INSTALLATION PROCEDURE OF REFRACTORY ANCHOR | METHOD STATEMENT

1.0 PURPOSE
2. 0 SCOPE
3.0 APPLICABLE DOCUMENTS
4.0 RESPONSIBILITY
5. 0 MANPOWER
6. 0 TOOLS ANO EQUIPMENT
7.0 METHODS / PROCEDURE
8.0 QUALITY CONTROL
9. 0 SAFETY PRECAUTION
10. 0 ATTACHMENTS

1.0 PURPOSE

This method statement shall provide Sungchang and Al- Shaikh (SAACO) minimum guidelines for installation of refractory anchor to Fired Heaters, Xylene Rerun Column Reboiler Furnace / Xylene Isom Reactor Heater for JAZAN REFINERY & TERMINAL PROJECT (PACKAGE- J 2 AROMATICS) in accordance with Project Drawings and DEC/ JGC Project Specifications.

2.0 SCOPE

This specification covers the minimum requirements for installation of refractory anchor to be applied at JAZAN REFINERY & TERMINAL PROJECT (PACKAGE- J 2 AROMATICS)

3.0 REFERENCES

1. Project Specification and Standard
2. SAEP-3 02 Instruction for obtaining a waiver of a mandatory Saudi ARAMCO Engineering requirement
3. SAES-H-1 0 IV Approved Saudi Aramco Data Sheets- Paint and Coating
4. SAES-N-1 00 Refractory Systems
5. SAES- N-1 20 Installation Requirements Extreme Erosion Resistant Refractories
6. SAES- N-1 I 0 Installation Requirements Castable Refractories
7. SAES- N-140 Installation Requirements Refractory Ceramic Fiber
8. SATIP- N-1 10-01 Castable Refractory Installation
9. SAIC N-2 022 Welding Anchors & Supports (SAES- N-1 10/ I 20/ 13 0)
10. Related Vendors Installation and maintenance manual and / or specifications.
11. Latest Revision of the following documents shall be used.
12. Vendor Drawing
13. Structural Drawing
14. Equipment Details
15. Safety Health and Environmental Standard:
16. Construction Safety Manual – compliance with schedule D
17. General Instruction (G. l’s) at the work site

4.0 RESPONSIBILITY

Construction Manager

Construction Manager is responsible for implementing HSE, study, analyze and schedule all Manager 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 technical Scope of Work and
Saudi Aramco Standard.

Mechanical Supervisor

Mechanical Supervisor shall study and review all necessary documents for the application activity 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 report to the Construction Manager. He shall be 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.

Mechanical Foreman

Mechanical Foreman shall be responsible for the direct work supervision at site and ensure that the work is performed in accordance with DEC/JGC Technical Scope of Work, Saudi Aramco Standard and latest approved for construction drawings. He shall monitor the availability of materials in line with his required schedule.

Quality Control Inspector

Quality Control Inspector shall be responsible in monitoring and inspection of the work and ensure that the work is performed and properly documented in accordance with DEC/J GC Technical Scope of Work and Saudi Aramco Standard.

Safety Supervisor/Officer

Safety Supervisor/Officer shall be responsible in monitoring safety aspects and ensuring that the work is done in accordance with DEC/JGC Safety Standard Procedure and Saudi Aramco Construction Safety Manual. He shall discuss to the workers the characteristics of related materials and status of work area giving reminders as an addition point to work safely.

5.0 MANPOWER CATEGORY

5. I The Mechanical Supervisor shall control the overall activity on installation of refractory anchor. The basic manpower under him shall consist but not limited to the following:

1. Mechanical Foreman
2. Welder
3. Helper
4. Scaffolder (by others)
5. Safety Engineer
6. QC Inspector.

6.0 TOOLS AND EQUIPMENT

6.1 Tools and equipment needed should be in good condition and must be checked by the Mechanical Supervisor / Safety Officer prior to use in the construction area. These includes but not limited to:

• Stud machine
• Stud gun
• Stud
• Welding equipment and accessories

7.0 INSTALLATION PROCEDURE OF REFRACTORY ANCHOR | METHOD STATEMENT

7.1 Jobsite Receiving and Inspection

7.1.1 Upon withdrawal and receipt of materials from DEC/JGC warehouse, receiving inspection shall be conducted immediately.
7.1.2 Record of inspection shall be documented as per applicable SAIC (Material Receiving Inspection) ; finding s and deviations shall be documented in Quality Control Inspection Report (OCIR) and Non Conformance Report (NCR) .

