COMMENT SHEET Yanbu Export Refinery Project Gasoline Package EPC-3 Company Transmittal No: WBS: Drawing / Document No: 111-IK3-CM-CCM-0003 Rev. A Comment Sheet No: 3 Pages Date returned: 28 Feb 2012 Discipline Name: Ref. Transmittal Number Date Issued YER- IK3-T-120045 Document Title: Method Statement Equipment. MECHANICAL IK3-YER-T-120053 26 March 2012 Contractor Reply: (Identify Section/Page/Paragraph) Done nd Please refer to Section 2.0, 2 sentence Page 3 of 17. Initials / Department forInstallation of Static Action : □ No Objection □ No Objection with Comments □ Re-Submit □ Reviewed No. □ Reviewed with Comments Initials / Department Discipline Comments: (Identify Section/Page/Paragraph) Reference Section 2.0 –first sentence suggest changing “which are be performed...” to “...Which are to be performed...” Reference Section 5.1 – the project manager shall have more responsibility than the quality management on the project. He shall be the overall responsible person for the management and execution of scope. Reference Section 5.5 – the site manager shall have more responsibility than the quality management on the project. He shall be the overall responsible person for the site management and execution of the site scope of work. Reference Section 5.7 – suggest changing “Civil Superintendent shall for …” to “Civil Superintendent shall be responsible for ...” Reference Section 5.11 - change the word “aliment” to “alignment” No. 1 PMT 1 Mechanical 2 PMT 2 Done Please refer to Section 5.1 Page 4 of 17. Mechanical 3 PMT 3 Done Please refer to Section 5.4 Page 4 of 17. Mechanical 4 PMT 4 Done Please refer to Section 5.6 Page 5 of 17. Mechanical 5 PMT 5 Done Please refer to Section 5.10 Page 5 of 17. Mechanical 6 Reference Section 6.8 – suggest changing the word “involving” to “involved”. PMT 6 1OF3 Done Please refer to Section 6.8 Page 6 of 17. Mechanical 3.1.5 .3. MECHANICAL IK3-YER-T-120053 26 March 2012 Contractor Reply: (Identify Section/Page/Paragraph) Done Please refer to Section 3. Transmittal Number Date Issued YER.2.5 – tenth bullet suggest changing the word “cement” to “ cementitious grout” PMT 10 Done Please refer to Section 8.2. Initials / Department forInstallation of Static Action : □ No Objection □ No Objection with Comments □ Re-Submit □ Reviewed No. □ Reviewed with Comments Initials / Department Discipline Comments: (Identify Section/Page/Paragraph) Reference Section 8.fourth bullet Page 7 of 17 Mechanical 9 Reference Section 8.5 – seventh bullet Page 7 of 17 Mechanical 10 Reference Section 8.1. A Comment Sheet No: 3 Pages Date returned: 28 Feb 2012 Discipline Name: Ref. 7 PMT 7 Mechanical 8 Reference Section 8.IK3-T-120045 Document Title: Method Statement Equipment.2.COMMENT SHEET Yanbu Export Refinery Project Gasoline Package EPC-3 Company Transmittal No: WBS: Drawing / Document No: 111-IK3-CM-CCM-0003 Rev.9 – change the word “slew” to “move” PMT 12 Done Please refer to Section 9.5 .5 – seventh bullet suggest deleting the word “as” and changing the word “below” to “less than” PMT 9 Done Please refer to Section 8.5 – fourth bullet suggest changing the word “below” to “less than” PMT 8 Done Please refer to Section 8.2.0 No.0 Page 3 of 17.2.tenth bullet Page 7 of 17 Mechanical 11 Reference Section 9.7 – change the word “whole” to “ hole” PMT 11 Done Please refer to Section 9.9 Page 9 of 17 Mechanical 2OF3 .1.1 – Define (STL/STR) and add to section 3.7 Page 8 of 17 Mechanical 12 Reference Section 9.2. 3.1.1.third bullet Page 10 of 17 Mechanical 16 Reference Section 12.1 – third bullet change the word “assemble” to “assembly” PMT 15 Done Please refer to Section 12. Transmittal Number Date Issued YER.13 .13 Page 9 of 17 Initials / Department forInstallation of Static Action : □ No Objection □ No Objection with Comments □ Re-Submit □ Reviewed No.2.2 – 3 bullet Page 10 of 17 Mechanical 17 Reference Section 12.COMMENT SHEET Yanbu Export Refinery Project Gasoline Package EPC-3 Company Transmittal No: WBS: Drawing / Document No: 111-IK3-CM-CCM-0003 Rev. A Comment Sheet No: 3 Pages Date returned: 28 Feb 2012 Discipline Name: Ref.1.2 Page 10 of 17 Done Please refer to Section 3.change the word “tackles “to “shackles” note: Man basket with crane shall be the last option to detach main crane shackles from a piece of equipment.0 PMT 17 Done Please refer to Section 12.0 add SATIP and SAIC to section 3.2 change the word “corner” to” comer” Reference Section 14.3.0 Page 3 of 17 Mechanical 18 PMT 18 Mechanical 3OF3 .1 Page 9 of 17 Mechanical 15 Reference Section 12.2. 