1. PURPOSE
2. SCOPE
3. APPLICABLE DOCUMENTS
4. RESPONSIBILITIES
5. MANPOWER
6. TOOLS AND EQUIPMENT
7. METHODS / PROCEDURES
8. QUALITY CONTROL
9. SAFETY PRECAUTION
10. ATTACHMENTS
1. PURPOSE
This method statement shall provide minimum requirements to implement final box-out works of related equipment during pre-commissioning works at plants and refinery projects to ensure that the work is implemented safely and in accordance with Project Specifications and Drawings.
2. SCOPE
2.1 This method statement shall apply to final box-up works for all of static vessels which have manholes and/or hand holes at plants and refinery projects.
3. APPLICABLE DOCUMENTS
3.1 Saudi ARAMCO Project Specifications and Standard
3.1.1 SAEP-351 Bolted Flange Joint Assembly
3.1.2 G.I.2.710 Mechanical Completion and Performance Acceptance of Facilities
3.1.3 CSM Saudi ARAMCO Construction Safety Manual
3.1.4 SAIC-L-2014 Inspection of Bolted Flange Joint Assembly
3.1.5 SAIC-D-2012 Final Inspection of Pressure Vessels (Re-Instatement)
3.2 Inspection and Testing Plan/ Method Statement
3.2.1 SATIP-D-001-01 Pressure Vessel Installation
3.2.2 SATR-D-2003 Vessel Closure Inspection Certificate
3.2.3 All Other Applicable Contractor’s Inspection and Test Plan
3.3 Contractor’s / Subcontractor’s Procedure and Method Statement
Method Statement – Installation of Vessel Internal (Contractor)
3.4 Contractor’s HSE Procedure
3.4.1 S-000-1650-001 Contractor Site Safety Program
3.4.2 S-000-1650-011 Isolation, Lockout & Tagout Procedure
3.4.3 S-000-1650-030 Confined Space Procedure
4. RESPONSIBILITIES
4.1 Pre-commissioning Manager
Ensure that all works are carried out according to this procedure and secure that all work areas are in safe working condition and monitor properly from time to time the implementation of safe procedure, requirements.
4.2 Pre-commissioning Mechanical Manager
Make planning and Implementation including preparation of box-up work schedule complying with the approved project standards and safety requirements. Prepare material requisition and assign competent supervisors to box-up work.
4.3 Pre-commissioning Mechanical Supervisor
Direct and control the box-up work schedules complying with the approved standards and safe guidelines. Ensure that, prior to enter to vessel, line-up of external pipes has been completed with blind plates, if required. Supervise all related activities on site and prepare the inspection request to QA/QC section. Ensure competent workers are assigned to execute the activities. Confirm all necessary work permits are in proper places and the availability of all the materials, tools, and equipment required to box-up work.
4.4 Quality Control Manager
Ensure full implementation of the required quality control procedures and maintain the required documentation as per applicable Saudi ARAMCO Inspection and Test Plan for the final acceptance and handover of the systems. Guide and inform QC inspectors to maintain the quality level of inspection for the scheduled inspection activities.
4.5 Safety Supervisor
Ensure that relevant safety precautions/ procedures are in operation and work permits have been obtained. Also, ensure that safety barriers and warning signs are posted where necessary. Verify all workers are using required Personal Protective Equipment (PPE).
5. MANPOWER
– Contractor/ Subcontractor Manpower
– Licensor Representative (for Witness)
– Superintendent / Supervisor
– Foreman
– Mechanical Workers
– Pipe Fitter (for Manhole Closure)
– Crane Operator (if required)
– Rigger (if required)
– Helper
6. TOOLS AND EQUIPMENT
6.1 Tools and equipment should be in good condition and must be checked by supervisor and/or foreman prior to use at site.