7.2 Preparation of Works

7.2.1 Secure all the valid documents such as Confined Space Permit Working Permit prior to work commence.
7.2.2 Tools and equipment shall be made operational and available for use. Ensure all tools are inspected and color- coded accordingly by color month.
7.2.3 Mobilize all manpower, tools and equipment needed for the job.
7.2.4 Manpower who will do the job should have proper training on confined space and necessary training to do the job at DEC
7.2. 5 Install barricades to confined space area for authorized personnel only.
7.2.6 Install required scaffold and must be inspected before to use. (by others)
7.2.7 For stud welding process:
7.2.7.1 Keep ferrules dry. Wet ferrules must not be used.
7.2.7.2 Keep studs dry. Rusty studs cause welding problems.
7.2.7.3 Do not weld when the temperature of base materials is below zero degrees F.
7.2.7.4  Do not weld where water is present on the weld surface.
7.2.7.5 Do not weld through dirt sand or other foreign material.
7.2.7.6 Hold gun perpendicular to base material.

7.3 Installation of refractory anchor

7. 3.1 Verify location of activities, location must not be exposed to sandstorm or rain.

7.3.2 Verify panel surface, steel surface shall be free of dust, loose dirt or other materials which will interfere with the welding operation.
7.3.3 Check condition of bend refractory anchor if it is repairable. Bended anchor will be replaced by new anchor only if the bended anchor showed cracks or failure at the weld after straightening on proper location. Conduct PT on straightened anchor.

7.3.4 Installation of new refractory anchor will be done through welding by GTAW process or by stud welding and in accordance with ASME SEC IX, QW-l 90 for fillet welds and QW-l 92 for stud welding as per SAES-W-0 l 0. Refer to attachment B for WPS and WPQR.
7.3.5 Remove panel paint prior to start welding of refractory anchor.
7.3.6 Using stud welding machine, refractory anchor is manually inserted into the stud welder chuck on the welding gun.
7.3.7 The refractory anchor is position into firm contact with the work surface. The welding gun is activated and the refractory is welded in a fraction of second which the refractory anchor weld develops full strength instantly.
7.3.8 After completion of application, SMCO QC will inspect prior to final inspection of client DEC/ JGC and Saudi Aramco.
7.3.9 If it found out satisfactory, proceed to next activity.

7.4 Damage and Nonconformity

7.4.1 Any damages and defects and nonconformity found at site and lay down yard shall be reported immediately.
7.4.2 SMCO QC Inspector will be responsible for all required documentation.

8.0 QUALITY CONTROL

8.1 QC Inspector shall be assigned to ensure the quality control requirement of the project
8.2 QC Inspector will coordinate with DEC/JGC Inspector to conduct inspection as required.
8.3 Inspector shall be responsible to conduct all required inspection/documentation and to ensure that all applicable requirements, codes and standards are complied with SAIC/SATIP
8.4 Contractor has to utilized the applicable SAIC for every activity.

8. 5. 5% or repaired anchor welds shall be subjected to Bend Test in accordance with clause 1.4.3 and 1.4.4 of SAES-N- 110.

9.0 SAFETY PRECAUTIONS

9. 1 Obtain the approval of work permit from the concerned DEC/J GC Representative before starting any work.
9.2 Work execution shall be carried out in accordance with the method statement And in compliance with Saudi Aramco project specification.
9.3 Continuous monitoring and inspection shall be implemented to detect and correct unsafe practices while performing the work activities.
9.4 Person involve on this job shall have trainings training especially in confined space.
9.5 Provide warning signs and sufficient barricades on working area and only assigned personnel will be allowed in the area.
9.6 Worker shall wear PPE’s needed for the work.
9. 7 Safety Supervisor / Officer shall monitor the work activities to help and to protect all assigned workers against exposure to safety hazards. He shall ensure that PPE are supplied and used and comply with DEC/ JGC applicable standards.
9.8 Housekeeping shall be maintained and working area shall be kept in a clean and tidy manner.
9.9 Job Hazard and Risk Assessment (J HRA) of this method statement shall be disseminated and explained to workers for safety awareness.

JOB HAZARD AND RISK ASSESSMENT OF REFRACTORY ANCHOR INSTALLATION