to be done on the ground)
7.7.10.7 Installation of Radiant arch structure for column line nos. B1, B2C1, C2, 01, 02.
7.7.11 For adjustment or alignment of radiant panels and column use dead man weight, turn buckle, wire rope/guy wire, clamps, wire clips, survey instrument and etc. Plumbness and alignment of radiant columns and beams to be inspected and confirmed before seal welding of the radiant panels. Inspection shall be done as per Saudi Aramco Standard.
7.7.12 Final bolt tightening for the radiant arch truss frame beams and radiant arch structure shall be commenced right after plumbness, alignment and level check and acceptance.
7.7.13 After completion of erection until transition duct and radiant section.
7.7.13.1 Installation of lower convection module.
7.7.13.2 Installation of convection module with breeching.
7.7.13.3 Installation of convection and piping structure ( to EL +32200 from EL+24200).
7.7.14 After completion of erection for convection section.
7.7.14.1 Installation of Stack bottom duct
7.7.14.2 Installation of flue gas outlet duct between flue gas x-over duct and stack bottom duct.
7.7.14.3 Installation of flue gas x-over duct.
7.7.14.4 Installation of stack structure
7.7.14.5 Installation of stack lower block. (Stack lower/middle sections and the damper unit to be combined on the ground by welding.
7.7.14.6 Installation of stack upper block.
7.7.14.7 Installation of piping structure (to EL +43250 from EL +32200)
7.7.14.8 Final bolt tightening for convection structure, stack support structure and piping support structure shall be commenced right after plumbness, alignment, and level check and acceptance.
7.7.15 Installation of radiant vapor barrier, ceramic fiber, Castable and brick (refer to refractory procedure for more detail information). After installation it will be inspected by ARCC QC Inspector as per Aramco Standard prior for final checking of client.
7.7.16 Using required crane, erect FDF using the approved rigging plan followed by IDF in accordance to approve for construction drawing. After erection align & level as per Aramco standard and should be within the tolerance limit.
7.7.17 Upon approval of client on erection of FDF & IDF connect ducting such as air duct & burner duct. All ducting should be done as per approved construction drawing and within Aramco standard.
7.7.18 Erection of APH and APH support structure.
7.7.19 Erection of flue gas duct support structure.
7.7.20 Erection of Hot and cold flue gas duct.
7.7.21 Installation of external insulation for hot air/burner ducting.
7.7.22 After installation, final bolt tightening for APH support structure and flue gas duct support structure shall be commenced right after plumbness, alignment, and level check and acceptance.
7.7.23 For miscellaneous equipments or accessories such as burners, access door, peep doors, expansion bellows & etc. will be installed manually and to be inspected by client JGC/DAEWOO & COMPANY after installation.
7.7.24 Installation of cross-over pipes, down-comer, spring hanger/support, inlet header, outlet header & etc. will be done as per piping installation & pipe support installation method.
7.7.25 Installation and inspection of access platforms as per structural steel installation procedure.
7.7.26 See vendor’s erection sequence for more details. (Attachment B).
7.8 Plumbness check:
• Take sight on the reference point at the top.
• Close the horizontal adjustment knob to lock line of sight of equipment against horizontal movement.
• Take sight on the reference point on the bottom.
• Out-of-plumb dimension from the reference point at the bottom can be measured from the reference point to the survey instrument line off sight using steel tape/measuring stick.
7.8.1 Use carbon steel shims if needed to adjust verticality and plumbness.
Wedge blocks when nosed during adjustments shall be removed after alignment before inspection and final alignment acceptance.
7.8.2 Shims used for level alignment shall be:
7.8.2.1 Less than 0.0110″ (2.5 mm) thick shall be stainless steel.
7.8.2.2 Shim thicker than 0.100″ (2.5 mm) shall be carbon steel.
7.8.2.3 The number of shim, shall be 4 (four) plates at one hold down bolts.
7.8.3 Using open wrench/hammer wrench, proceed to preliminary tightening of anchor bolts nuts to bring to “snug tight” condition.
7.9 Alignment of radiant main columns and beams, seal welding of radiant panels and final bolt tightening of radiant arch support structure shall be completed before grout setting.
7.10 Setting and Alignment:
7.10.1 Horizontal equipment requiring allowance for thermal expansion shall be installed at the correct position so as that opening of slot holes have sufficient space for expansion movement in accordance with the drawing.
7.10.2 Check elevation, levelness, squareness and plumbness as per SATIP-D001-01 Typical Inspection Plan Pressure Vessel Installation.
7.10.3 When leveling jack bolts are not provided on the equipment shims may be used for leveling. All shims shall straddle the hold down bolt if the machine foot mounted, the shims shall be the size of the foot. When shims are used directly under channel or “H” beam sub bases, the shims shall cover the entire width of the channel “H” Beam and shall be a minimum of 4 (four) times as the diameter of the both.
7.10.4 After any installation of the equipment and up to grouting commencement foundation Chipped surface shall be protected from harmful contamination for grouting with a Suitable way.