6.2 Torque wrenches shall have valid calibration certificates.
6.3 Tools and equipment must be color-coded.
6.4 Required tools and equipment are as follows but not limited to:
6.4.1 Wrenches
6.4.2 Torque Wrenches
6.4.3 Cleaning Tools for Internal Vessel
6.4.4 Temporary Blowers and Lightings
6.4.5 Borescope (High Resolution Type with Minimum Reach of 2m Length)
6.5 Personal Fall Arrest Systems.
7. VESSEL FINAL BOX-UP WORK PROCEDURE | METHOD STATEMENT
7 .1 Preparation
- Prior to the start of final box-up, Licensor Representative will conduct the detailed inspection of the equipment as per Attachment-3 and this should be completed before issuance of RFI (Request for Inspection) to Company that final box-up has been made.
- Confirm that all internals shown on design drawings have been correctly installed and inspected. Typically this shall include not only trays, but also all internal parts, such as structure packing, baffles, dividers, vortex breakers, nozzles, flow distributors, piping, demister pads and catalyst supports and other mechanical parts of equipment.
- Confirm that all external pipes connected to the vessels have been hydro-tested and completed lay-up and reinstatement as per marked-up P&IDs. Flange connection and bolt tightening inspection shall be conducted appropriately.
- Also confirm that the line-up of all connected pipes such as blind plate installation, bolt torqueing and valve closing has been completed as per marked-up P&ID to ensure there is no chance of hazardous gas such as argon I nitrogen can intrude into inside vessels during the final box-up works. If such hazardous gas needs to be remained in a part of system, ensure that vessels have been isolated by installing blind plates with isolation tags. Manholes shall be kept open during final box-up inspection and proper ventilation shall be provided.
- Confirm that all instruments have been installed in proper locations.
- Open all manholes and install ventilation fans and lightings (low voltage types) as required inside the vessels.
- Prepare and obtain confined space work permit for all vessels appropriately.
- Protect all surfaces of manhole flange to avoid any damages during the final box-up works.
- Confirm that mandatory access shall be remained inside of vessels to inspect all points.
- Confirm that all temporary covers and preservation material such as VpCI shall be A removed from (shall not be remained) inside vessels as much as possible. General cleaning inside vessels shall be completed prior to the final box-up works.
7.2 Final Box-up & Charging Activities (Licensor Driven)
Guidance Note – Upon completion of Licensor driven activities no further internal works such as manway closure or charging will be required, the vessel shall therefore qualify for both Sections A and B of SATR-D-2003 to be signed. This certifies the vessel is complete and ready for start-up.
7.2.1 Contractor shall ensure all necessary components have been installed per the drawings and SATR-D-2003, prior to initiating request for Final Closure inspection, to the best of their ability.
7.2.2 Contractor shall ensure the vessel is free of debris and moisture per SATR-D-2003, prior to initiating request for Final Closure inspection.
7.2.3 Licensor shall proceed to perform box-up activities jointly with all Invested Parties (1).
7.2.4 Where a step-wise box-up is required, which involves the installation of internal components and loading of consumables, the Licensor shall guide the process. Such cases include J 12-D-0201 A&B Adsorbent Towers.
7.2.5 The Licensor shall ensure Invested Parties remain informed on progress of installations, and will be responsible for ensuring Invested Parties are included in all necessary inspections. Upon acceptance of each stage of box-up/charging, the Proponent shall authorise the Contractor/Licensor to proceed to the next stage.
7.2.6 At completion of all box-up/charging stages, the Invested Parties shall perform the Final Box-up inspection. The Proponent team shall inspect the external manways and authorise closure of the vessel and witness insertion of the permanent external manway gaskets and hot-bolting of the manway cover. Proponent team shall then sign SATR-D-2003 Section A and B to verify the vessel is complete and charged, and was released.
7.2.7 PID representatives shall ensure SATR-D-2003 Sections B2 and B3 are completed, then sign SATR-D-2003 to verify the action were complete.