13 PMT 13 Mechanical 14 PMT 14 Done Please refer to Section 10. □ Reviewed with Comments Initials / Department Discipline Comments: (Identify Section/Page/Paragraph) Reference Section 9.IK3-T-120045 Document Title: Method Statement Equipment. Reference Section 10.2 – remove the space before the period and add space after the period. MECHANICAL IK3-YER-T-120053 26 March 2012 Contractor Reply: (Identify Section/Page/Paragraph) Done Please refer to Section 9. PMT 16 Done ed Please refer to Section 12.1 – change the word “cementite” to “cementitious” No. . .........................3 2....................................................................: 111-IK3-CM-CCM-0003 Revision No.......0 GROUTING (By Civil) ........................................: B Issue Date : 26 March 2012 Table of Contents 1.......................................................................................................0 ATTACHMENTS ........................................................................................0 RESPONSIBILITY ................0 TOOLS AND EQUIPMENTS ...............................................16 General Confidential Page 2 of 17 .................................................................................................................................8 10....................................................10 13.........................................................................................................0 OTHER WORK ..................12 14....................0 SAFETY REQUIREMENTS ..........................................0 DEFINITION ...............................9 11..............................................................................................................................................................................................................................................................................................0 EXECUTION WORKS ..............3 5...........................................................................................................5 7..................................................................................................................3 4...........................................................................6 9....3 3.........................................4 6....................................................................Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.......0 INTERNAL TRAYS ..............................6 8.......................................................0 INSPECTION AND TESTING 15..........................................0 REFERENCES ................10 12........................0 PREPARATION OF FOUNDATION ................0 SCOPE ..........................................0 MOUNTING OF ACCESSORIES ..........................................................................11 ..........0 PURPOSE ........................................................... 4 4. such as columns. Tolerances for Pressure vessels SAES–C–001. General Confidential Page 3 of 17 4. derrick. jacks and slings.0 4. VESSEL Tolerances (elevation & orientation).Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No. vessels. (DSA) American Society of Mechanical Engineers American Petroleum Institute International Standard Organization Safe Load Indicator Quality Control Inspection Test Plan Health.3 REFERENCES Manufacturer’s instruction Manual.: 111-IK3-CM-CCM-0003 Revision No.0 PURPOSE The purpose of this procedure is to set out in detail the practices concerning the static equipment erection. process industry practices fabrication/installation fabrication / installation details VEFV 1102. which are to be performed at YERP-EPC3. heat exchangers and other static equipment. hoists.: B Issue Date : 26 March 2012 1.2 4.5 . In the event of conflict between this procedure and vendor’s instructions.0 SCOPE This Method Statement is applicable for the installation of all static equipment. YERP-SAES-C-001: Process Design of Tray and Packing. hooks. company approved construction drawings and specifications for Yanbu Export Refinery Project Gasoline Package (EPC-3). 2.1 4. ANSI B30. Process Design of Trays and Packing. cranes. internal trays and accessories in accordance with design. Safety standards for cable ways. the later shall govern subject to DAELIM / PMT’s approval. SASD – AD – 036981.. Ltd. Safety and Environmental Personal Protective Equipment Steel Structure Saudi Aramco Typical Inspection Plan Saudi Aramco Inspection checklist B 3. DEFINITION PMT YERP Contractor ASME API ISO 9001 SLI QC ITP HSE PPE STL/STR SATIP SAIC Project Management Team Yanbu Export Refinery Project EPC-3 Daelim Saudi Arabia Co.0 B 4. PIP/API REIE 686 Recommended practices for machinery installation and installation design. Steel Supports & Miscellaneous STL/STR SAIC – D – 2001: Review of Safety Instruction Sheet (S.