Method Statement for MIP6-CM-1300-011

Pressure Vessel PAGE 2 OF 11

Internal HDEC PROJECT PROCEDURE REV A1
PROJECT MANAGEMENT

Table of Contents

1. SCOPE
2. REFERENCES
3. RESPONSIBILITY
4. MANPOWER
5. TOOLS & EQUIPMENTS
6. WORK PROCEDURES
7. QUALITY CONTROL
8. HEALTH SAFETY & ENVIRONMENT
 Method Statement for MIP6-CM-1300-011
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1. SCOPE
1.1 This procedure provides the instruction for safe working practice inside pressure vessels.

2. REFERENCE
2.1 Company Standards
2.1.1 32-SAMMS-004 - Manufacture of Pressure Vessels
2.1.2 32-SAMMS-020 - Manufacture of Trays and Packing
2.1.3 SAES-D-001 - Design Criteria for Pressure Vessel
2.1.4 SAES-A-005 – Safety Instruction Sheet
2.1.5 SAES-C-001 – Process Design of Distillation Trays and Packing
2.1.6 Safety, Health and environmental requirement of schedule “D”

2.2 International
2.2.1 ASME Sec VIII D1 & D2 Rules for Construction of Pressure Vessels
2.2.2 API RP 686 - Recommended Practice for Machinery Installation and Installation
Design

2.3 Others
2.3.1 MIP6-PM-1332-001 - Storage, Handling and Preservation
2.3.2 Manufacturer’s Drawing / Installation Operation Manuals
2.3.3 MIP6-MS-1300-001 Installation Procedure for Static Equipment

3. RESPONSIBILITIES
3.1 Construction Manager
3.1.1 Coordinates with his team for the safe and proper execution of the work.
3.1.2 Specific attention to all safety measure in coordination with HSE Manager / Officer
as per SAUDI ARAMCO Procedure and Policy.
3.1.3 Shall implement all HSE requirements for the job, 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. He shall study all aspects of work
procedure as per HDENC/DAENC Technical Scope of Work.
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3.2 Safety Supervisor / Officer

3.2.1 Check the work areas for any unsafe conditions.
3.2.2 Ensure that installation work is being carried out in accordance with SAUDI ARAMCO
and HYUNDAI project safety requirements. Any deviation from the standard method
of installation shall be immediately ceased.
3.2.3 Inspect all the site activities and train the persons to prevent accidents and its proper
reporting to Site or Construction manager.
3.2.4 Daily toolbox talks are to be conducted every morning before commence of the work
by the concerned supervisor and the minutes and details shall be documented.

3.3 Construction Supervisor

3.3.1 Direct responsible for the implementation of safety requirements as well as
construction procedure to the work force and to make sure that the relevant work is
delivered accurately in precise manner.
3.3.2 Make and prepare construction report and daily appurtenances to successfully
accomplish the specific task.
3.3.3 Direct supervision on the work force and implementation of proper construction
standards and procedures.
3.3.4 Coordinate with the HSE Manager to ensure that the work are carried out in a safe
working practice.
3.3.5 Plan works in advance as per the work sequence.

3.4 QA/QC Personnel

3.4.1 The Quality Assurance and Quality Control program shall be instituted that the work
performed under the contract, meets the requirements of standards and the designed
drawings.
3.4.2 Conduct inspection in accordance with this procedure and approved Saudi Aramco
Quality Control Inspection and Test Plan.
3.4.3 Approved independent testing agency or contractor’s own laboratory can perform
testing on specific requirements of the work.
3.4.4 Monitor and conduct visual inspection every stage of the work during and after the
construction phase until the completion of the activity.
3.4.5 Record and test results shall be gathered and kept to future use.
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4. MANPOWER
4.1 All personnel supervising the equipment’s installation shall have documentary evidence of
suitable experiences.
4.2 The Mechanical Supervisor shall control the overall activity on erection of Water Treatment
Package. The basic manpower under him shall consist but not limited to the followings:
4.2.1 Supervisor (Mechanical, Scaffolding)
4.2.2 Foreman (Mechanical, Scaffolding)
4.2.3 Millwright
4.2.4 Mechanical Fitter
4.2.5 Truck Driver
4.2.6 Surveyor
4.2.7 Common Laborer (including Flagman, Firewatcher, etc.)
4.2.8 Structural Fitter
4.2.9 Scaffolder
4.2.10 Safety Supervisor / Officer
4.2.11 QC Supervisor / Inspectors

