- PURPOSE
- SCOPE
- REFERENCES
- RESPONSIBILITY
- MANPOWER CATEGORY
- REQUIRED TOOLS
- METHOD OF EXECUTION
- QUALITY CONTROL AND ASSURANCE
- SAFETY INSTRUCTIONS & PRECAUTIONS
- ATTACHMENT
1.0 PURPOSE
The purpose of this Method Statement for Static Equipment is to ensure that the work activities such as material handling, equipment installation and test & inspection shall be carried out safely, efficiently and
in accordance with the project requirements.
2.0 SCOPE
The scope of works under this Method Statement applies to all installation of Static Equipment covered.
3.0 REFERENCES
PIP VEFV 1100/1102 – Vessel; Tolerances (elevation, orientation).
PIP RESE001 – Specification for General Purpose Skid Mounted Equipment.
32-SAMMS-004 – Manufacture of Pressure Vessels.
SAES-Q-011 – Cement Based, Non Shrink Grout for Structural and Equipment Grouting.
SAES-A-004 – General Requirements for Pressure Testing.
SAES-A-007 – Hydrostatic Testing Fluids and Lay-up Procedures.
SAES-D-001 – Design Criteria for Pressure Vessels.
SAES-H-100 – Coating Materials and Application Requirements for Industrial Facilities.
SAIC-M-2006 – Inspection of Support Foundation Prior to Structural or Equipment Installation.
SAIC-D-2005 – Storage, Handling and Preservation.
SAIC-D-2006 – Equipment Pre-installation Inspection.
SAIC-D-2007 – Equipment Installation – Alignment & Elevation Check (Vertical & Horizontal Vessel).
SAIC-D-2008 – Inspection of Vessel Trim Installation.
SATIP-D-001-01 – Pressure Vessel Installation.
SATIP-M-001-01 – Structural Steel-Pipe Rack, Steel Supports & Miscellaneous* Steel Structures (* Incl. Piping Supports per Specification).
S-000-3150-001 – Construction Procedure for Installation of Static Equipment.
4.0 RESPONSIBILITY
Site Manager
Ensure full compliance by all Millwrights, Mechanical Foreman, Labor regarding execution of work and implementation of HSE procedure in accordance with project requirement and specifications. Confirm availability of all materials, tools, equipment and required personnel who will carry out the work.
Quality Control Inspector
Conduct inspection in accordance with this procedure. Monitor daily activities and verify compliance to ARAMCO Specifications. Prepares record and final acceptance documentation where required.
Construction Manager
a. Pre-mobilization Inspection and color coding for all tools and equipment used on site. Ensure that all safety requirements have been adequately addressed and the work is carried out in accordance with ARAMCO project safety procedures.
b. Ensure relevant documentation and certifications are submitted for operators, drivers, scaffolding and rigging.
Mechanical Supervisor
Prepare and submit method statement for JGC/DAEWOO/SAUDI ARAMCO review and approval.
Provide latest revision of AFC drawings, procedures, material specifications standards and technical
specifications. Provide latest as built drawings for every receive equipment.
Rigging Supervisor
To ensure that rigging and heavy lift activities are performed by SAUDI ARAMCO certified rigger in a
safe and efficient manner. Rigging is engineered, performed and inspected to satisfy the customer’s
requirements in accordance with the issued project drawings and specifications.
Safety Officer
Check the work areas and monitor from time to time in the implementation of safety procedure and
assuring that all safety equipment and tools are present at site and in good working condition.