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.6 4. SAIC – D –2006: Equipment Pre-Installation Inspection. YERP-SAES-01-100: General Requirements of Safety and Security.8 111-IK3-CM-CHC-0001. The Field QA / QC Manager shall be responsible for supervisory of all kinds of field quality control activities and check the operating status and effects.I.0 5. Project Construction Manager General Confidential Page 4 of 17 5.3 QA/QC Engineer / Inspectors QA/QC Engineer / Inspectors Shall be responsible for carry out all necessary inspection and test involving in equipment erection works as per approved ITP in co-ordination with site equipment engineers/supervisors and also submission of inspection reports to client.S. He shall preside over the quality meeting and supervise and assure the performance of the quality plan. SATIP-D-001-01: Pressure Vessel Installation. 5. 5. YERP-SAES-E-004: Design Criteria for Shell and Tube Exchanger.: B Issue Date : 26 March 2012 YERP-SAES-D-001: Design Criteria for Pressure Vessel.4 B Project Site Manager The Project Site Manager assist the Project Manager to establish the field activity control system and be responsible for supervisory of all kinds of field activities and check the operating status and effects. SAIC – D –2004: Receiving Inspection of Fabricated Structural Attachment of Equipment (Access and Supports). Method statement for installation work of heavy Equipment’s with Crane Accessibility Information. 4.7 4.1 B RESPONSIBILITY Project Manager The Project Manager will take the prime and full responsibility and control of all the activities pertaining to this procedure. QA/QC Manager The QA/QC Manager shall be responsible directly for Project Manager and be concerned in establishing Field Quality Plan. 5. SATIP-E-004-01: Heat Exchanger Installation.: 111-IK3-CM-CCM-0003 Revision No.) SAIC – D –2007: Equipment Installation – Alignment and Elevation. SATIP-M-001-01: Structural steel-Pipe Rack.5 .2 5. YERP-SAES-O-119: Work Permit Procedure. Latest IFC Drawings. He shall preside over the field activities meeting and supervise and assure the performance of the site management and execution of site work. 2 6.0 6.9 Equipment Superintendent Equipment Superintendent shall be responsible for planning. including field quality control activities. 5. including procurement quality control activities.5 6.11 6. Safety Supervisor Ensure all work permits are available prior to commencement of any work.: 111-IK3-CM-CCM-0003 Revision No. 5. in accordance with Project Quality Control Plan and Project Execution Plan.: B Issue Date : 26 March 2012 Project Construction Manager will take the responsibility for management and coordination of all the project construction activities. All tools and tackles shall be inspected and colour coded prior to use. All lifting operation shall be carried out during day time only. in accordance with Project Quality Control Plan and Project Execution Plan. prior to start any work with job safety analysis plan. Liase with Field Supervisor and Foremen that work is carried out in accordance with Project Safety Plan / Procedure and the feedback of “Job Safety Analysis”. controlling and monitoring of all equipment installation works at site and also responsible for allocating jobs to site equipment engineers/supervisors.7 5.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.10 B Equipment Engineers/supervisors Equipment Engineers/supervisors shall be responsible for all equipment erection and alignment works at site and co-ordinate with QC engineers in all equipment inspection activities. ensuring the implementation of project procurement activities.6 B Civil Superintendent Civil Superintendent shall be responsible for all equipment grouting works and minor equipment foundation modification works if necessary.1 6. Lifting area shall be barricaded and safety signs shall be posted. Check work area for any unsafe conditions.8 Project Material Manager Project Procurement Manager will take the responsibility for management and coordination of all the project procurement activities. All personnel shall wear complete PPE as per the project safe work requirements. 