Method Statement: Al-Khafji FDP Phase-I Onshore Facilities
Method Statement: Al-Khafji FDP Phase-I Onshore Facilities
Method Statement: Al-Khafji FDP Phase-I Onshore Facilities
Project No.
Plant No.
81402
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METHOD STATEMENT
MS-
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Project No.
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Index
1.
Scope
2.
Purpose
3.
References
4.
Definitions
5.
Responsibilities
6.
Procedure
7.
Safety
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1.0 SCOPE
This method statement contains the general requirements for the equipment site erection and alignment.
2.0 PURPOSE
The purpose of this procedure is to provide a general guide line for the receiving and installation of all
kind of equipment static and rotary in accordance with the project specification and applicable standard.
3.0 REFERENCE
QCP-907-162
ITP-907-156
ITP-907-144
COMPANY
KJO
CONTRACTOR
CCC.
QCP
ITP
4.0 DEFINITION
5.0 RESPONSIBILITIES
5.1
The following CCC site personal shall be involved as responsible for the equipment
erection.
Section Engineer Equipment
Rigging Superintendent
Equipment Superintendent
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Equipment Supervisor
QC Engineer
QC Equipment Inspector
Surveyor
5.2
Section Engineer is over all responsible for monitoring equipment erection operation in
accordance with the procedures, specification and construction drawing.
5.3
QC Inspectors in conjunction with the QC Engineer are responsible for the inspection in
accordance with specification and procedure of the equipment erection and the compilation
of equipment reports and records as per required ITP.
5.4
The equipment supervisor shall be responsible for the safe operation and quality of work
and shall ensure that the procedures are adhered to and that technical standard is
maintained.
5.5
The rigging superintendent is responsible for all rigging operation that includes off loading,
transporting, and erection and for the selection of proper crane capacity and rigging gear.
5.6
The surveyor is responsible for checking elevations and verticality as per construction
drawing.
6.0 PROCEDURE
6.1
EQUIPMENT RECEIVAL
6.1.1
6.1.2
Equipment shall be off loaded from trailer using the vendor recommended lifting
point and approved techniques.
6.1.3
All loose items that are not required for immediate installation shall be suitably
identified and retained in the stores.
6.1.4
Protective covers on all equipments shall be removed if they appear damage and
equipment inspected before replacing the cover, if any damage has occurred,
Discrepancy report shall be issued with photograph showing damages as necessary.
6.1.5
6.1.6
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6.2
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HANDLING OF EQUIPMENT
6.2.1
The shall be unpacked in the presence of CCC-QC Inspector and KJO representative
or vendor representative. All spare parts and tools shall be unpacked clearly marked
with equipment numbers and stored in the warehouse. Fragile parts such as level
oiler, capillary tubes, small piping shall be removed from the equipment after match
marked and stored. The parts shall be clearly identified by the tags with equipment
number.
6.2.2
6.2.3
The equipment should not be placed directly on the earth, wooden blocks to be used.
6.2.4
All couplings shall be uncoupled and coupling elements shall be clearly marked with
equipment numbers matching the shaft hub and stored in the warehouse.
6.2.5
After checking the equipment and confirming that there are no discrepancies,
equipment shall be stored or delivered to installation site.
6.2.6
Bottom of the base plate shall be cleaned or wiped by suitable means to remove mud
oil or grease before installation.
6.3.2
6.3.3
All documents related to the equipment should be at job site with the concerned
crew following erection.
Dress up items, which cannot be erected in horizontal position will be erected in
vertical position after make alignment and vertically.
6.3.4
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6.4
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INSTALLATION OF EQUIPMENT
A STATIC EQUIPMENT
1.
2.
3.
4.
5.
Internals Work:
a- For internals installation, proper ventilation shall be provided prior to any entry.
Air movers will be used for ventilation during installation activities.
b- Gas test will be performed to confirm the oxygen level inside the vessel prior to
any entry. Confined space permit will be issued prior to the activity with the proper
lighting. All workers to be trained for confined space. Standby man will be assigned
to control entering of personnel and for emergency cases.
c- Suitable air winch will be used for lifting internal parts to the required level
through the nearest platform. Man ways will be used to pass the internal parts inside
the vessel. All channels, trays, pipes inside the vessel will be fixed as per vendors
construction drawing for the internals.
B ROTARY EQUIPMENT
1. Elevation of shim plates on foundation or on structural supports shall be verified as per
erection drawing.
2. Anchor bolt spacing and projection shall be verified as per erection drawing.
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3. Orientation and center lined shall be checked before placing equipment on foundation.
4. Utilizing a master level with precision of 0.02mm, leveling of the equipment to be
achieved and the preliminary alignment using dial indicators with precision of
0.01mm will be done.
5. Grouting will be done when leveling is achieved for the equipment.
6.
Regular preservation for any rotary equipment required to prevent any defect on
mechanical parts.
7.
8.
Keep all nozzles closed temporally until all piping work is ready to be connected
with equipment nozzles.
2.
3.
4.
5.
For static equipment after all inspection and tests given in the vendor normal all
necessary connection and adjustment are complete. All trays and internals shall be
visually checked.
All trays and other internals shall be cleaned and checked to insure that all dirt, loose
scale, slag and any parts or tools are removed from inside of the vessels using
vacuum machine, cleaning sheets, or compressed air.
Manhole after man way decks when installed the vessel manholes shall be closed.
This shall be witnessed and signed by JGC and CCC after final internal inspection.
All bolts and clamps on trays shall be torqued as required torque value.
Leak test shall be done on chimney trays after any required welding on chimney
panels.
For rotary equipment after Hydrotest activity completed and reinstatement of all
piping spools. The parallelism of flanges discharge and suction shall be checked
with equipment nozzles.
2. Final alignment using dial indicators by reverse alignment method or face rim method
will be used. Coupling shall not be installed until after the no load test for the drivers
is completed.
3. Oiler cans and all lubrication system shall be checked to assure, no leak on all tubing.
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4. All coupling guards should be in place to prevent any accident with the running parts.
5.
All equipment shall be barricaded and provided with warning signs, when its
energized.
7.0 SAFETY
7.1
7.2
7.3
Work at height full body harness shall be used with 100%Tie off.
7.4
7.5
Hot work, A Gas/Oxygen level check through the use of gas detector shall be used
prior to any hot work (welding-gas cutting).
7.6
Confined space ventilation using air mover is required for any vessel prior to entry
for any internal activity.
7.7
7.8
7.9
All warning signs shall be fixed in proper location to ensure personnel safety.
7.10
Rigging operation will be done under control of rigging superintendent all using
rigging study or lift plan as required for each lift.