5.0 MANPOWER CATEGORY
5.1 Foreman
5.2 Millwright
5.3 Mechanical Fitter
5.4 Fabricator
5.5 Helper
5.6 Scaffolder
5.7 Surveyor
5.8 Rigger
5.9 Permit Receiver and other involved Manpower
6.0 REQUIRED TOOLS
6.1 Appropriate Crane for Specified Lift
6.2 Slings/Non Metallic Ropes/Soft Tag Lines
6.3 Shackles/Seam Clamps
6.4 Spreader Beam or Frame/Chain Hoist
6.5 Welding Machine for Tacking of Liners/Wedges
6.6 Wrenches/Leveling Tools/Feelers and Dial Gauges
6.7 Precision Levels/Calibrated Gauge/Torque Wrench/Hand Tools
6.8 Grouting Tools and Equipment/Survey Equipment
6.9 Equipment shall be maintained and checked prior to use for safe work assurance
6.10 Equipment shall be approved and certified by SAUDI ARAMCO
6.11 All tools must be calibrated before using.
7.0 METHOD OF EXECUTION
7.1 Storage, Handling and Preservation
7.1.1 Ensure that equipment and materials to be transported to the work area from the warehouse/lay down area is in accordance with the project specifications and contract requirements. Project specification as per SAIC-D-2005 and 32-SAMMS-004.
7.1.2 Verify equipment and/or materials are undamaged prior to removal from the material receiving lay down area or warehouse.
7.1.3 Temporary covers on all openings shall be tightened firmly and shall not be removed until the related pipelines are connected during the installation stage.
7.1.4 The bottom of the base plate shall be cleaned. When oil, grease, dirt or any loose particles are found, it shall be cleaned utilizing the appropriate solution and or solvent before installation works.
7.1.5 Tagging of mechanical materials shall be in accordance with the specific project requirements. Ensure that all tags and identification are clearly shown and readable.
7.1.6 For equipment such as vessels, heat exchanger, filters, drums, skid mounted equipment and etc. handling method shall be determined by the preparation of specific procedures prior to the commencement of work. The following shall be considered:
7.1.6.1 Size, weight and shape of the equipment for the appropriate lifting procedure.
7.1.6.2 Maximum allowable loads for roads in handling route.
7.1.6.3 Width, unevenness and crookedness of the handling route.
7.1.6.4 Temporary road if necessary.
7.1.7 All center marks, orientation mark, center mark of gravity points and sling point marks, if required, to be used during handling works. It shall be checked according to the AFC drawing.
7.1.8 Skids and spreader beams for the handling and temporary placing shall be made suitable for the equipment so as to prevent damage and occurrence of any permanent distortion.
7.1.9 Only certified and approved lifting equipment and personnel shall be used to move mechanical materials and equipment.
7.1.10 Where required, proper reinforcement and protection shall be made to the roads, underground facilities and buried objects or existing structures around the handling route to prevent damage to equipment. Temporary measures shall be promptly restored to their original condition after the handling works is completed.
7.1.11 Loading of mechanical materials to a truck/trailer is to be carried out in accordance with the appropriate lifting and handling plan/procedure.
7.1.12 Ensure that all mechanical materials are adequately secured prior to transport to the work area.
7.1.13 Transportation from the material receiving/lay down area to site installation location shall be carried out by JGC/DAEWOO in accordance with the appropriate plan.
7.1.14 Unloading of materials from a truck/trailer to a designated site installation location shall be performed in accordance with the appropriate plan/procedure.
7.1.15 Any materials/equipment left overnight or unattended on roads/highway shall be suitably identified to prevent accidental collision; ie. Hard barriers, warning devices, signs, etc.
7.1.16 Ensure that the mechanical materials are properly forwarded to the mechanical installation group.
7.2 Pre-Installation
7.2.1 Obtain the AFC drawings and detail for the internal and external shall be studied and available at the work place. A) Position
B) Orientation
C) Dimension
D) Others as specified
7.2.2 Review construction drawings by identifying the following requirements:
7.2.2.1 Prepare a specific heavy and multi-crane lift plan and procedure considering
weight, size and shape of the equipment to be installed, when required.
7.2.2.2 Arrangement of lifting, hoisting and construction equipment during lift.
7.2.3 Issue the correct AFC drawings to all personnel associated with work.
7.2.4 Review the construction drawings and check availability of the following:
7.2.4.1 Lifting hoist and construction equipment tools. Check validity
7.2.4.2 Temporary facilities and consumables to be used for the installation.
7.2.5 Visit the installation location and consider the following items:
7.2.5.1 Feasibility of lifting plan/procedure and provision of access.
7.2.5.2 Installation of safety equipment/facilities (scaffolding, safety nets and ropes) at strategic locations. Preparation for the provision of firefighting equipment.
