LUBE OIL RUNDOWN TANK BOX-UP WORK PROCEDURE | METHOD STATEMENT

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.

LUBE OIL RUNDOWN TANK BOX-UP WORK PROCEDURE | METHOD STATEMENT

1. PURPOSE

This method statement shall provide a minimum and general guideline to implement final box­ up work of Lube Oil Rundown Tank during pre-commissioning works at Plants and refineries to ensure that the work is
implemented safely and in accordance with Project Specifications and Drawings.

2. SCOPE

This method statement shall apply to final box-up works for all Lube Oil Rundown Tanks for Compressor at Site of Plants and refineries. The applicable items are as follows:

► D-0208 Rundown Tank for K-0XXX

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-D-001-01 Pressure Vessel Installation
3.2.2 SATR-D-2003 Vessel Closure Inspection Certificate
3.2.3 SATIP-L-350-01 On-Plot Metallic Piping Installation
3.2.4 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.

3.4 Contractor’s HSE Procedure
3.4.1 S-000-1650-001
3.4.2 S-000-1650-029
Contractor Site Safety Program
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 lube oil rundown tank box-up work schedule complying with the approved project standards and safety requirements. Prepare material requisition and assign competent supervisors to lube oil rundown tank box-up work.

4.3 Pre-commissioning Mechanical Supervisor

Direct and control the lube oil rundown tank box-up 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 lube oil rundown tank box-up 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 lube oil rundown tanks have been correctly installed and inspected.
7.1.2 Confirm that all external pipes connected to the rundown tank have been aligned and hydro-tested. Also, confirm that required chemical cleaning has been completed.
7.1.3 Confirm proper access and/or platforms are available for bolt tightening for nozzles of lube oil rundown tanks.
7.1.4 Make sure to conduct cleaning work inside rundown tanks by using air blowing and/or vacuum cleaning prior to box-up work.
7.1.5 Confirm that all rundown tank nozzles have been isolated and protected with temporary blind plates and gaskets.
7.1.6 Prepare and obtain the required work permit.

7.2 Final Box-up Work

7.2.1 Final box-up work of lube oil rundown tanks shall be implemented as per the following steps.
Step-1: Climate should be good when the box-up work starts.
Step-2: Loosen all bolts of nozzles and remove blind plates.
Step-3: Perform visual internal inspection through all nozzles.
Step-4: If any debris or foreign materials were found inside rundown tanks, they shall be removed by hand cleaning or air blowing or vacuum cleaning.
Step-5: After visual inspection was accepted, immediately start installation of permanent pipes, if lube oil flushing of the permanent pipe was completed at that time. If lube oil flushing was not yet conducted, reinstall temporary blind plates again and wait for lube oil flushing.
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 box-up work and permanent pipe installation work, lube oil flushing work through the rundown tank shall be implemented to ensure all lube oil system are clean and acceptable.

8. QUALITY CONTROL

8.1 Ensure that required inspections for lube oil rundown tank installation work have been completed and accepted prior to the final box-up inspection.
8.2 Contractor’s and Subcontractors’ QC inspectors shall attend all inspections of the final box-up works on site to ensure that all applicable requirements, codes and standards are complied with.

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 Ensure that proper working access and platforms have been provided for bolt tightening work.
9.4 Ensure that all supervisors and workers have taken “working at heights” training and always use the proper PPE.
9.5 Ensure that barricades and warning signs are properly installed.
9.6 All power/hand tools must be secured with tool lanyard or string.

10. ATTACHMENTS

ATTACHMENT- Job Safety Analysis for Lube Oil Rundown Tank Box-up Work