METHOD STATEMENT FOR AFC COLD POSITION RE-SETTING

1. PURPOSE.
2. SCOPE.
3. DEFINITIONS.
4. APPLICABLE DOCUMENTS.
5. RESPONSIBILITIE.
6. MANPOWER.
7. TOOLS AND EQUIPMENT.
8. METHODS / PROCEDURES.
9. QUALITY CONTROL.
10. SAFETY CONSIDERATION.

1. PURPOSE

1.1 This method statement shall provide minimum guidelines to carry out AFC Cold Position Resetting for plants and refineries to ensure that the work is carried out safely and in accordance with Project Drawings and Project Specifications.

2. SCOPE

2.1 This method statement will cover the activities for AFC Cold Position Re-setting.

3. DEFINITIONS

3.1 COMPANY

3.2 CONTRACTOR

3.3 Subcontractor

4. APPLICABLE DOCUMENTS

4.1 Reference Documents

4.1.1 S-000-1630-003 Material and Equipment Protection Program.
4.1.2 S-000-1650-001 Contractor Site Safety Program.
4.1.3 S-000-1650-004 Construction Environmental Management Program.
4.1.4 S-000-1139-011 Project Quality Plan.

5. RESPONSIBILITIES

5.1 Construction Manager

Ensure that all works are carried out according to this procedure. Implement the procedure and shall make sure that all personnel involved in the control, verification and documentation of the works are inducted and aware of the requirements set out herein. Ensure that all works are carried out according to Project Safety Plan.

5.2 Mechanical Manager

Planning and Implementation of ARC Cold Position Re-setting, including preparation of work schedule complying with the approved project standards and safety requirements. Requesting for the inspection & testing activity to QA/QC department. Prepare material requisition.  Designate competent personnel to supervise the activity.

5.3 Mechanical Supervisor

Ensure competent people are assigned to execute the activities. Necessary work permit & safety requirements should be in a proper place. Confirm the availability of all the materials,  tools, and equipment required to complete AFC Cold Position Re-setting in a timely manner. Review standard procedure needed prior to commencement of the work.

5.4 QA/QC Manager

Ensure the implementation of required quality control procedure, Inspection Test Plan, and maintain required documentation. Guide and inform QC inspector to maintain the quality level of inspection for the scheduled inspection activity. Manage inspection and test with regard to standards and specification.

5.5 Safety Supervisor

Ensure relevant safety precautions / procedures are in operation and work permits have been obtained. Barriers and warning signs are posted where necessary. Verify personnel are utilizing the relevant Personal Protective Equipment (PPE).

6. MANPOWER

6.1 Superintendent / Supervisor
6.2 Foreman
6.3 Crane Operator (Aramco Certified)
6.4 Rigger (Aramco Certified)
6.5 Structural Fitter
6.6 Welder
6.7 Surveyor
6.8 Helper

7. TOOLS AND EQUIPMENT

7.1 Tools and equipment should be in good condition and must be checked by Competent Person
and respective Supervisor prior to use in the plant.
7.2 Measuring instruments shall have valid calibration certificates.

7.3 Tools and equipment must be color-coded according to the color of the month. Defective tools and equipment shall be returned to Central Tool room and Equipment Services to avoid inadvertent use.

7.4 Tools and equipment shall consist but not limited to the following:

7.4.1 Mobile Crane or Boom truck.
7.4.2 Auto level.
7.4.3 Theodolite.
7.4.4 Carpenter Hand Tools.
7.4.5 Grinder.
7.4.6 Structural Fitters Hand Tools.
7.4.7 Welding Machine.
7.4.8 Hydraulic Jack with Wooden Blocks.
7.4.9 Chain Block with Slings.

8. METHODS / PROCEDURES

8.1 Preparation

8.1.1 Prepare hydraulic jack with wooden blocks or chain block with slings.
8.1.2 Any piping connected to nozzle on stationary headers shall be disconnected.
8.1.3 Nitrogen is released from the bundles.