7.11 Bolt Tightening:
7.11.1 All bolts shall be aligned to permit insertion of bolts without undue damage to the threads.
7.11.2 Bolts shall be placed in all holes with washers positioned and nuts threaded to complete the assembly.
7.11.3 Any abnormal wear on the equipment and parts during installation and assembly shall be corrected by the subcontractor. Prior to the commencement action written work procedure shall be approve by contractor/company.
7.12 Grouting:
7.12.1 Water for mixing grout non-shrink material must be fresh and clean, and free from Injurious of oil acid alkali, salt or organic as per SAES-Q-010 Cement Based, Non-Shrink Grout for structural and Equipment Grouting.
7.12.2 This grout shall meet the requirement of STS 03600 when used in high fluidity range. Compressive strength shall be in excess of 34 .5 Mpa (5000 psi) when mixed according to manufacturer instructions.
7.12.3 Grout shall be mixed in accordance’s with grout manufacture’s instruction. Shall prepare sufficient quality of grouting material, clean tools and equipment and suitable water mixture at site to complete the job.
7.12.4 Grout inside skirt for vertical vessel must be filled with slope, and an all opening for Drainages must be provided under the base plate to be toward the nearest surface drain. Instruction will be issue for item by item by Subcontractor/Contractor.
7.13 Setting of liner:
7.13.1 Prior to the installation of liners and equipment, the liners and grouting portion of foundation shall be chipped and all concrete laitance shall be removed from portion.
7.13.2 Flat liners shall be installed at the positions with pads of cement grout at least seven days before equipment installation. lncase non-shrink grout material is used; the curing duration shall according to the manufacture’s recommended.
7.13.3 In case that wedges liners are used the level of padding with a flat liners need to be adjust to meet with the final equipment elevation.
7.14 Alignment Tolerances:
7.14.1 Vertical Tolerance
7.14.1.1 The angular variation of the working line from a plumb line shall be equal to or less than 1/500 of distance between working points. AISC Code of Std Practice – Steel Bldgs & Bridges Para. 7 .13.1.1 & PIP STSO 5130, Para. 6.2.1.
7 .14.2 Plumbness tolerance for stack shall be max of 25 mm per 15 m as per API 560 4th edition, Aug 2007.
7.14.3 Position ±3mm
7.14.3.1 Every 90 degree orientation of base plate shall be measured with reference to the Orientation of the foundation.
7 .14.4 Elevation ±3mm
7.14.4.1 The bottom of base plate shall measure with reference to the level marking of the foundation. At least, one point of the base plate shall be aligned within these tolerances.
7.14.5 Levelness 1/1,000 (for horizontal equipment)
7.14.5.1 The center line of equipment shall be in alignment with the horizontal line within the tolerances of 1/1,000. If slope is required, the inclination shall be considered.
7.14.6 Perpendicular ±6mm for each 10m (for vertical equipment only)
7.14.6.1 The center line of the equipment shall be in alignment with vertical line within the tolerance of ±6mm for every 1 Om length of the equipment, in principle, provides that such tolerance 20m and longer equipment shall not exceed ±12mm.
7.15 Damages and Nonconformity
7.15.1 Any damages and defects and nonconformity found at site and lay down yard shall be reported immediately.
8.0 QUALITY CONTROL
- QC Personnel shall be assigned to ensure the quality control and assurance requirement of the project.
- QC Personnel well coordinate with JGC/DAEWOO inspector to conduct inspection as required.
- QC Inspector shall be responsible to conduct all required inspection/documentations and to ensure that all applicable requirements, codes, and standards are complied with SAIC/SATIP.
- Contractor has to utilize the applicable SAIC for every activity.
9.0 SAFETY PRECAUTION:
Obtain the approval of the work permit from the concerned Representative before starting any work.
- TSTI to conduct daily prior to execution of work.
- Fire Watcher with Fire Extinguisher shall be at work area whenever there is hot work.
- Work execution shall be carried out in accordance with method statement. And in compliance with Saudi ARAMCO General Instruction G.1.7.028, Crane Lifts; Types and Procedure.
- Continuous monitoring and inspection shall be implemented to detect and correct unsafe practices while performing the work activities.
- Provide warning sign and sufficient barricade on working area and only assigned personnel will be allowed in the area.
- Worker shall wear PPE’s needed for the work.
- Install PWAS on all equipment moving in this activity.
- All rigging equipment shall be in good condition and possess a valuable certificate from authorized certifying and inspection department. In compliance with Saudi ARAMCO General Instruction G.1.7.030 Inspection and Testing Requirements for Elevating/lifting Equipment.
- Man lift users shall be trained and certified to operate and use the equipment.
- Mechanical Supervisor shall monitor the work activities to help and to protect all assigned workers against exposure to safety hazards. He shall ensure that Personal Protective Equipment (PPE’s) are supplied and used and comply with Saudi Aramco Standards.
- Housekeeping shall be maintained and working area shall be kept in a clean and tidy manner.
- Job Hazard and Risk Assessment (JHRA) of this method statement shall be disseminated and explained to workers for safety awareness.
10.0 ATTACHMENT