MATERIALS AND EQUIPMENT PRESERVATION METHOD STATEMENT

1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 RESPONSIBILITY
5.0 SAFETY PRECAUTION
6.0 MANPOWER
7.0 TOOLS & EQUIPMENT
8.0 METHODS / PROCEDURES
9.0 QUALITY CONTROL
10.0 ATTACHMENTS

1.0 PURPOSE

1.1 This method statement shall provide minimum Guideline for materials and equipment preservation/protection at storage yard /or work site during construction for plants and refinery projects.

2.0 SCOPE

2.1 This specification covers the minimum requirements for materials and equipment as required in project specification and instruction from vendor/manufacturer for plants and refinery projects.

3.0 APPLICABLE DOCUMENTS

3.1 S-000-1630-001 Field Material Control Procedure.
3.2 SCHEDULE “Q” Quality Requirements.
3.3 SCHEDULE “G” Materials, Tools and Equipment.
3.4 04-SAMSS-035 General Requirements of Valves.
3.5 S-000-1640-005 Procedure for Work Release between Disciplines.
3.6 SAIC Saudi Aramco Inspection Checklist.
3.7 SATIP Saudi Aramco Typical Inspection Plan.
3.8 SAEP-302 Instruction for Obtaining a Waiver of a Mandatory Saudi Aramco.
3.9 Engineering Requirements.
3.10 Industry Codes and Standards.
3.11 Saudi Aramco Safety Manual.
3.12 1770-SMMP-001 Site Materials Management Plan.
3.13 Manufacturer’s Recommendation for Preservation vendor.

4.0 RESPONSIBILITY

4.1 Construction Manager shall responsible for all HSE matters and to study, 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 Technical Scope of Work.
4.2 Material Manager / In-Charge – shall be responsible for the implementation of this procedure.

4.3 QC Inspector shall be responsible in monitoring and inspection of the work and ensure that the work is performed in accordance with JGC/DAEWOO Technical Scope of Work and Standards.
4.4 QC Manager shall be responsible for the verification of this procedure through audits and surveillances.

5.0 SAFETY PRECAUTION

5.1 Obtain the approval of the work permit as required.
5.2 Tools and equipment should be made operational and available for use.
5.3 Sufficient number of fire extinguishers shall be provided to prevent materials and equipment from fire. All warehouse and preservation crew personnel shall be trained in the use of portable fire extinguishers.
5.4 Provide sufficient warning signs and barricade as required in the area and only assigned and authorized workers will be allowed in the area.
5.5 Man-lift and Crane users shall be trained and certified to operate and use the equipment. Certified Rigger shall be assist in any lifting / rigging works.
5.6 Good housekeeping shall be maintained around the area. The site of all materials and  equipment shall be kept in a clean and tidy manner.

6.0 MANPOWER

6.1 The Construction Manager shall head the preservation and maintenance activities. The basic manpower will include but not limited to:

6.1.1 Foreman Mechanical.
6.1.2 Millwright.
6.1.3 Pipe Fitter.
6.1.4 Electrician.
6.1.5 Crane Operator.
6.1.6 Forklift Operator.
6.1.7 Rigger.
6.1.8 Helper.

6.2 The preservation crew shall also coordinate with warehouse personnel for confirmation of storage areas for equipment that arrived but not yet installed.
6.3 The preservation crew shall always coordinate with the construction crew for preservation of installed equipment.

7.0 TOOLS AND EQUIPMENT

7.1 The basic tools and equipment will inclulde but not limited to:
7.1.1 Hand Tools, Jigs and Fixtures.
7.1.2 Crane.
7.1.3 Forklift.
7.1.4 Pallet Truck.
7.1.5 Ladder.