5.3 6.4 6. Erection Supervisors Erection Supervisors shall be responsible for all equipment erection work at site as per the project safety procedures in co-ordination with equipment engineers/ supervisors. Review personnel and their compliance with safety requirements such as wearing Personnel Protection Equipment (PPE). Necessary personnel shall be posted at appropriate location to prevent unauthorized entry General Confidential Page 5 of 17 . 5.6 SAFETY REQUIREMENTS Proper work permit shall be obtained. ensuring the implementation of project construction activities. 5. 5 7. 6.13 8. Shackles / Beam Clamps / Blocks / Wrenches.2 7. Check anchor bolts for location.: B Issue Date : 26 March 2012 during lifting. General Confidential Page 6 of 17 6.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.8 7.0 8. clearance notification shall be received from civil department to confirm that the concrete foundation has reached the curing period up to the required compressive strength.1 8. Calibrated Dumpy Level / Theodolite. Wire Slings / Nylon Web Sling / Soft Tag Lines. plate washer (if provided) and nuts engagement length etc.4 8. PREPARATION OF FOUNDATION DIMENSIONAL CHECK Prior to start any work on the foundation and on the steel structure.3 7.1 7. TOOLS AND EQUIPMENTS Crane and Fork lift.1. bolt spacing. Wrenches / Leveling Tools / Filler Gauge.7 7. Grinding Machine.10 7. equipment base plate.0 7. Necessary work permit and confined space entry permit shall be obtained by Entry supervisor and trained attendant shall be posted at the confined space entrance.10 7.12 7. gas test shall be conducted to measure atmospheric condition inside the confined space. Check anchor bolt top elevation & projection length and cross check with the actual length required considering grout thickness. Any variation in dimension shall be rectified or cleared prior to start chipping work. Number of bolts. Hammer & Spanner set. Theodolite.2 8.: 111-IK3-CM-CCM-0003 Revision No. Measuring Tools / Precision Scale /Manometer/ Hose Level.7 B All lifting tools and tackles shall have valid inspection certificate and available at site during lifting.1. Size. Continuous forced ventilation shall be provided and prior to entry.1. Welding Machine for tack welding of Liners.3 8. All personnel involved in confined space activities shall complete the training required for confined space entry/work. thread condition & number of nuts and verify this conforms to the equipment detail drawing.9 7.6 7.9 6. Spreader Bar or Frame / Chain Hoist.5 .4 7.8 6. Hydraulic Jack and Certified Lifting Tools &Tackles.1 8. Protect all anchor bolts from damage and threads shall be covered by masking or vinyl tape. Concrete chipping machine.1.11 7.1. bolt circle diameter. 2.2. Single plate shall be installed if the distance between anchor bolts is less than 500mm (Attachment#1. Section A-A).2. Section A-A).1. shim/pad plate shall be provided on both sides of the anchor bolt (Attachment#1. All shim/pad plate shall be installed as per the above procedure and cured for minimum three days.2.2 8.: B Issue Date : 26 March 2012 8.: 111-IK3-CM-CCM-0003 Revision No. Equipment co-ordinates/centre lines and reference elevation shall be marked on the foundation as per the IFC drawing. vertical equipment-plan-Type-2).3 8. and other foreign matters up to the level of sound concrete. All Plates shall be Galva coated prior to installation on the foundation. Section B-B).6 8. sand. oil.1 8. Top of concrete elevation shall be checked to confirm the amount of chipping required to get minimum 25mm thick grouting height.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No. SHIM / PAD PLATE INSTALLATION This section shall be interpreted in conjunction with Attachment #1. Top of elevation of all plate shall be minimum 25mm from top of chipped concrete to allow minimum 25mm thick Non-shrink cement based grout (Attachment#1.5 • • • B • • • • B • • B • • 8. Additional plate shall be installed if the distance between anchor bolts exceeds 750mm (Attachment#1.2 8. 8.2. Chip the foundation with hammer to remove laitance. grease. Anchor bolts or other steel embedment’s shall not be used as the means of grounding electrical equipment and shall not be tied to grounding neutral conductors. vertical equipment-plan-Type-1).7 9.2. vertical equipment-plan–General). or any part of the lightning protection system. Plate shall be provided on one side of each anchor bolt for horizontal equipment’s and additional plates shall be provided if the distance between anchor bolts exceeds 750mm (Attachment #1 Horizontal equipment – plan). All plate shall be away from equipment base on either side by minimum 15mm and maximum 25mm (Attachment#1. Non-shrink cementitious grout