5. TOOLS & EQUIPMENTS

5.1 Equipment (Theodolite / Surveying Tools, Spirit Level, Torque Wrench, Millwright Precision tools,
etc.). Used for inspection, testing and measuring shall be calibrated.
5.2 Equipment (Theodolite / Surveying Tools, Spirit Level, Torque Wrench, Millwright Precision tools,
etc.). Used for inspection, testing and measuring shall be calibrated.
5.2.1 Tools:
5.2.1.1 Chain Blocks / Lever Blocks
5.2.1.2 Wrenches / Calibrated Torque Wrench
5.2.1.3 Nylon Slings, Nylon Rope, Shackles
5.2.1.4 Steel Wire and Clips
5.2.1.5 Calibrated Auto Level / Theodolite / Total Station / Torque Wrench
5.2.1.6 Impact Wrench
5.2.1.7 Hydraulic Jack
5.2.2 Equipment:
5.2.2.1 Fork Lift
5.2.2.2 Air Compressor
5.2.2.3 Boom Truck
5.2.2.4 Crane
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6. WORK PROCEDURE
6.1 Preparatory of Work
6.1.1 Manhole Opening
6.1.1.1 All manhole opening shall be done as per construction and safety procedure.
6.1.1.2 Approved safety permit shall be produced prior to nitrogen gas removal.
6.1.1.3 Manhole flange serration shall be check as necessary incase as there are
damage, it should be reported immediately to authorized person involve on
the activity.
6.1.1.4 Manhole flange specially the serration shall be protected against incoming
materials to be installed inside vessels. Put rubber cover for protection on
serration area.
6.1.1.5 Bolts, nuts and washers shall be kept accordingly for final re-instatement /
final box-up.

6.1.2 Scaffolding Inside and Outside of Vessel

6.1.2.1 Scaffolding inside and outside of the vessel shall be done by an approved
Saudi Aramco Scaffolder only.
6.1.2.2 Scaffolding plan shall be provided for proper execution and installation.
6.1.2.3 Scaffolder shall install scaffolding with maximum effort not to damage the
shell surface of the equipment specially inside of vessel as it will result into
scratches and will lead to rust development / contamination.
6.1.2.4 All sharp corners and protruding metal ends of scaffolding materials shall be
adequately covered with rubber or any means of protection.
6.1.2.5 Inside scaffolding shall be installed in such a way that enough working space
is provided for installation of vessel internals.
6.1.2.6 Outside scaffolding shall be installed with enough platform size in front of all
manholes for worker’s access during working activities.
6.1.2.7 Safety for all workers inside and outside the vessel shall be given much
consideration in the scaffolding erection.
6.1.2.8 In some cases of access that scaffolding cannot be installed, manlift can be
use as a form of access.

6.1.3 Davit Arm and Rope Pulley Installation

6.1.3.1 Davit arm and rope pulley shall be installed as necessary, at the location
where equipment needed to lift vessel internal components.
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6.1.3.2 Safety shall be ensured prior its installation. Working load shall be considered
before its installation.
6.1.3.3 Davit arm and rope pulley shall be installed in such a way that it will not
obstruct the manhole access.
6.1.3.4 Rope size shall be of enough size to carry the possible load weight of the
vessel internal component.

6.2 Material Transportation and Control Method

6.2.1 Before arrival of vessel internal components, unloading plan and storage area shall
be carefully reviewed. Storage of equipment shall be either outdoor or indoor as per
vendor’s recommendation.
6.2.2 Packing condition shall be inspected upon arrival of equipment to ensure safe arrival
of equipment damage during transportation.
6.2.3 Unless otherwise agreed, it is preferable to store the internal components without
opening of shipment packing to have good protective condition from the environment.
6.2.4 According to delivery schedule and site condition, the plan shall be established
whether the vessel internal components is too installed directly or to be unloaded for
storage.
6.2.5 Tagging of vessel internal components shall be accordance with specific project
requirements. Ensure that all tags and identification area clearly shown and readable.
6.2.6 A dedicated Material controller shall take full control in the material transportation
and storage of vessel internal components.
6.2.7 Latest IFC drawing shall be made available on the material container for perusal.
6.2.8 Any discrepancy between IFC drawings and packing list shall be reported
immediately to the designated discipline for proper disposal.

