Method Statement for Junction Box Installation - 004

July 13, 2017 | Author: sakthivel | Category: Screw, Galvanization, Safety, Industries, Manufactured Goods
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SADARA MIXED FEED CRACKER PROJECT METHOD STATEMENT FOR JUNCTION BOX AND SUPPORT INSTALLATION (FOR INSTRUMENTATION WORKS)

Document No. A554-E-103-IC-GEN-DOC-004 Revision:

0

Prepared by:

J.U. Saguagan

Reviewed by:

J.H Lee

Checked by QA/QC:

K. K. Akhter

Approved by:

S.H Joo

1

2

3

Owner Approved by: Revision Date:

19 FEB 13

Issue Purpose:

IFA

This document contains technical information that may be subject to the export control regulations of the United States and/or other jurisdictions. It may not be exported or re-exported except as authorized under applicable U.S. or other export control regulations.

Contains Confidential Information of SADARA Page 1 of 9

SADARA Mixed Feed Cracker 004

Document No: A554-E-103-IC-GEN-DOC-

Document Title: Method Statement For Junction Box & Support Installation Purpose: IFA

SUMMARY OF DOCUMENT REVISIONS Rev. No.

Date Revised

0

19 FEB 13

Section Revised

Revision Description Initial Issue

Contains Confidential Information of SADARA Page 2 of 9

Revision: 0 Issue

SADARA Mixed Feed Cracker 004

Document No: A554-E-103-IC-GEN-DOC-

Document Title: Method Statement For Junction Box & Support Installation Purpose: IFA

Revision: 0 Issue

Table of Contents

Section

Topic

1.0

Purpose ……………………………………………………………………………. 4

2.0

Scope ………………………………………………………………………………. 4

3.0

Responsibilities ……………………………………………………………………. 4

4.0

References ……………………….…………………………………………………. 5

5.0

Definitions ……………………….…………………………………………………. 5

6.0

Method of Preparation ……………………….….………………………….……. 6

7.0

Safety Requirements …………………………………………………….………. 6

8.0

QA / QC Requirements ……………………….….…………………….…………. 7

9.0

Procedure ……………………….…………….………………………….…………. 7

Contains Confidential Information of SADARA Page 3 of 9

SADARA Mixed Feed Cracker 004

Document No: A554-E-103-IC-GEN-DOC-

Document Title: Method Statement For Junction Box & Support Installation Purpose: IFA

1.0

Revision: 0 Issue

PURPOSE: The purpose of this procedure is to ensure that all works regarding Junction Box and Support (Indoor and Outdoor) Installation for Instrumentation Works shall be done in accordance with the SADARA standards and all other applicable international codes and standards.

2.0

SCOPE: The scope covers the steps to be followed for the Junction Box and Support (Indoor and Outdoor) Installation for Instrumentations intended for permanent installation in the plant. DAELIM and AIC shall ensure that the construction method of procedures is adhered to the SADARA Standards with reference to SADARA specifications.

2.0

RESPONSIBILITIES: The DAELIM Instrumentation Construction Manager is responsible to plan and schedule activities for the installation execution in co-ordination with client personnel. It is the responsibility of the materials personnel; to receive & visually inspect Junction Box, delivered on site before handing them over to SADARA Instrument Dept. and shall be responsible for the safekeeping and its reservation that received. It is the responsibility of the Instrument QC inspector to carry out inspection. Check the physical condition of the JB boxes before installation. Any damages found must be reported immediately.

3.0

REFERENCES: A554-O-PRG-IC-GEN-BOD-003 G6A-0002-00 G6A-0041-00

: SADARA Instrument Basis of Design

: DOW Global Instrument Administrative Guideline : DOW Global Instrument Job Specification Master Dictionary

G7C-0326-XX to G7C-0327-XX :DOW Global FJB/MCJB & Support Installation Details RT6D-0301-XX to RT6D-0303-XX

: DOW Global Field Junction Box Specs.

SADARA Approved IFC Drawing. Contains Confidential Information of SADARA Page 4 of 9

SADARA Mixed Feed Cracker 004

Document No: A554-E-103-IC-GEN-DOC-

Document Title: Method Statement For Junction Box & Support Installation Purpose: IFA

4.0

Revision: 0 Issue

DEFINITIONS: Field Junction Box (FJB) – a metallic/nonmetallic equipment use for connection of wires and cable which is installed in a designated area or outdoor. Motor Control Junction Box (MCJB) – junction box in which cables and wire for motor controls is being connected with.

5.0

METHOD OF PREPARATION: 5.1)

The Instruments Construction Manager /or Superintendent shall plan and schedule activities for the installation of the instrument junction box in co-ordination with Mechanical Construction group.

5.2)

Instrument Junction boxes are subject to inspection and witness by the client.

5.3)

Forms, procedures and sign off sheets for activity shall be prepared and submitted for review and approval of the client prior to beginning of any activity.

5.4)

Availability of equipments like welding machines, to be able to weld to the steel post column, and drill machine to make a hole to mount JB boxes on its location where it is supposed to place. The assigned supervisor or foreman will be in supervision to do in the mode of JB handling to avoid scratches or dented. Ensure that the area is barricaded for safety purposes.

5.5)

All instrument JB supports shall be in accordance to standard details of IFC drawings.

5.6)

Necessary clearances shall be taken from other group, (like piping and structural group) before proceeding with the works to avoid any overlapping/interference of work executions.

5.7)

The Safety Work Permit shall be prepared based on the schedule of field erection activities, or in a daily base activities.

5.8)

JB systems shall be electrically continuous, or safety grounded to earth as shown on the approved drawing.