shall be used for fixing the plate with foundation. Plate dimension shall be 10mm thick x 100mm wide x L (Depends upon the width of equipment base) (Attachment#1. The following procedure shall be followed for shim/Pad plate installation: Material shall be 10mm thick carbon steel grade ASTM A-36 or equivalent.1.4 8. Equipment pre-installation inspection shall be completed and foundation shall be released for Equipment Erection. Reinforcing Steel bars.2.0 EXECUTION WORKS General Confidential Page 7 of 17 . In general. Plate shall be installed per the site situation for the Equipment’s which base dimension is less than 150mm.7 Prior to the installation verify with piping GA for the minimum clearance requirements.6 8. equipment and Tail crane shall be positioned at the designated location sequentially and rest in flat position.: 111-IK3-CM-CCM-0003 Revision No.6 B PLANNING Total weight to be lifted shall be determined which is total of certified equipment weight.4 9. crane operator and Equipment Supervisor (with Rigger) prior to start any lifting activities.3 9.1 9. Lifting tackles shall be attached to main and tail crane hooks as per the lift plan. PREPARATION Ground compaction shall be done as per the lift plan requirement and all the obstacles in lifting area shall be cleared. Both cranes shall hoist the load slowly up to minimum height required for tailing.: B Issue Date : 26 March 2012 9.3 9.3.7 9. slings and shackles etc. ground condition and underground details shall be studied carefully. shackles and requirement of ground compaction shall be determined. centre of gravity.4 9.3.1 9.3.3.2 9. tailing and lifting points and interference of fixed items shall be checked.8 . Wind condition shall be checked if found ok.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.1.1. lifting elevation. Lift plan shall be submitted to PMT for approval as per the contract requirement. crane hook.2. working radius.3.1. attach main and tail crane lifting tackles to the respective lifting points and ensure shackles are closed properly. ERECTION Pre-lift toolbox talk shall be conducted by Equipment Supervisor (with Rigger) with all personnel involves in lifting work to explain the risk involved and measures to be taken. working radius.1. Length.1. lifting beam.1 9. spacing and numbers.2. Protect the slings from sharp corners with packing or sleeves and ensure that the equipment is free from all fixed attachments before lifting. Equipment Supervisor (with Rigger) shall physically examine the jobsite and the equipment to be used prior to giving signature approval for lifting. Equipment Supervisor (with Rigger) who is familiar with hand signals shall give signal to crane operator and crane operator shall receive signal from one rigger only at a time. crane capacity at working radius and percentage of load capacity. pattern. Position the hooks over the centre of the lifting point. Equipment size.3.7 9.3. lifting weight with actual load chart and percentage of capacity with approved lift plan at site. Then General Confidential Page 8 of 17 9.5 9.4 9. Equipment location.1.2.3. Equipment base plate shall be checked for bolt hole diameter.2 9. Main crane.2 9. Observe cranes and slings carefully by lifting the load slightly from the original elevation and avoid shock loading.1. if required steel mats/plates or wooden blocks shall be used.6 9. Detailed lift plan shall be prepared showing sketch of crane position.2. Type of crane. working radius.3 9. slings. Lift plan form shall be properly completed and signed by originator.5 9. This shall be cross checked with anchor bolt dimensional check report. equipment delivery location.3 9.2 9. Rigger-1 shall counter check crane location.1 9. obstacles in the way of lift. 11 Care shall be taken for threads of anchor bolt and rest the load over shim/pad plate and bolt up with anchor bolts.6 9.4 9. which is necessary for lifting and lowering the load for shimming during alignment.7 9.12 Horizontal equipment’s shall be lifted by single crane using basket hitch.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.4. 9.3 9.3.9 B Once the equipment is vertical. 9.4 ALIGNMENT Equipment shall be aligned as per the following procedure: Equipment centrelines shall be checked with co-ordinates already marked on the foundation.4. 