8.0 MATERIALS AND EQUIPMENT PRESERVATION METHOD STATEMENT / PROCEDURES

8.1 As a general rule, the manufacturer packaging and preservation measure shall not be disturbed unless required for the installation or the check of equipment / materials except those items that shall require preventive maintenance during storage.
8.2 The equipment vendor / manufacturer’s maintenance and preservation procedure shall be made available.
8.3 Manufacturer’s recommended information shall be collated for the implementation of this preservation activities.
8.4 Materials receiving and inspection.
8.4.1 When the equipment arrives at site, receiving inspection shall be conducted in accordance with applicable procedures / specifications and Warehouse Department shall be responsible in monitoring all information such as shipping list, storage requirement, inistallation manual and drawings before arrival of Machinery / Equipment at site.
8.4.2 Record of Inspection shall be documented in Quality Control Inspection Report (QCIR) and Non Conformance Report (NCR)
8.4.3 Material receiving (supplement to S-000-1630-001 Sec. 6.1.1) Field Material Control Procedure.

8.5 Storage of Materials and Equipment

8.5.1 Materials and equipment shall be strored at correct arrangement and requisite enviroment, material stoage classification shall serve as a guide for proper area where equipment / materials should be stored / laid. Refer to S-000-1630-001.

8.5.2 The storage area and equipment shall be kept clean by provIding physical protection and covering when work operation such as concrete chipping, sandblasting, painting and rigging are performed in the area.
8.5.3 Mechanical equipment requiring storage under nitrogen gas filling will be purge as per manufacturer’s recommendation’s instruction directly proportional to the internal volume prior to pressurization at the level specified in the manufacturer procedure.
8.5.4 Accessories not necessary during construction shall be tagged identified the equipment to which they belong and shall be stroed in a suitable condition.
8.5.5 Dunnage or proper material shall be provided underneath the pipe and / or pipe spool in such a way as to avoid contact with the soil. Piping material shall be properly
segregated and stored as to avoid contamination and confusion.
8.5.6 Electrical and instrumentation materials shall have separate storage area from the other mechanical parts.

8.6 Examination of Equipment Upon Arrival at Work Site

8.6.1 All equipment shipped with protective covers or plugs over openings, and with rust preventive coatings applied on exterior machined and threaded surfaces, shall be treated on arrival at the Job Site as follows:
8.6.1.1 Protective covers, plugs and coatings shall be renewed if not intact. If water or dirt has entered the equipment, through damaged or improperly secured covers and plugs, the equipment shall be cleaned before covers , plugs and coatings are restored.
8.6.1.2 If the vapor phase inhibitors or nitrgoen gas or desiccant are used to protect the interiors of mechanical equipment, the seals shall be examined when the equipment is received at the site. Any damage vapor seals or interiors shall be checked. Repair or replacement work is carried out in accordance with inspection result.
8.6.1.3 Vapor seals shall be protected until the equipment is serviced for start-up. Any damage to seals prior to such time shall be immediately repaired.
8.6.2 Warehouse personnel shall check the equipment before receiving and acceptance prior to release between disciplines.

8.7 Protective / Preservation Activities

8.7.1 Prior to the application of preservatives/preventatives: surface shall be clean, free of water, grease, oil, metal particles dirt and debris.
8.7.2 Internal/External protection and or preservation materials to be use shall be approved by JGC/DEC in accordance with Manufacturer’s / Vendor’s recommendation.
8.7.3 Kerosene or gasoline shall not be used as cleaning agents.
8.7.4 All carbon and low alloy steel shall be protected from any contact with corrosive atmosphere. This shall include the timely rotating of shafts, which shall be executed and recorded. Motors shall have their shafts rotated every three months as per Vendor’s recommendation to prevenet bearing damage and the dates recorded.
8.7.5 Machinery-Compressors, Pumps, Agitators and Fans, Gear unit cases, Turbines.

