1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 RESPONSIBILITY
5.0 MANPOWER CATEGORY
6.0 REQUIRED TOOLS AND EQUIPMENT
7.0 METHOD OF EXECUTION
8.0 QUALITY CONTROL AND ASSURANCE
9.0 SAFETY INSTRUCTIONS & PRECAUTIONS
10.0 ATTACHMENT
1.0 PURPOSE
The purpose of this Method Statement for Application Mastic Coating is to ensure that the work activities such as material handling, installation and test & inspection shall be carried out safely, efficiently and in accordance with the project requirements for refractory installation on Fired Heaters, Xylene Rerun Column Reboiler Furnace / Xylene Isom Reactor Heater of Plants and Refinery Projects.
2.0 SCOPE
The scope of works under this Method Statement is prepared to describe the various activities involved and the methodology to be followed by the project team for successful completion of Refractory works of Xylene Rerun Column Reboiler Furnace / Xylene Isom Reactor Heater to ensure that the work is carried out safely and in accordance with Project drawings and specifications.
3.0 REFERENCES
3.1 ARAMCO Project Specification and Standard
3.1.1 SAEP-302 Instruction for obtaining a waiver of a mandatory Saudi ARAMCO Engineering requirement.
3.1.2 SAES-H-101V Approved Saudi Aramco Data Sheets-Paint and Coating
3.1.3 SAES-N-120 Installation Requirements Extreme Erosion Resistant Refractories
3.1.4 SAES-N-140 Installation Requirements Refractory Ceramic Fiber
3.1.5 SATIP-N-120-01 Extreme Erosion Resistant Refractories
3.1.6 SATIP-N-140-01 Refractory Ceramic Fiber Installation
3.1.7 Related Vendors Installation and maintenance manual and / or specifications.
3.2 Latest Revision of the following documents shall be used.
3.2.1 Vendor Drawing
3.2.2 Structural Drawing
3.2.3 Equipment Details
3.3 Saudi ARAMCO Safety Health and Environmental Standard:
3.3.1 Construction Safety Manual – compliance with schedule D
3.3.2 General Instruction (G.I’s) at the work site
4.0 RESPONSIBILITY
Site Manager
Ensure full compliance by all refractory installer 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 work permits are obtained prior to start of work.
Mechanical Supervisor
Prepare and submit process procedure for 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.
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 The Mechanical Supervisor shall control the overall activity on application of mastic coating. The basic manpower under him shall consist but not limited to the following:
5.1.1 Mechanical Foreman.
5.1.2 Applicator.
5.1.3 Helper.
5.1.4 Scaffolder (by others).
5.1.5 Permit Receiver and other involved manpower.
5.2 Safety Engineer.
5.3 QC Inspector.
6.0 REQUIRED TOOLS AND EQUIPMENT
6.1 Tools and equipment needed should be in good condition and must be checked by the Supervisor incharge / Safety Officer prior to use in the construction area. These includes but not limited to:
- Rag.
- Masking or packing tape..
- Spray / Trowel / Brush.
- Bucket.
- Inspection Tools.
- HSE Tools / Equipment (Ventilation, blower, lighting, coverall, face protection, ear plug, dust mask, eye protection and etc.).
7.0 METHOD OF EXECUTION
7.1 Jobsite Receiving and Inspection
7.1.1 All receiving Mastic coating materials from DEC / JGC warehouse, receiving inspection shall be conducted immediately. Check the validity of materials. Material must not be expired. Materials will be stored indoor or keeping under shelter protections against direct sunshine and rain.
7.1.2 Record of inspection shall be documented as per applicable SAIC (Material Receiving Inspection); finding s and deviations shall be documented in Quality Control Inspection Report (QCIR) and Non Conformance Report (NCR).
7.1.3 Material shall not be stored below application temperature, if it was stored do not heat by any means. Move material storage area where application temperature can be achieved.
