MS for Installation of Air Finned Coolers

NGHI SON REFINERY AND PETROCHEMICAL PROJECT

Document Title :METHOD STATEMENT FOR MECHANICAL INSTALLATION AIR FINNED COOLERS

Contractor Doc. No:VV3160-001-C-017 REV – 0

METHOD STATEMENT FORMECHANICAL INSTALLATION

AIR FINNED COOLERSDOCUMENT CLASS: X

0 01 - Jan - 2015 Issued for Approval

Rev. Date Description Prepared by Checked by Approved by

Responsible Company Prepared by: Checked by: Approved by:

WEC Velpandi Nava

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Issue Purpose For Approval




Table of Contents

1. SCOPE 3

2. PURPOSE 3

3. REFERENCES3

4. ORGANIZATION & RESPONSIBILITIES 5

5. EQUIPMENT 6

6. LIFTING CATEGORIES6

7. INSTALLATION OF SCAFFOLDING FOR ACCESS 11

8. IMPLEMENTATION 12

8.1. Preparation 12

8.1.1. Material Check and Preservation 12

8.1.2. Construction Tools 12

8.1.3. Foundation 13

8.1.4. Liners14

8.2. Setting and Alignment 15

8.2.1. Rigging and lifting 15

8.2.2. Setting and alignment 15

8.2.3. Alignment tolerances 16

8.1. Grout 17

8.1.1. Types of grout and materials 17

8.1.2. Application 17

8.1. Shaft Alignment 19

8.1.1. Preliminary alignment 19

8.1.2. Final alignment 19

8.1.3. Hot alignment 19

8.1.4. Tolerances for shaft alignment 19

8.1. Coupling 20

9. PRECAUTION ON PIPING ASSOCIATED WITH ROTARY MACHINERY 20

10. CLEANING OF ASSOCIATED PIPING 21

10.1. Chemical cleaning21

10.2. Oil Flushing of Lube Oil and Seal Oil System 22

11. SCOPE OF INSPECTION / TEST ITEMS22

12. DOCUMENTATION 22

12.1. Installation Procedure and Method Statement 22

12.2. Contents of Procedure 23

12.3. Inspection Record 23

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1. SCOPE

This method statement contains the general requirements for the installation of Air Finned coolers.

2. PURPOSE

This document is established to outline general procedure and implementing effective activities for all Air Finned coolers installation works. This provides guidance includes addressing programs for:

- Implementing commitments regarding the efficiency and quality with the safe of work.

- Managing and providing oversight to ensure installation with explain step by step whole of activities accordance standard code and related document.

3. REFERENCES

3.1. JGCS Documents:

- S-000-1654-0001V Construction HSE plan

- 3550-8410-SP-0017 Positive displacement Pumps – Rotary API 676

- S-000-1654-0002V HSE audit and inspection plan

- S-000-1654-0100V Job safety analysis (JSA) & safe work method statement

- S-000-1654-0110V START program procedure

- S-000-1654-0120V Incident management plan

- S-000-1654-0130V Emergency response plan.

- S-000-1654-0160V Spill Contingency Management Plan.

- S-000-1654-0200V Permit to Work Procedure

- S-000-1654-0240V Person Protective Equipment (PPE) Procedure

- S-000-1654-0400V Scaffolding Procedure

- S-000-1654-0405V Site Barricades

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- 3550-8710-SP-0001 Construction execution requirements

- 3550-8710-SP-0001 Construction execution requirements

- 3550-8430-TN-0001 Technical Note Scope narrative

- S-000-1320-1001V Construction specification for concrete works (for grating)