8.7.5.1 All Internal/Exteral protection requirements shall be as per Vendor’s Manufacturer recommendation.
8.7.5.2 Shaft coupling and exposed machined surfaces shall be cleaned and coated with exterior preservative.
8.7.5.3 The suction and discharge nozzles of compressors and pumps shall be covered with leak tight metal closure’s or blinds, which shall remain in place until required testing, flushing, or connecting piping is completed.
8.7.5.4 Preventive maintenance for vertical pumps shall be in accordance with the manufacturer’s recommendation.
8.7.5.5 All loosely shipped items shall be identified and tag and shall be stored in a covered area as required.
8.7.5.6 Spare rotating elements shall be stored indoors and stored as per Vendor’s / Manufacturer recommendations.
8.7.5.7 Storage requirement of machine rotors in a controlled environment such as vertical storage of larger rotors shall be noted.
8.7.5.8 Large Compressors/Turbines needs special protection such as nitrogen purging or sealing of case opening if expected to be in the field for a longer period.
8.7.5.9 Reciprocating Compressor, Pumps and Internal Combustion Engines shall be protected as follows:
a) Machinery Prior to and after installation at their final service location; turbines, gear until cases, centrifugal fans, agitators, centrifugal pumps and centrifugal compressors shall be protected as follows:
 Coat all internal surfaces of bearing housing and gear unit cases with a liquid concentrate for multi-metal protection. Vent and drain connections shall be plugged, capped or blinded as applicable, using steel fittings, Blinds shall be installed with gasket. The internal survaes will be protected with a vapor phase circlulating oil continuously base on vendor’s recommendation. The internal surfaces shall be periodically checked and recorded if necessary.
 Clean shaft, couplings and exposed machined surfaces and coat them with a barrier coating that provides extended, multi-metal protection.
 Covers the suction and discharge nozzle of centrifugal compressors, pumps, and steam turbines with leak tight metal closures. The closures shall remain in place or be replaced with blanks unitl hydrostatic testing and flushing/mechanical cleaning of connecting piping is completed. Gasketed surfaces and unpainted surfaces shall be coated.
 All pump seals shall be removed and stored until the pump is ready for use. Seal locations shall be filled with non-corrosive material that is readily removable and provides a tight seal.
 Spare rotating elements shall be installed indoors in accordance with the vendor’s recommendation.
b) Internal combustion engines shall be protected as follows:
 Electrical accessories, which can be damage by moisture, shall be stored in a dry, warm place where condensation of humidity will not occur. Calbe cut end shall be sealed so as to avoid moisture ingress.
 A vapor phase circulating oil will be placed in the crank case at 25% crank case operating level. The engine will be cranked for one minute to circulate the oil through the lubrication system.
c) Other mechanical equipment shall be protected as follows:
 Flush oil lubricated bearing brackets and gear unit cases with solvent until clean. Fill the units to 25%of normal operating level with a vapor phase circulating oil.
 Apply a barrier coating that provides extended, multi-metal protection.
 Removed all exposed chains with solvent, coat with a barrier coating that provides extended, multi-metal protection and wrap them in kraft paper. Label each wrapped chain to provide the proper identification and store with accessories.
 Rotating equipment shall be “turned” and valves stroked per vendor’s recommendations.

8.7.6 Pressure Vessels

8.7.6.1 These shall be protected in accordance with Vendor’s specification. The protection required for shipping shall be applied during all phases of storage and erection at the site. Prior to shipment from Vendor Factory. The interior shall be cleaned and inspected. A corrosion preventer, suitable for sea shipment, shall be applied to all internals. This coating shall be soluble in crude oil its products. The dissolved coating shall not plug. The following procedures shall be followed to protected vessels until start-up.

a) Coat all exposed bolts and flanges with a barrier coating that provides extended, multi-metal protection.
b) Cover all nozzles with a gasketed cover and close all other openings tightly.
c) Check exterior prime coat for damage, if any, and touch up where necessary.
d) Exposed internal surfaces shall be protected with a vapor phase corrosion inhibitor or a nitrogen gas purge maintained at 5 psig.

8.7.7 Air Cooled Exchangers

8.7.7.1 Motor larger than 100hp shall have their shafts rotated every three months to Vendor’s recommendation to prevent bearing damage and the dates recorded.
8.7.7.2 These shall be protected in accordance with Vendor’s specification. Additionaly, exposed stainless steel fabrication, being shipped by sea, shall be protected by a temporary protective coating.

8.7.8 Package Equipment

8.7.8.1 Preservation and maintenance of equipment constituting the package unit shall be strict compliance with Vendor/Manufacturer and Sub-vendor instruction.
8.7.8.2 Package equipment inludes individual items of equipment requiring different preservation and maintenance from the package as a whole and shall be made avialable by SMP for implementation.