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SADARA Mixed Feed Cracker 004

Document No: A554-E-103-IC-GEN-DOC-

Document Title: Method Statement For Junction Box & Support Installation Purpose: IFA

Revision: 0 Issue

5.10) Work shall be done according to the approved IFC. Technical query shall be submitted officially for any amendment from the approved IFC drawing, prior to start any work.

6.0

7.0

SAFETY REQUIREMENTS: 6.1)

Safe work permit requirement is mandatory. All personnel involved in the activities shall wear complete personal protective equipments (PPE) in accordance with the safe work requirements.

6.2)

Conduct job safety tool box before starting the work, and issue daily JSA. And the safety officer shall verify that all the necessary and applicable documents, related to the safest operation are in possession before commencing the job.

6.3)

Place barricade and warning sign boards in applicable locations. Restrict Personnel/equipments entering the work area.

6.4)

Check adequacy and availability of all tools, before commencement of installation activity.

6.5)

If the weather conditions turns bad, (like sand storms, wind storms raining or hailstorms) shall immediately coordinate to safety officer and all works shall be stopped.

6.6)

Safety procedures shall be followed at all times.

QA/QC REQUIREMENTS: 7.1)

The Quality Control Program shall be as per DAELIM Project Procedure, SADARA MIXED FEED CRACKERS Project Procedure in conjunction with the SADARA Engineering Standard. The detailed inspection stages and methods shall be as per the Approved Inspection and Test Plan.

7.2)

Prior to commencing the installation work, the Instrument JB shall be inspected visually for any damages during the transportation.

7.3)

All installed instrument JB shall be inspected for elevation as per the IFC drawings.

7.4)

Inspection and test plan must be submitted ahead of time for PMT & Daelim approval.

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SADARA Mixed Feed Cracker 004

Document No: A554-E-103-IC-GEN-DOC-

Document Title: Method Statement For Junction Box & Support Installation Purpose: IFA

7.5)

All RFI’s shall be submitted 24 hours ahead of scheduled date of inspection.

7.6)

All relevant attachments including IFC Drawing must be attached on all submitted RFI’s.

7.7)

Work execution, material approval and testing shall be monitored witnessed and recorded on documents in accordance to the inspection list, QC form given by applicable ITP JB installation and support installation.

7.8)

Instrument inspector shall carefully check against IFC drawing for the following items: a.) b.) c.) d.) e.)

8.0

Revision: 0 Issue

Check Check Check Check Check

for correct elevation as per IFC drawing. the correct size and materials. for proper grounding as per IFC drawing. area Classification. for maintenance accessibility.

PROCEDURES: 8.1

Handling

Every Item delivered shall be inspected to ensure compliance to specification, Data sheet & free from damages. Offloading shall be in responsible & Safe Manner. 8.2

Issue of Document and Drawings and pre-installation check: Ensure receipt of all related documents and IFC drawings from the client before proceeding with transportation & installation.

8.3

Installation of Instrumentation junction box: 8.3.1)

Instrument JB installations shall meet the requirements of G7C0326-XX to G7C-0327-XX DOW Global FJB/MCJB Installation Details and Manufacturer’s recommendation.

8.3.2)

Supports (Hot dipped galvanized, Unistrut channels, steel Cchannels, steel angle bars, flat bars) shall be welded to structural steel columns and not limited to anchoring to concrete column if necessary otherwise specify. Approved galvanized coating will be done for damaged galvanized surfaces. Before touch-up coat, the metal surface must be cleaned, brushed to ensure effective coatings. Contains Confidential Information of SADARA Page 7 of 9

SADARA Mixed Feed Cracker 004

Document No: A554-E-103-IC-GEN-DOC-

Document Title: Method Statement For Junction Box & Support Installation Purpose: IFA

Revision: 0 Issue

8.3.3)

Junction boxes and instrument cases shall be positioned so doors may be fully opened, covers are fully removable, vent holes are not blocked, and adjustment screws, valves, wiring and piping connections are accessible.

8.3.4)

The height installation shall be 5’6” (1675 mm) top of the junction box to grade level. Both on paved and unpaved area or directly mounted on beams. Or also 4’4” (1321 mm) centerline of the enclosure to grade level.

8.3.5)

All instrumentation JB systems shall be connected to the plant grounding system as per approved IFC drawing.

8.3.6)

All material of JB components and accessories shall be inspected and approved by company before installation.

8.3.7)

All grounding cable jumper for JB must be as indicated in IFC Drawing.

8.3.8)

All JB support must be fabricated and installed in a skillful manner considering proportionality and alignment.

8.3.9)

All support installed shall be level and plumb.

8.3.10) Conduit or cable shall not enter through the top of field junction boxes. All conduits are to enter from the bottom of the junction boxes unless there are more conduits required that can fit. All conduits coming from locations above the junction box shall have a low point drain adjacent to the junction box. 8.3.11) Adequate spare conduit or cable entry hubs fitted with threaded plugs shall be provided in the junction boxes. 8.3.12) Junction boxes shall be independently mounted and shall not rely on the mechanical support of the attached conduit for support. 8.3.13) All fastening hardware like bolt, nut etc. should be stainless steel. 8.3.14) Final alignment shall be done after installing the JB. Ensure all elevation shall be as per approved IFC drawing. 8.3.15) Tighten the JB bolts after alignment. 8.4

Receipt and Inspection Contains Confidential Information of SADARA Page 8 of 9

SADARA Mixed Feed Cracker 004

Document No: A554-E-103-IC-GEN-DOC-

Document Title: Method Statement For Junction Box & Support Installation Purpose: IFA

Revision: 0 Issue

8.4.1)

When the unit is received shall be examined, inspected to ensure that it is free from any physical defects or damages and conduct visual inspection as required to established the condition of the materials.

8.4.2)

Receipt of each package items shall be documented with details such as received date, type of parts or fittings, quantity, and avoid loss of parts during storage.

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