6.3 Confined Space Control Method

6.3.1 Registration of Personnel and Personal Belonging Control
6.3.1.1 All personnel shall have confined space training from HDEC Safety.
6.3.1.2 A confined space entry permit shall be produced to start of any internal works.
6.3.1.3 Complete gas testing shall be made by a competent safety personnel.
6.3.1.4 Trained and competent hole watcher / standby man shall be available.
6.3.1.5 Hole watcher / standby man must wear reflective vest for easy identification
and continue observe the activity inside the vessel at all times.
6.3.2 Personal Protective Equipment (PPE)
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6.3.2.1 All workers that will work inside vessel must wear proper mandatory PPE.
6.3.2.2 If necessary, wearing of full body harness without lanyard and shoe cover will
be provided for worker safety.
6.3.3 Lightning Method
6.3.3.1 An explosion proof with 12 volts illumination capacity light shall be made
inside the vessel during working and inspection time.
6.3.3.2 Light shall be place at the area most necessary for workers and inspectors.
6.3.4 Ventilation System
6.3.4.1 Ventilation shall be done using fans/blowers with sufficient capacity.
6.3.4.2 Vacuum mode operation shall be preferred for ventilation, where required
force ventilation to vessel top and allow fresh air from bottom.
6.3.4.3 Distance of the ventilation is critical as it will obstruct access to the manhole,
careful planning shall be done prior to positioning of the fans / blowers in
order to address the circulation inside the vessel.

6.4 Internal Installation Method

6.4.1 Cleaning of internal surface of vessel shall be done prior to installation of internals.
6.4.2 Wiping out of dust and other foreign particles shall be clean by means of clean cotton
made rags.
6.4.3 Any visible rust contamination shall be check and clean as necessary to prevent from
spreading.
6.4.4 Latest AFC drawing shall be available at jobsite working area in order to start
installation of vessel internals.
6.4.5 In some cases, pre-assembly of vessel internal outside the vessel can be done for
better result prior for installation.
6.4.6 Vessel internal components shall be ensured its cleanliness and completeness
before installation.
6.4.7 Internals shall be installed as per latest AFC Drawing. Clean the portion inside the
shell of dust and other foreign particles. From the pre-assembled parts, start install
the vessels internals.
6.4.8 Installation shall be done on level wise stage starting from the lowest level. Carefully
assembled and place the components as per latest AFC Drawing.
6.4.9 Once the installation of vessel internal on the first level was completed, clean the
portion of the internal surface where the second level of internals will be assembled.
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6.4.10 Place a sheet of non-combustible material on the completed first level to ensure its
cleanliness from dust and other foreign particles.
6.4.11 Start bolting the components to ensure stability and continue doing the same process
until completion of internal installation.
6.4.12 Remember to always check the internal identification and orientation to ensure
continuity of work.
6.4.13 Ensure that gaps and spacing of individual internals are correct based on the latest
AFC drawings.
6.4.14 Once the assembly and installation of individual internals are completed, bolts shall
be tighten using a calibrated torque wrench.
6.4.15 Apply torque value which will be given from latest AFC drawing. Ensure that no force
fit on bolts shall be happen that it will damage the bolt tread once being torque by
wrench on the final stage of bolt tightening.
6.5 Internal Piping Installation
6.5.1 In some cases, installation of internal piping shall be done together with installation
of vessel internals.
6.5.2 All internal piping shall be check and inspect as per required SATIP
6.5.3 Equipment and piping nozzle shall be inspected for flange face serration.
6.5.4 If there should be any unacceptable damage to serration, it shall be corrected by re-
facing with approved procedures.
6.5.5 Check all materials like gaskets, bolts, nuts and washer as per AFC drawings.
6.5.6 Bolt tightening of Internal Piping shall be done as per SAEP-351
6.5.7 Equipment nozzle shall never be use as support by piping connection.
6.5.8 Install internal piping as per latest AFC Drawing.