8.7.9 Piping Materials

8.7.9.1 Pipes (Plain/Random)

a) Handling and storage of all piping shall be in accordance with Vendor’s instruction.
b) Be sure that all ends of piping shall be closed with temporary caps or covers to prevent intrusion of debris, dust, and sand, etc.
c) Even or wither Pipe material identification or color coding shall be maintained throughout the blasting, painting, fabrication and erection process.
d) Pipes shall be supported with wood dunnage and securely wedged.

e) Maximum stacking height shall not exceed five diameters for pyramid stacking. Above this, pipe shall be parallel stacked and wedged with timber dunnage between eachlevel to a maximum height of two meters or two layers at the field.
f) All pipes and tubing stored outside and on racks or sleepers shall be properly supported to avoid damage and bending.
g) When pipes are stored in stacks, each layer of pipe shall be supported by its own row of sleepers.
h) Painted and galvanized pipes shall be handled with care to reduce abrasion of the coating.

8.7.9.2 Prefabricated Pipes

a) Pre-fabricated piping spools shall be stored properly so that small branches or spools do not support heavy weight.
b) Flange faces and beveled weld ends of prefabricated pipe should be protected with wooden covers, vinyl caps or equial to protect from damage and preventing ingress of foreign matters.
c) Ensure that the end protection of the pipes is securely installed as required.

8.7.9.3 Fittings (Elbows, Tees, Reducers, Flanges)

a) Store items size 2” NPS and smaller size indoors after unpacking.
b) Flange face can be protected against damage by storing them face to face.
c) Any carbon steel / alloy flanges that stored outside due to their size shall be palletized and have their face treated with “rust ban” or equivalent.
d) Any fittings that stored outside due to their size shall be palletized or supported by timber dunnage and stacked in such a way so as to allow rainwater to drain out.

8.7.9.4 Stainless Steel

a) Small pieces stainless steel (alloys containing more that 10% chromium) equipment, components and materials shall be stored in covered area.
b) In lieu of covered area. Approved Protective coating shall be an alternative for large pieces.

8.7.9.5 Valves

a) Valves shall be protected in accordance with 04-SAMSS-035.
b) The valve shall be stored in part open position. Store items sizes 2” NPS and smaller sizes indoor or as per manufacturer’s recommendation.
c) Manually operated valves size 6” NPS or larger may be stored outdoors on a paved area with valve stem upright.
d) Large automatic control valves such as slide valves and motor operated valves may store outdoors on a paved area, on a pallet provided with shed roof and/or tarpaulin sidings (or equivalent). Actuators on control valves shall be protected against mechanical damage and have covers on all flange connections.

e) Soft seated ball and plug valves shall be stored in closed position. All other manually operated valves shall be stored as per manufacturer’s instruction / recommendations.
f) Maintain the sealed threaded plastic plugs or cap provided in threaded connection valves.
g) On regular basis, protective coatings or rust preventatives shall be inspected and renewed when required.
h) Relief valve’s upstream and downstream connections shall be closed with covered and tagged. Relief valves shall be stored in vertical position not directly contact with sand.

8.7.10 Cables

8.7.10.1 All cables ends shall be protected with proper cable end seal caps to prevent moisture ingress.
8.7.10.2 Cable drums shall be IR measured / recorded when cable drums arrive on site and before cable is pulled.
8.7.10.3 Manufacturer’s / Vendor’s recommendation shall be followed in preservation and installation.

9.0 QUALITY CONTROL

9.1 Obtain the approval of the work permit as required.
9.2 Tools and equipment should be made operational and available for use.
9.3 Sufficient number of fire extinguishers shall be provided to prevent materials and equipment from fire. All warehouse and preservation crew personnel shall be trained in the use of portable fire extinguishers.
9.4 Provide sufficient warning signs and barricade as required in the area and only assigned and authorized workers will be allowed in the area.
9.5 Man-lift and Crane users shall be trained and certified to operate and use the equipment. Certified Rigger shall be assist in any lifting / rigging works.
9.6 Good housekeeping shall be maintained around the area. The site of all materials and equipment shall be kept in a clean and tidy manner.