9.3.4. Verticality shall be checked in all directions at three-reference point (Tan line to Tan line) marked on Equipment at vendor fabrication shop. B 9.: 111-IK3-CM-CCM-0003 Revision No. Then confirm orientation and lower the load slowly.2 9. Horizontal Equipment centrelines shall be marked on the saddle support base and checked with co-ordinates already marked on the foundation.10 Equipment foundation.3.1 9.4. After grouting has reached the required curing period. Verticality of the equipment shall be checked by calibrated theodolite or plump bob depending upon the height of the equipment. The equipment shall be released for other activities. Then move the load over the top of foundation. top of shim/pad plate. Alignment inspection shall be completed by MMG/TCC/DAELIM/PMT QC representatives. 9.0 General Confidential Page 9 of 17 . all anchor bolts shall be retightened up to hammer tight unless otherwise indicated.0 10.4.2 10. If there is any interference from objects in measuring.4. Horizontal level shall be checked at two reference points (fixed side to Sliding side) marked on Equipment at vendor fabrication shop and shims shall be added if necessary.3.3. GROUTING (By Civil) Grouting shall be done as per the approved method of statement for Non-Shrink Cementitious grouting. threads of anchor bolts and base of equipment shall be cleaned properly. 9. MOUNTING OF ACCESSORIES 9.3.1 B 10.13 Man basket with supporting crane shall be used to detach main crane lifting shackles from the equipment if required. The equipment shall be released for Base Grouting after inspection. 9.14 Heavy equipment’s shall be aligned with lifting tackles in position. it shall be mutually discussed and agreed.: B Issue Date : 26 March 2012 main crane shall hoist the load while tail crane lower the load and this operation shall continue till the equipment is fully vertical. Alignment shims shall be provided in between equipment base and top of pad plate and minimum thickness of shim shall be 1mm.5 9. tail crane shall be detached from equipment and tie guide rope to the equipment to control the load.3 11.4.4.8 10. brackets shall be attached first. the accessories shall be mounted after centring of the vessel. such as tray part nomenclature. Vendor supplied installation procedures and assembly drawing. Sort and prepare the material such as insulation. For assembly of the platforms.3 11. support and riser pipe etc. pipe. Further details shall conform to the manufacturer’s drawings. Where such apparatus are to be equipped. B 12. Attached piping and instruments shall be installed as per the manufacture’s instruction. etc.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.1 12. Tower attachment drawings: show the supports welded to vessel where tray parts will be installed.7 11. installation notes. Accessories shall. attention shall be paid to the location of long bolt holes and step bolts. be attached in the order from lower to upper parts of the vessel. ladder.4 11.2 11.2 Install the major support members (beam & Down comer trusses) General Confidential Page 10 of 17 . platform.1 Preparation of Technical Documents • Assembly of Tray Drawing: these provide general installation information. gasket location (when required). care shall be taken to avoid damaging it or the equipment in the course assembling and installation. When staircase and ladder are mounted. and shows various installation assembly details for joint portions of tray parts and installations numbers.The sequence of installation activities are as follows: B 12. Assembly and part list Drawings: Contains the parts list that makes up the completed trays.2.1.1 Verify the roundness of the inside circumference of the tower shell and check the dimensions of the down comer bar and welded attachments prior to commencement of installation works. considering by operating temperature.: 111-IK3-CM-CCM-0003 Revision No.6 11. to meet the requirement in the manufacturer’s drawing and or parts list.0 12. Confirm the availability and the quality of all the parts against packing list.1. In general but not always. assembly details with each description.2.2 Execution Sequence The installation of internal Trays will be carried out in strict adherence with all approved for construction drawing. INTERNAL TRAYS General Preparation The following set document shall be used for the installation of trays: 11.8 12.: B Issue Date : 26 March 2012 11. and all the bolts and nuts shall be finally tightened after adjustment has been completed.5 Accessories shall be checked for quantity. distorting. Any damage or shortage of the components should be recorded and reported to the QC department immediately. whole layout. as well as job specifications prior to work commencement .1 11.2 Equipment Receiving and inspection 12. as a rule. handrail. and the assembly charts with quantity of each assembly for each type of tray. • B • 12. specifications and all other relevant contract documents. as required in the associated drawing. draw-off sumps are to be verified to have been installed correctly and in the specified orientation in the tower. 