Equipment Erection, Static and Rotary

AL-KHAFJI FDP PHASE-I ONSHORE FACILITIES METHOD OF STATEMENT FOR INSTALLATION OF MECHANICAL EQUIPMENT ROTARY & STATIC Issued Date

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METHOD STATEMENT

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AL-KHAFJI FDP PHASE-I ONSHORE FACILITIES METHOD OF STATEMENT FOR INSTALLATION OF MECHANICAL EQUIPMENT ROTARY & STATIC Issued Date

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Index

1.

Scope

2.

Purpose

3.

References

4.

Definitions

5.

Responsibilities

6.

Procedure

7.

Safety

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AL-KHAFJI FDP PHASE-I ONSHORE FACILITIES METHOD OF STATEMENT FOR INSTALLATION OF MECHANICAL EQUIPMENT ROTARY & STATIC Issued Date

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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

:

Installation of Mechanical Equipment

ITP-907-156

:

Installation of Drums / Tanks

ITP-907-144

:

Shell and Tube Heat Exchanger Installation

COMPANY

:

KJO

CONTRACTOR

:

CCC.

QCP

:

Quality Control Procedure

ITP

:

Inspection Test Plan

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

AL-KHAFJI FDP PHASE-I ONSHORE FACILITIES METHOD OF STATEMENT FOR INSTALLATION OF MECHANICAL EQUIPMENT ROTARY & STATIC Issued Date

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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

All equipment received at site shall be inspected in accordance with vendor’s instruction for site storage, installation and preservation.

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

Preservation of rotary equipment will be maintained during storage period, by shaft rotation as per vendor manual.

6.1.6

Preservation for static equipment will be maintained during storing period by observing the gauge of Nitrogen and recording on weekly basis.

AL-KHAFJI FDP PHASE-I ONSHORE FACILITIES METHOD OF STATEMENT FOR INSTALLATION OF MECHANICAL EQUIPMENT ROTARY & STATIC Issued Date

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81402

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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

All machined surfaces shall be checked and applied with rust-preventatives.

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 EQUIPMENT PREPARATION 6.3.1

Dress up to be completed as much as possible in horizontal position, dress up for platforms and ladders for all elevations from top to bottom including all insulation required.

6.3.2

Before installation, all location, elevation and orientation of the equipment foundation and support structures shall be checked and verified in accordance with installation drawing.

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

AL-KHAFJI FDP PHASE-I ONSHORE FACILITIES METHOD OF STATEMENT FOR INSTALLATION OF MECHANICAL EQUIPMENT ROTARY & STATIC Issued Date

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INSTALLATION OF EQUIPMENT

A – STATIC EQUIPMENT 1. 2. 3. 4.

5.

Installation of shim plate for foundation or equipment supporting structure to be verified as per erection drawing. Anchor bolt spacing to be verified as per equipment saddle plates or skirt. Sliding plate provided by vendor for horizontal equipments to be erected on foundation embedded plate as per vendor drawing. Proper crane capacity shall be selected for the equipment erection. Rigging superintendent with appropriate and certified rigging gear shall execute rigging operation. Barricading to be maintained during the erection operation.

6. Orientation, Level and verticality to be achieved as per construction drawings and utilizing theodolight, shims and wedges. 7. Equipment will be released for grouting after achieving the required alignment, leveling, or verticality. 8.

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 vendor’s 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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METHOD OF STATEMENT FOR INSTALLATION OF MECHANICAL EQUIPMENT ROTARY & STATIC Issued Date

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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.

Filling of preservation oil in rotary equipment as vendor requirement.

8.

Keep all nozzles closed temporally until all piping work is ready to be connected with equipment nozzles.

6.5 FINAL CHECK FINAL CHECK FOR STATIC EQUIPMENT 1.

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.

FINAL CHECK FOR ROTARY EQUIPMENT 1.

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.

AL-KHAFJI FDP PHASE-I ONSHORE FACILITIES METHOD OF STATEMENT FOR INSTALLATION OF MECHANICAL EQUIPMENT ROTARY & STATIC Issued Date

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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 it’s energized.

7.0 SAFETY 7.1

Job safety analysis attached.

7.2

All workers shall conduct orientation course.

7.3

Work at height full body harness shall be used with 100%Tie off.

7.4

Make sure access completely safe on scaffolding with green tag.

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

24V or 12V power lighting shall be used as required.

7.8

Working area shall be barricaded. (Crane operation area, erection or dismantling of Scaffolding)

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.