Note (1): Invested Parties – The team required to perform the sign-off of Box-up. Team shall include the Contractor/Third Party members (Construction Representative, QC Inspector & QC Supervisor) and Saudi Aramco members (PMT Representative, JAPID Representative and Proponent)
7.3 Final Box-up Activities — No Charging Required (Without Licensor)
Guidance Note – Vessels which are found to be mechanically complete, and require no further internal works such as manway closure or charging, will qualify for both Sections A and B of SATR-D-2003 to be signed. This certifies the vessel is complete and ready for start-up.
7.3.1 Contractor shall ensure all necessary components have been installed per the drawings and SATR-D-2003, prior to initiating request for Final Closure inspection, to the best of their ability.
7.3.2 Contractor shall ensure the vessel is free of debris and moisture per SATR-D-2003, prior to initiating request for Final Closure inspection.
7.3.3 Invested Parties shall perform inspections per Saudi Aramco and International Standards.
7.3.4 At completion of the inspection activities, the Proponent team shall inspect the external manways and authorise closure of the vessel and witness insertion of the permanent external manway gaskets and hot-bolting of the manway cover. Proponent team shall then sign SATR-D-2003 Section A and B to verify the vessel is complete and charged, and was released.
7.3.5 PID representatives shall ensure SATR-D-2003 Sections B2 and B3 are completed, then sign SATR-D-2003 to verify the action were complete.
7.4 Final Box-up Activities — Delayed Charging (Without Licensor)
Guidance Note – Vessels which are found to be mechanically complete, but require further internal works such as manway closure or chemical/catalyst charging, will qualify for sign off on Section A of SATR-D-2003. This certifies the vessel is mechanically complete but not ready for start-up. Only at the completion of man way closure or chemical/catalyst charging can the Invested Parties sign off on Section B of SATR-D-2003, indicating the vessel is now complete and ready for start-up.
7.4.1 Contractor shall ensure all necessary components have been installed per the drawings and SATR-D-2003, prior to initiating request for Final Closure inspection, to the best of their ability.
7.4.2 Contractor shall ensure the vessel is free of debris and moisture per SATR-D-2003, prior to initiating request for Final Closure inspection.
7.4.3 Invested Parties shall perform inspections per required Saudi Aramco and International Standards.
7.4.4 At completion of the inspection activities the Proponent team shall inspect the external manways and authorise closure of the internal manways where applicable. Invested Parties shall then sign SATR-D-2003 Section A.
7.4.5 Proponent team will authorise the Contractor to close the vessel using compressed fibre non-asbestos gasket pending completion of charging, and subsequent installation of the permanent gasket.
7.4.6 Vessel will be placed under preservation conditions, pending charging at a later date. Preservation must be performed within 14 days of signing SATR-D-2003 Section A.
7.5 Final Box-up Activities — Internal Manway Closure (Without Licensor)
Guidance Note – Vessels which are found to be mechanically complete and require only the internal manway closure, the Invested Parties shall sign off on Section A of SATR-D-2003. At the completion of manway closure the Invested Parties shall then sign off on Section B of SATR-D-2003. This now certifies the vessel is complete and ready for start-up.
7.5.1 Contractor shall ensure all necessary components have been installed per the drawings and SATR-D-2003, prior to initiating request for Final Closure inspection, to the best of their ability.
7.5.2 Contractor shall ensure the vessel is free of debris and moisture per SATR-O-2003, prior to initiating request for Final Closure inspection.
7.5.3 Invested Parties shall perform inspections per required Saudi Aramco and International Standards.
7.5.4 At completion of the inspection activities the Proponent team shall inspect the external manways and authorise closure of the internal manways. Invested Parties shall then sign SATR-D-2003 Section A and B to verify the vessel is released for manway closure. Internal manway closure shall begin immediately.
7.5.5 Upon completion of internal manway closure, Contractor shall inform Invested Parties that the vessel is ready for Final Vessel Closure Inspection. Invested Parties shall perform the required inspection.
7.5.6 Following satisfactory inspection, Proponent Inspection shall witness the insertion of the permanent external manway gaskets and hot-bolting of the manway covers.