7.1.3.1 Do not store mastic at or below freezing temperatures. Freezing will cause product to separate.
7.2 Preparation of Work
7.2.1 Secure all the valid documents such as Confined Space Permit, Working Permit prior to work commence.
7.2.2 Tools and equipment shall be made operation and available for use. Ensure all tools are inspected and color-coded accordingly by color month.
7.2.3 Mobilize all manpower, tools and equipment needed for the job.
7.2.4 Manpower who will do the job should have proper training on confined space and necessary training to do the job.
7.2.5 Install barricades to confined space area for authorized personnel only.
7.2.6 Install required scaffold and must be inspected before to use. (by others)
7.3 Application of HT Mastic 500NF
7.3.1 Verify location of activities, location must not be exposed to sandstorm or rain, and area must not be exposed to direct sunlight.
7.3.2 Verify panel surface, steel surface shall be free from dust, loose dirt or other deleterious material.
7.3.3 Manufacturer’s instruction must be followed for the application of the vapor barrier / HT mastic 500NF.
7.3.4 Mastic applicator must ensure that area to be applied is clean.
7.3.5 Install packaging tape or masking tape where mastic must not be applied.
7.3.6 HT Mastic 500NF can be applied by spray, trowel or brush. HT Mastic 500NF is water soluble before setting.
7.3.7 Surface area to be kept dry before, during and after installation.
7.3.8 The refractory material shall be installed as soon as the vapor barrier is dry to touch.
7.3.9 Vapor barrier / HT Mastic 500NF shall be overlapped; edges and punctures shall be sealed.
7.3.10 After completion of application of Mastic QC Inspector will inspect prior to final inspection of client and Saudi Aramco.
7.4 Damage and Nonconformity
7.4.1 Any damages and defects and nonconformity found at site and lay down yard shall be reported immediately.
7.4.2 Any damage found on stud anchor at panel shall be repair before application of Mastic.
7.4.3 SAACO QC Inspector will be responsible for all required documentation.
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 INSTRUCTION AND PRECAUTIONS
9.1 Mastic 500NF materials are chemical composites and the mixtures can contain or form hazardous chemical components. These can occur in freshly produced mixtures as well as in use and during removal of aged material.
9.2 All Mastic 500NF materials shall be followed the MSDS provided by Vendor.
9.3 Approved Work Permit shall be obtained prior to start application of Mastic coating.
9.4 Make sure that all necessary work permits are issued.
9.5 Work execution shall be carried out in accordance with the approved Method Statement.
9.6 Wear minimum Personal Protective Equipment (PPE’s) and full body harness when working at elevated area and confined space.
9.7 Install adequate illumination when working in confined space.
9.8 Copy of approved Job Hazard and Risk Assessment (JHRA) to be maintained at work site by Work Supervisor. Conduct daily TSTI and discuss work methodology prior to commencement of work.
9.9 When working in a confined space, certified Permit Issuer, Permit Receiver, hole watcher and all entrants should have a proper training conducted by the main Contractor Training Department.
9.10 Ensure all electric hand tools are in a good condition and coded accordingly to its color month inspected by certified and authorize safety in charge at work site.
9.11 The Mechanical supervisor with the assistance of the safety department will carry-out a safety risk assessment identifying the actual hazard and possible precaution to be taken to eliminate or lessen the risk prior to start of any activities.
9.12 Hard hats, disposable coverall (if necessary), safety shoes, safety harness, hand gloves, safety glasses (dark or clear), reflective vests and dust mask are mandatory.
9.13 Ensure that barricades and warning signs are visible and properly installed.
9.14 Implement and monitor safety instruction on site.
9.15 Housekeeping shall be maintained and working area shall be kept in a clean and manner before and after work activity.
10.0 ATTACHMENT
Attachment A JHRA (Job Hazard and Risk Assessment)
Product Technical Data (HT Mastic 500NF)
Material Safety Data Sheet (MSDS)