7.2.5.3 Removal of obstruction such as structural beams and braces, where necessary
7.2.5.4 Ensure appropriate protection for the equipment and its surrounding areas; i.e. pipe protection for the existing piping system.
7.2.6 Visually check equipment/accessories are free from damage.
7.2.7 Ensure that the foundation should be released from the Civil Department prior to installation of mounting plates. Handover release shall be filled and duly signed by concerned persons.
7.2.8 Obtain work permit before the commencement of work activities.
7.2.9 Concrete foundation, mounting plates and anchor bolt preparation prior to equipment installation. Check and verify the following;
7.2.9.1 Concrete foundation preparation
a. Remove by chipping all laitance (poor quality concrete), oil soaked and damaged concrete prior to equipment installation. Ensure that using chipping hammer with a chisel bit shall carry out concrete chipping. Heavy tools such as jack hammer must not be used as it could damage the structural integrity of the foundation. Upon completion of surface chipping, the foundation shall be thoroughly clean, air blown, free from all dust by free-oil dry air. Provide protective sheeting to cover the prepared surfaces when work is not in progress.
b. Ensure that the top of foundation shall be lower that the finished height of the grout thickness indicated on the drawing.
c. Establish and mark the foundation center line and elevation.
7.2.9.2 Leveling
7.2.9.2.1 Liners and shim plates preparation
– In general, liners to be used shall be made of galvanized carbon steel and shim plates to be used shall be made of austenitic stainless steel or brass plate. However, shim plates made of brass plate shall not be used for ammonia or acid service equipment, unit or area.
– Dimensions of liners shall be:
o Thickness of liner minimum 9mm
o Width of liner minimum 50mm
o Length of liner 20mm to 40mm longer than the width of the base plate of the equipment
o Gradient of wedge liner 1/30-1/40
– Liners shall be so arranged that the load of the equipment shall be uniformly and distributed over the foundation. Liners shall be placed as near as possible to and both sides of each anchor bolt.
– When placing of liners on both sides of anchor bolts is not possible due to limited space between anchor bolts, a liner shall be placed at the center of the neighboring anchor bolts.
– Distance between liners shall be a maximum of 500 mm for rotating equipment.
– In cases where only flat liners are used for alignment, no more than maximum of 5 pieces of shim plates shall be used in anyone stack.
– Shim plates placed on flat liners for alignment of very small adjustment shall be less than 1mm thickness of one shim plate.
– Where the liners are used in multi-layers for alignment, it shall be tack welded to each other after completion of alignment of the equipment.
– Surface of straight liner do not need machining. The gradient surface of wedge liners shall be finished smoothly by grinding and all the corners of the liner shall be rounded.
– When the equipment is installed on structural steel, elevation of top surface of structural steel shall be adjusted using liners or shim plates, if required.
– Materials of liners shall be ASTM A36 or equivalent, unless otherwise specified.
– Liners that will be used on top of the structures shall be galvanized.
7.2.9.3 Anchor Bolt Preparation
– Check anchor bolt condition embedded in concrete foundation.
– Ensure that templates have been used for anchor bolt setting.
– Anchor bolt location, projection and diameters have been field verify to match the anchor bolt hole pattern in the mounting plate prior to grouting.
– Ensure bolt threads have been covered with duct tape or other suitable means to keep them clean and to prevent any damage that might occur during the chipping and grouting operation.
7.2.10 Once the foundation preparation has been completed, equipment installation commences. Ensure that lifting and rigging shall be done with JGC/DAEWOO/SAUDI ARAMCO job specification and approved Method Statement respectively.
7.3 Installation of Equipment
7.3.1 Lifting and Rigging of Equipment
7.3.1.1 Ensure all personnel and equipment to be utilized for the installation work are qualified and certified in accordance with SAUDI ARAMCO SAIC-D-2007 AND SATIP-D-001-01.
7.3.1.2 Provide the necessary protective materials such as wood softeners or equivalent to prevent any damage that may result from lifting.
7.3.1.3 Construction equipment, machine tools and calibrated measuring instrumentsto be used during installation shall be thoroughly inspected.
