1.0 PURPOSE.
2.0 SCOPE.
3.0 APPLICABLE DOCUMENTS.
4.0 RESPONSIBILITY.
5.0 MANPOWER.
6.0 TOOLS & EQUIPMENT.
7.0 METHODS/PROCEDURE.
8.0 QUALITY CONTROL.
9.0 SAFETY PRECAUTION.
10. ATTACHMENTS.
METHOD STATEMENT FOR RUST REMOVAL INSIDE SURFACE OF TOWER, VESSELS
1.0 PURPOSE
1.0 This method statement shall provide minimum guidelines to carry out rust removal inside surface of vessel and towers for plants and refinery projects.
2.0 SCOPE
2.0 This Method Statement covers the procedure of rust removal inside surface of vessel and towers for plants and refinery projects.
3.0 APPLICABLE DOCUMENTS
3.1 Project Specifications and Standards
3.1.1 SAEP-302 Instruction for obtaining a waiver of a mandatory Saudi ARAMCO Engineering requirement.
3.1.2 SATIP-D-001-01 Typical Inspection Plan Pressure Vessel Installation
3.1.3 SAIC-D-2003 Receiving Inspection of Pressure Vessel Internals
3.1.4 Related Vendors Installation and maintenance manuals/procedure and /or specifications.
3.1.5 Construction Safety Manual
3.1.6 Schedule “Q” Quality Requirement
4.0 RESPONSIBILITY
4.1 Construction Manager is responsible for implementing HSE and shall 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 JV Technical Scope of Work.
4.2 Superintendent shall assist Construction Manager in the overall construction activities. Receives and carries out directives and strategies of Construction Manager in various phases of duties assigned by this immediate Supervisor.
4.3 Foreman shall be responsible for the direct work supervision at site and ensure that the work
is performed in accordance with JV Technical Scope of Work and specification.
4.4 QC Engineer/Inspector shall be responsible to verify the work and ensure that the work is being performed in accordance to project specification and standards.
4.5 Safety Supervisor/officer shall monitor and ensure that the work is done in accordance with JV Safety Standard Procedure and in accordance with Saudi ARAMCO Safety Standard Procedure.
5.0 MANPOWER
5.1 The Superintendent shall control the overall activity of cleaning works and he shall be directly reporting to the Construction Manager. The basic manpower under him shall consist but not limited to the following:
5.1.1 Mechanical Supervisor
5.1.2 Mechanical Foreman
5.1.3 Pipefitters/Mechanical Fitter
5.1.4 Electrician
5.1.5 Rigger
5.1.6 Crane Operator
5.1.7 Helper
5.1.8 Hole Watcher
5.1.9 Scaffolder (by others)
5.2 QC Inspector
5.3 Safety Supervisor
5.3.1 Safety Officer
6.0 TOOLS AND EQUIPMENT
6.1 Tools and equipment needed should be in good condition and must be checked by Mechanical Supervisor or safety officer. These includes but not limited to:
6.1.2 Tools and Equipment
6.1.2.1 Hand Tools
6.1.2.2 Power Tools
6.1.2.3 Compressor with Dry air.
METHODS/ PROCEDURE:
7.1 Preparatory Works
7.1.1 Secure work permit from DEC/JGC concerned personnel prior to start of work/activity especially confined space work permit.
7.1.2 Prepare all materials needed for the job. Installation of scaffold shall be complete and rigid, enough to withstand loads applied.
7.1.3 Top and bottom manholes shall be opened carefully. Protection covers to rain and dust shall be installed surrounding the opening of manholes. Proper
barricade also be installed especially for top manhole to protect fall accident.
7.1.4 Install and position lightings and ventilation fans on best location as per site condition.
7.2 General Requirements
7.2.1 All surfaces (visible or not) of all equipments must be perfectly clean before any assembly; no scales; no particles, no rust and no barbs.
7.2.2 Make sure there is no foreign material inside. If any, it shall be removed and perfectly cleaned using vacuum cleaner and special devices provided by vendor.
7.2.3 Make sure there are no foreign materials inside the pipes.
7.2.4 No rust shall be present inside the adsorbers. Presence of rust leads to an important loss of time when getting rid of it.
7.3 Cleaning method
7.3.1 In case inside adsorbent towers are not clean or not satisfying the general requirements specially rust. Cleaning will have to perform prior to start any installation work inside the adsorbers. Mill scale, rust, grease and foreign matter except tightly adhering residue of mill scale shall be removed by through scraping, wire brushing or any suitable methods.
7.3.2 After cleaning and prior to commencing on the next activity, AXENS to inspect and decide whether cleaning done is acceptable or not.
8.0 QUALITY CONTROL
8.1 QC Inspector shall be responsible to conduct all required inspection/documentation and to assure that all applicable requirements, codes and standards are complied with.
8.2 After completion of rust removal and checking by Axens, RFI shall be raised for PIO inspection as per SATIP-D-001-01, Item 3.20 (Internal inspection/SAIC-D-2003.)
9.0 SAFETY PRECAUTION
9.1 Construction Manager/Supt./Supv./FM shall be responsible for the implementation of this procedure and the required orientation necessary for the work force.
9.2 Safety Supervisor/officer shall monitor compliance of the entire working crew regarding safety procedures until the work is fully completed.
9.3 The necessary manpower inclusive of supervisory staff, tools, equipment, materials, and other resources required must be made available and ready to use.
9.4 Barricade and signages shall be provided at all times of this rust removal.
9.5 All workers shall wear mandatory PPE and additional PPE if required. e.g. Respirator, BA to prevent inhalation of dust.
9.6 Sufficient lighting shall be provided.
9.7 Only trained personnel are allowed to work inside the vessel.
9.8 ARCC Superintendent shall control entry of all personnel.
9.9 Good housekeeping must be maintained for the duration of work.
9.10 Job Hazard and Risk Assessment (JHRA) of this method statement shall be disseminated and explained to workers for safety awareness.
9.11 Provide ventilation with dry air (-10 dew point degree). The space should be adequately ventilated and tested for air contaminant and supplied respirator air.
10. ATTACHMENT:
Job Hazard and Risk Assessment