8.2 Dis-assembly accessories in below sequence

8.2.1 Thrust block.
8.2.2 Header stopper.
8.2.3 Doubling plate.

8.3 Cold position setting

8.3.1 Prepare hydraulic jack or chain block.
8.3.2 Install hydraulic jack and wooden support, or install chain block with sling connected to nozzles.
8.3.3 Push or pull the header box using hydraulic jack or chain block according to the approved header detail.
8.3.4 Move the stationary header which Subcontractor wants to adjust the position. Do not move the floating header.
8.3.5 Make sure there is enough gap between the tube and wall for the specified movement.

8.4 Reassembly accessories in below sequence

8.4.1 Doubling plate.

8.4.2 Header stopper.
8.4.3 Thrust block.

8.5 Leak test with nitrogen

8.5.1 Purge the nitrogen in the bundles and check the pressure.
8.5.2 Set the initial pressure 10psi(0.69barg)
8.5.3 Hold it for minimum 48 hours (Acceptance criteria : 0.35barg)
8.5.4 In case any leakage is observed, inform JV field engineering.

9. QUALITY CONTROL AND ASSURANCE

9.1 QC Inspector will be assigned to attend to the quality control and assurance of this work.
9.2 QC Inspector shall be responsible to conduct all required inspection to ensure that all applicable requirements, codes and standards are complied with.
9.3 All stages of work shall be inspected in accordance with the Saudi Aramco Typical inspection plan or approved Inspection and Test Plan.

10. SAFETY ACTION PLAN

10.1 All personnel shall have E&C safety inductions.
10.2 Obtain the approval of work permit from E&C before starting any work.
10.3 Continuous monitoring and inspection shall be implemented to detect and correct any unsafe practices while performing work activities.
10.4 Good housekeeping shall be maintained in the duration of works.
10.5 Only qualified and certified crane operators and riggers will carry out rigging works.
10.6 Lifting equipment certificate required, checked, in-date and available on site for inspection.
Third party equipment inspections required. E&C monthly color code tags for lifting equipment to be used.
10.7 Provide warning sign and sufficient barricade on working area and only assigned personnel be allowed in the area.
10.8 Provide hole-watcher and log-in, log out data sheets when working at excavated area below 1.2 meters and above.
10.9 Firewatcher with fire extinguisher shall be at work area whenever there is hot work.
10.10 Welding location shall be enclosed with wind barrier and provided with non-asbestos fire blanket to prevent spread of any welding sparks.
10.11 Safety Officer shall monitor the work activities to help and protect all assigned workers against exposure to safety hazard. He shall ensure that Personnel Protective Equipment   (PPE’s) are supplied, used and in compliance with E&C applicable instruction and standards.

WORK INSTRUCTION FOR RE-COLD SETTING

0. Preparation

Hydraulic jack with wooden blocks, or Chain block with slings.
Any piping connected to nozzles on stationary headers shall be disconnected.
Nitrogen is released from the bundles.

1. Dis-assembly accessories in below sequence

1.1) Thrust block.
1.2) Header Stopper.
1.3) Doubling Plate.

2. Cold position setting.

Using Hydraulic Jack or Chain Block, move the stationay header which you want to adjust the position. Do not move the floating head

2.1.1) Prepare Hydraulic Jack or Chain Block [Sample photo]

NOTE: Thinner doubling plate (10mm THK for this case) shall be installed to the side nearer to the fixed point. Do not remove the doubling plates which you don’t want to move the bundle at the moment.

2.1.2) Install Hydraulic Jack and wooden support, or install a Chain Bock with sling connected to nozzles.

NOTE: Proper size of jack or chain block shall be used for the adjustment. When wooden block is used, wooden block size shall be decided in consideration of safety.

2.1.4) Push or pull the header box using hydraulic jack or Chain Block according to the approved Header Detail DWG (1/3), (Sample picture shows the case of hydraulic jack.)

2.1.5) Make sure there is enough gap between the tube and wall for the specified lateral movement.

NOTE: If doubling plate is installed in accordance with header detail drawing, the header should be located at the proper location. Even if the nozzle location does not completely comply with the GA drawing, the doubling plate requirement shall be.

3. Reassembly accessories in below sequence.

3.1) Doubling Plate
3.2) Header Stopper
3.3) Thrust block

4. Leak test with Nitrogen

Purge the nitrogen in the bundles and check the pressure. Set the initial pressure 10psi (0.69barg) and hold it for minimum 48 hours. Acceptance Criteria: 0.35 barg. In case any leakage is observed, please inform to Field Engineering.