12. such as down comer braces and weirs are to be seal welded. Similarly. Determine the tray centrelines and mark the support ring or vessel wall with 90-Degree intervals. 13.5 Do not install man way access panels until trays have been inspected.2. 12.2. until installation of all trays have been completed.2. Piping furnished by the equipment manufacture as part of the purchase order shall be installed according to the equipment manufacturer’s drawing and piping instruction. protective measures shall be taken to protect workers on lower levels from falling objects. 12.: B Issue Date : 26 March 2012 • • Beam are to be bolted to bolt bar as per applicable drawing. perform tack welding of parts.0 13.2 OTHER WORK Electrical and instrumental work will be treated in other electrical and instrumental instruction.3 Inspection All equipment inspections shall be as per the relevant project ITP.6 Secondary tray parts. work is to commence from the lower end of column. In the event of simultaneous installations at other levels.4 Install decking tray floor sections starting from the outer pieces and work inward towards the centre of the tower.1 13.2.3 Install Tray Component Parts • When installing tray panels. Mark the locations of trusses on the tray support ring and on flanges of trusses or down comer beams as shown on detailed drawing. in order to allow for later adjustment. Upon positioning of parts against the tower attachments as shown on applicable design drawing. remove any loose hardware.: 111-IK3-CM-CCM-0003 Revision No. Welding of tray parts shall be performed as per approved WPS / Drawing. Welding as part of the installation of the equipment furnished by the manufacture shall be done according to the manufacturer’s drawing and instruction and welding procedure General Confidential Page 11 of 17 13. 12.8 Repeat the steps above.7 Upon completion of all installation activities.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No. • • • • 12. Tray floors should be adjacent and avoid any angular contact between floors.4 . Install vertical tray member such as down comer aprons or low down comer plates making sure clearance requirements and tolerances are met. making sure that the top surface of the upper beam flange are within the dimensions specified in the applicable drawings. 12. 12. tools and foreign matter and clean the trays accordingly. Verify the correct installation of beams and trusses.3 13. Desiccants or foreign material shall be removed before pipe connection.2. Stitch welding is to be followed when welding tray parts followed by filler passes to fill gaps between stitches. Painting on the equipment which is described in equipment list shall be performed according to the painting instruction. which is submitted by electrical part.2. Also to include. All inspection shall be in accordance with SATIP / SAIC’s. MECHANICAL SAUDI ARAMCO TYPICAL INSPECTION PLAN( SATIP) NO SATIP NO DESCRIPTION 1 SATIP – D – 001 – 01 Pressure Vessel Installation Heat Exchanger Installation – Shell & Tube (Including Brazed Aluminum Heat Exchanger) Air Cooled Exchanger ( Fin Fan Cooler ) 3 SATIP – D – 004 – 01 4 SATIP – D – 007 – 01 5 SATIP – D – 007 – 01 Flare Package Installation 6 SATIP – D – 001 – 01 Structural Steel General Confidential Page 12 of 17 .5 13. All instruments such as Theodolite. Stencilling shall be carried out for all Static Equipment in accordance with SAES – B – 067 Para 6.1. Piping. 14.8 13.9 Insulation on the equipment described in the equipment list shall be performed according to the insulation instruction. 13. 13.0 INSPECTION AND TESTING • Inspection and testing shall be performed in accordance with the applicable contract and code requirements.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.: B Issue Date : 26 March 2012 approved by the Company Representative.12 Lifting & Installation of equipment shall be full compliance to all applicable Saudi Aramco General Instruction. E & I release should be submitted prior to final box up of the vessel.6 13. dial gages etc.: 111-IK3-CM-CCM-0003 Revision No.11 Bolt Torqueing shall be carried out with calibrated torque wrenches and calibration of Torque wrenches shall be cross checked with Calibrated Torque analyzer every time when used. Gasket verification shall be done at all flange joints connection to the nozzle of the equipment during final box up.7 13. used for the installation shall be calibrated periodically as per contract requirements. 