Proponent team shall then sign SATR-D-2003 Section A and B to verify the vessel is complete and charged, and was released.
7.5.7 Company representatives shall ensure SATR-D-2003 Sections B2 and B3 are completed, then sign SATR-D-2003 to verify the action were complete.
PRESSURE VESSELS AND HEAT EXCHANGERS | SCOPE OF WORK
8. QUALITY CONTROL
8.1 Ensure that all required inspections for vessel installation work had been completed and accepted in accordance with SATIP-D-001-01 and applicable Contractor’s Inspection and Test Plan prior to the final box-up inspection.
8.2 Ensure that all open Work Sheet, NCR and LBE had been closed prior to the final box-up inspection.
8.3 The inspection of final box-up shall be conducted in accordance with SATR-O-2003.
8.4 Contractor shall prepare a document folder of “final box-up inspection package” for each equipment item. The document folder will contain as minimum:
a) P&ID
b) Equipment Data Sheet
c) General Arrangement Drawings
d) Marked-up P&ID showing Location of Package Limit /LOTO’s Blinds / Vent & Drain Points for Purging and/or Preservation
e) Blind List
f) SATR-O-2003
g) Preservation Method
All documents shall be verified as being correct with all piping and equipment correctly identified. Red-line drawings will be acceptable, but must be properly incorporated in the document folder prior to final box-up inspection.
A Contractor shall ensure the line-up of LOTO’s blind positions as per marked-up P&ID prior to the final box-up inspection, and if any LOTO’s blinds had been changed (removed or added) after the box-up inspection due to the preparation/line-up of adjoining systems, or extension/combination of LOTO’s boundaries, Contractor shall update the marked-up P&ID as per the actual condition. The updated marked-up P&ID shall be incorporated in the final box-up inspection package without removing the previous marked-up P&ID, so that history of LOTO’s boundaries can be monitored appropriately.
8.5 Company Project Inspection Division, Company Representative, Proponents, Licensor (if required), Contractor’s and Subcontractors’ QC inspectors shall attend all inspection of the final box-up works on site to ensure that all applicable requirements, codes and standards are complied with. RFI should be submitted 3-4 working days in advance.
8.6 Preservation of vessels after the final box-up shall be conducted as a part of the system lay-up together with related piping which are connected to the vessels. System preservation shall be reinstated within 14 days following the box-up per SATR-D-2003 Section A and B has been accepted. Preservation status shall be monitored and tracked weekly and documented. The record shall be available for Company upon request.
9. SAFETY PRECAUTION
9.1 Ensure that no hazardous gas is remained in related piping system or those parts have been isolated by blind plates with isolation tags.
9.2 Ensure that confined space entry permit of each vessel shall be obtained prior to the final box up works and that all persons involved in confined space entry work have attended. Contractor’s confined space entry training including standby men. Required gas test inside vessels shall be conducted properly and frequently as per the safety requirement.
9.3 Assign designated standby men who are always present at manholes to control the related persons’ entry and exit of the vessels. The duties of standby men shall be as follows:
► Keep recording the entrants list for confined space entry/ exit
► Maintain the contract with entrants at all time
► In case of emergency, make direct contact to emergency response team
► In case of emergency, make evacuation alert to entrants using whistles, radios or other method
9.4 Prepare and install sufficient blowers and lights (LV types) to maintain good conditions inside vessels.
9.5 Ensure that barricades and warning signs are properly installed.
9.6 Conduct Safety Tool Box and TSTI every morning prior to the box-up works.
9.7 Ensure that JSA and rescue plan are prepared and approved for all confined space entry works.
9.8 Ensure that heat stress is taken into consideration during confined space entry works and appropriate rotation of personnel in/out of the confined space is implemented.
10. ATTACHMENTS
ATTACHMENT-1 Job Safety Analysis for Vessel Box-up Works.
ATTACHMENT-2 SATR-D-2003 – Vessel Closure Inspection Certificate.
ATTACHMENT-3 Equipment List for Final Box-up.