7.3.1.4 The installer shall verify that the cables and slings are bearing only on the intended lift points and are not transmitting any loads onto auxiliary piping, instruments, chain guards, and etc. Equipment shall be shifted from lay down area by Trailer flatbed truck according to size and delicacy of the equipment.
7.3.1.5 The installer shall keep all other personnel from working under the lift and keep them a safe distance away until the equipment is secured in place on its foundation or structure.
7.3.1.6 Install the equipment by mounting onto base plates, foundations or structural platform and/or skids.
7.3.1.7 During installation, ensure that anchor bolts and foundations are not damaged. Slings shall be positioned in a way which will not cause any excessive distortion to the equipment base during the lifting operation.
7.3.2 Setting and Alignment of Equipment
7.3.2.1 Check and verify that the center of the equipment matches the centerline marked on the foundation.
7.3.2.2 Ensure that the base of the equipment is clean, free from oil and other debris prior to setting/mounting onto foundation.
7.3.2.3 Set and align the equipment to meet the required elevation, center line and plumbness in case of vertical vessel. Ensure that nozzle orientation is correct as indicated on piping drawing and general arrangement drawing. Alignment inspection report for each equipment shall be done.
7.3.2.4 Leveling of equipment shall be done with calibrated leveling instrument.
7.3.2.5 Tolerances (elevation and orientation) shall be in accordance with PIP-VEFV1100/1102.
7.3.2.6 Confirm completion of leveling and elevation work before firmly tightening the locknuts of the anchor bolts.
7.3.2.7 Upon completion of leveling and elevation work, grouting works commence and shall be carried out in accordance with the approved Method Statement for Grouting.
7.3.2.8 All internal works to equipment shall commence only upon completion of inspection and acceptance of grouting works by Company.
7.3.2.9 Vessel box-up activity shall commence only upon completion of piping connections and flushing. Prior to commencement of the work, ensure that all personnel working and foreign materials were out of the equipment.
7.3.3 Piping Connection and Final Alignment
7.3.3.1 Upon completion and acceptance of grouting works by Company, piping connections and final alignment commence. Ensure that the connections and alignment shall be carried out in accordance
with job specifications.
7.3.3.2 Upon completion of preliminary piping alignment and fit-up to equipment, conduct pressure testing of the piping system in accordance with SAES-A007, SAES-A-004 and approved Method Statement for Pressure Testing.
7.3.3.3 Prior to final checking of piping alignment to the equipment, listed below are relevant piping works to be checked and verified:
– Installation of permanent supports
– Removal of temporary supports and hangers
– Removal of test blinds and major field welds are completed, as pressure test blinds and field welds can result in changes in piping-to-machinery alignment.
– Check and verify that the inlet and outlet piping is properly constructed in accordance with the latest AFC drawing. Verification shall include gasket size and material, size and length of flange, bolts, studs and nuts.
– Check and verify that spring hangers and spring supports are installed and locked at the cold load setting position.
7.3.3.4 Upon satisfactory piping alignment has been completed, spring hanger and spring support function shall be verified. All spring hanger turnbuckle locknuts
shall be verified and check as tight.
7.3.3.5 The same methodology shall be carried out for setting and alignment of the next equipment until the last equipment is completely installed.
7.3.3.6 Upon completion of inspection and acceptance by Company, conduct housekeeping properly.
8.0 QUALITY CONTROL AND ASSURANCE
8.1 Inspection shall be conducted and recorded in accordance with the Job Specification Inspection and Test Plan.
9.0 SAFETY INSTRUCTIONS AND PRECAUTIONS
9.1 Make sure that all necessary work permits are issued.
9.2 Check all lifting equipment prior to commencing lifting activities.
9.3 Stay away from any suspended load/falling objects.
9.4 Wear full body harness when working at elevated platform.
9.5 Install safety nets when necessary.
9.6 Ensure that barricades and warning signs are properly installed.
9.7 Ensure that there are no hazardous or combustible gases present in the work area.
9.8 Install flashing lights to traffic.
9.9 Copy of approved JSA to be maintained at work site by Work Supervisor. Conduct daily Tool
Box Talk and discuss work methodology prior to commencement of work.
9.10 Implement and monitor safety instruction on site.
10.0 ATTACHMENT
10.1 JSA (Job Safety Analysis)
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