13. 13.10 Final Box – up shall be done after connection of all the related piping to the equipment with prior release from QC department. I.S.: 111-IK3-CM-CCM-0003 Revision No.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.: B Issue Date : 26 March 2012 MECHANICAL SAUDI ARAMCO INSPECTION CHECKLIST( SAIC ) NO SAIC NO DESCRIPTION 1 SAIC – D – 2001 Review of Safety Instruction Sheet ( S. Of Small Tanks per SAES-D-109(Int Insp) Under Tank Leak Detection & Sub-Grade Protection( if Required ) 14 SAIC – D – 2018 General Confidential Page 13 of 17 . Of Small Tanks per SAES-D-109(Ext Insp) 13 SAIC – D –2016 Review Insp.) 2 SAIC – D – 2002 Visual Inspection ( Vessel External) 3 SAIC – D – 2003 Visual Inspection ( Vessel Internal ) Receiving Inspection of Fabricated Structural Attachment of Equipment’s ( Access and Supports ) Storage Handling and Preservation( Vessels and Tanks ) 4 SAIC – D – 2004 5 SAIC – D – 2005 6 SAIC – D – 2006 Equipment Pre-Installation Inspection Equipment Installation – Alignment and Elevation Check( Vertical and Horizontal Vessels ) Inspection of Vessel Trim Installation 7 SAIC – D –2007 8 SAIC – D –2008 9 SAIC – D –2019 Tray Installation Final Inspection/Punch listing for Reinstatement(By Contractor) Review of Tank Data Sheet and Safety Instruction Sheet 10 SAIC – D –2012 11 SAIC – D –2014 12 SAIC – D –2015 Review Insp. Handling and Preservation of Equipment Inspection of Support Foundation Prior to Structural or Equipment Installation Inspection of Structural Alignment During Erection 30 SAIC – M – 2006 31 SAIC – M – 2007 General Confidential Page 14 of 17 .: B Issue Date : 26 March 2012 15 SAIC – D – 2019 Inspection of Above Ground Small Tank Installation 16 SAIC – D – 2020 Inspection of Tank Trim Installation 17 SAIC – D – 2021 Punch Listing/Final Inspection of Tank Installation Verification of Non-Material Requirement for Vessels and Trays Review of SIS for Shell and Tube Heat Exchanger 18 SAIC – D – 2022 19 SAIC – E – 2001 20 SAIC – E –2002 Receiving Inspection of Shell and Tube Heat Exchanger 21 SAIC – E –2003 Storage Handling and Preservation of Heat Exchanger 22 SAIC – E –2004 Review of SIS for Air Cooled Heat Exchanger 23 SAIC – E –2005 Receiving Inspection of Air Cooled Heat Exchanger Inspect Assembly of Air-Cooled Heat Exchanger Components In-Situ Strength Test of Fin Fan Cooler( Preparation ) 24 SAIC – E –2006 25 SAIC –E –2010 26 SAIC – E –2031 Receiving Inspection of Flare Package Components 27 SAIC – F – 2032 Handling.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.: 111-IK3-CM-CCM-0003 Revision No. Storage & Preservation(Flare System Packing) Final Inspection Package(Re-Instatement) of Flare System 28 SAIC – F – 2033 29 SAIC –G – 2001 Review of Procedure for Storage. 6.: B Issue Date : 26 March 2012 32 SAIC –M – 2010 Inspection on Access Structure Installation 33 SAIC – N –2024 Pre-Application Inspection of Castable Refractory 34 SAIC – N –2037 Receiving Inspection of Fireclay Bricks and Mortar 35 SAIC – N –2038 Storage and Preservation of Fireclay Bricks and Mortar 36 SAIC – N –2039 Inspection of Mixing Equipment 37 SAIC – N –2040 In-process Inspection of Fireclay Bricks Installation 38 SAIC –N –2042 Inspection of Curing and Dry-Out of Fireclay Bricks MECHANICAL SAUDI ARAMCO TEST REPORT ( SATR ) NO SATR NO DESCRIPTION In-Situ Strength Testing of Fin-Fan Coolers( Per SAES-A-004 Para.5 ) 1 SATR – A – 2001 2 SATR – A – 2011 Final Inspection/Punch listing for Reinstatement(By Contractor) 3 SATR – D – 2001 Alignment Inspection Record – Horizontal Vessel 4 SATR – D – 2002 Alignment Inspection Record – Vertical Vessel 5 SATR – D – 2003 Vessel Closure Inspection 6 SATR – D – 2004 Tray testing report General Confidential Page 15 of 17 .4.: 111-IK3-CM-CCM-0003 Revision No.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No. : 111-IK3-CM-CCM-0003 Revision No.1 ATTACHMENTS Shim / Pad Plate Installation General Confidential Page 16 of 17 .0 15.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.: B Issue Date : 26 March 2012 7 SATR – G –2005 Mounting Plate Level Data Sheet 8 SATR – M –2002 Pre-Installation Procedure Verification Testing Using the Turn-of-Nut Method(ASTM A325 or ASTM A490 Bolts ) 15. : B Issue Date : 26 March 2012 ATTACHEMENT # 1 General Confidential Page 17 of 17 .: 111-IK3-CM-CCM-0003 Revision No.Yanbu Export Refinery Project METHOD STATEMENT FOR INSTALLATION OF STATIC EQUIPMENT Document No.