6.6 Final Box-up / Final closure of Vessels

6.6.1 After completion of the inside vessel internal installation, final inspection shall be
made by concerned parties.
6.6.2 Ensure the vessel is free of debris and moisture prior for box-up / final closure of
manhole.
6.6.3 Manhole serration shall be check, if there’s no means of damage final closure can
be done by installing new gaskets, required bolts, nuts and washer as per latest AFC
drawing.
6.6.4 Once the complete inspection and acceptance were done, immediately close the
manholes. Apply required torque value on the bolts of manhole flange.
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6.6.5 Purge again the equipment with nitrogen until required pressure. Vessel will be place
again under preservation until start-up.

7. QUALITY CONTROL
7.1 QC personnel shall be assigned to ensure quality control and assurance requirement of the project.
7.2 QC personnel well coordinate with Hyundai inspector to conduct inspection as required.
7.3 QC inspector shall be responsible to conduct all required inspection / documentations and to ensure that
all applicable requirements, code and standards are complied with SAIC/SATIP.
7.4 Calibration shall be done as required for all machines and tools going to use in the work in accordance
with Schedule “Q”.
7.5 Contractor has to utilize the applicable SAIC every activity.
7.6 On completion of all erection activities, equipment shall be check for mechanical completion in accordance
with “Inspection and Test Plan”.
7.7 In General, following points shall be check prior to the final acceptance;
7.7.1 Alignment check has been carried out and result are recorded.
7.7.2 Accessories installed and ready for service.
7.7.3 Bolting is check by using calibrated torque wrench (Tightening).
7.7.4 Cleanliness checked.
7.7.5 Tag and name plate to be checked.

8. HEALTH SAFETY & ENVIRONMENT

8.1 Permit to Work and other related approved documents should be carried out by Trained Work Permit
Receiver (Area Supervisor or Foreman).
8.2 Ensure all Aramco Approved Certificate for equipment and operator should be attaching in the Work
Permit.
8.3 Prior to the start of erection activities, the site should be inspected and approved by the Site Authorities
or their representatives.
8.4 Toolbox Talk Meeting and Pre-Task Meeting must be conducted carried by assigned Foreman/Supervisor
with assistance of assigned Safety Personnel.
8.5 According to the client regulations all Heavy equipment and Operator shall have an Aramco Approved
Third Party Certification.
8.6 Ensure that Equipment Daily Inspection Checklist must be conducted prior to operate.
8.7 Before erection, conditions of foundations and surroundings to be checked to ensure safe working
conditions.
8.8 Works shall be carried out according to Aramco Construction Safety Manual (CSM) and General
Instruction (G.I.).
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8.9 All locations of erection activity, regardless of elevations should be provided with substantial barriers and
signboards. The required lighting facilities shall be provided during night time works if required.
8.10 List of emergency contact telephone numbers shall be provided to all key personnel.
8.11 Ensure the Communication Device to be used.
8.12 All personnel involved in works shall be aware of safety requirements of the project and the site shall be
kept clean and in tidy conditions.
8.13 Safety sign boards shall be placed all along the temporary access road and erection sites.
8.14 Maintain good housekeeping at all times.
8.15 Full supervision by assigned Area Supervisor/Foreman and Safety Personnel to monitor the site
personnel during all erection activities.
8.16 Personnel working in equipment erection sites should be provided with the Necessary protective
equipment (PPE).
8.17 Provide drinking water, potable water shelters for the employees
8.18 Fire extinguishers shall be provided at the site wherever required
8.19 Make sure that the erection work does not undermine the scaffolds or the nearby areas.
8.20 Ensure all steel erector and scaffolding crew undergo in Working @ Heights Training and familiar in Full-
Body Harness for 100 % Tie-Off.
8.21 All Power Tools and Hand Tools are inspected by competent person prior to use.
8.22 While erection pay attention to possible surrounding areas.
8.23 Flagmen are to be always accompanied with the equipment while standby as well as working.
8.24 Flagmen shall also be deployed for signaling during the lifting actives across the road.
8.25 Inspection and Testing Requirements shall be per ASME A92.3, A92.5, & A92.6 Elevating work platforms
shall receive a periodic inspection every six (6) months or as determined by the Inspection Department.