- S-000-1654-0410V Tools and Portable Powered Equipment

- S-000-1654-0425V Mechanical Equipment and Heavy Equipment

- S-000-1654-0430V Electrical work procedure

- S-000-1654-0510V Working at Heights

- S-000-1654-0530V Lifting and Rigging Operation

- S-000-1654-0540V Welding and Cutting

- S-000-1654-0545V Radiography Procedure

- S-000-13A0-0001V Specification for Painting

- S-000-1635-0003V Equipment Protection during Construction

- S-000-1654-0001V Worker's Occupational Health and Safety Management Plan

- 3550-8710-SP-0003HSE Instructions To Contractors

- 3550-8150-PR-0001 Project HSE Plan: Environmental Plan

- 3550-8150-PR-0002 Project HSE Plan: Health and Safety Plan

- 3550-8710-PR-0001 Mechanical Completion Requirements

- 3550-8710-PR-0004 Emergency Evacuation Requirements

- 3550-8820-TN-0009 Guidelines on Application of Mandatory Vietnamese Standards/Statutory Regulations.

3.2. The vendor’s manual shall have the first priority. All the equipment shall be installed accordance with installation instruction and procedure given by the equipment and the component manufacturer.

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3.3. If any conflicts or question for among this specifications, the specifications for installation shall be referred to client and owner of resolution.

3.4. Manufacturer’s installation standard

3.5. Equipment drawing

3.6. Equipment foundation drawing.

3.7. List of Air finned coolers

XYXZ

4. ORGANIZATION & RESPOSIBILITIES

Air Finned coolers installation work organization shall be headed by Project Manager supported by whole of people involved in site key personnel construction organization below.

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4.1. Organization chart

4.2. Responsibilities

Site Manager: Responsible for ensuring that all works are performed in accordance with this procedure.

Construction Manager:Responsible for the overall planning, coordination and control of theinstallation activities

Field Engineer Responsible for field installation work implementation and maintaining acceptable quality standard

Field SupervisorResponsible for the actual checking of the work, Give Instructionwork control for ensuring all activities during installation work done safely.

Field Superintendent

Responsible for the actual performance of the Installation crew andactual checking of the work Progress to make sure that it is drawing specification and standard & in accordance with established safe work practices.

Safety Officer Responsible for monitoring that all activities are carried out in asafety manner and compliance with the established safety procedure.

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Quality Control

Responsible to monitor and inspect the erection and installation activities ensuring it is being done in compliance with this procedure, ITP (Inspection and Test Plant), Drawing, Project specification and other reference standard document and procedure.

Crane Operator To operate crane in safely manner and under guidance by signal man

Scaffolder To build scaffolding for access worker to installation equipment.

Signalman To guide crane operator during lifting work

Rigger To do rigging work under supervision rigging foremanMechanicalFitter/Millwright To do Fit-up work under supervision mechanical

General Worker To do mechanical work under supervision

5. EQUIPMENT

All equipment required will mobilize, included listed as follows:

- Calibrated Alignment Tools/Instruments- Steel plate for crane (defend on crane size)- Crane- Forklift- Man Baskets and Man lift.- Crawler and Hydraulic cranes to be used- Lifting Gears Accessories- Mechanical hands Tools- Scaffolding materials - Electrical hand Tools

6. LIFTING CATEGORIES

Prior to Lifting Works, it must have an approved Lifting Plans. Which indicate the type of cranes & lifting gears accessories indicated. The lifting plans must be followed during all lifting works.

To Provide safely work when erection Air Finned coolers, there are consideration which take according to weight of the equipment. The lifting categories are shown on list below:

WEC shall employ an experienced, competent and responsible Lifting Engineer to plan and review lifting operations.

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Duties shall include the review and approval of lifting studies provided by specialist heavy lift crane subcontractors.

The Lifting Engineer shall also be responsible for providing other heavy lift studies.

WEC shall develop a lift classification schedule identifying all lifts and studies required for each lift.

The method of review by the Owner or Owner’s representative shall be agreed with the Contractor.

All loads greater than 200t shall be submitted for review by Owner/Owners representative.

Lift studies will be based upon using a maximum of 90% lifting capacity of the intended crane to be utilized.

Lifting studies shall be carried out by the WEC or specialist subcontractor for all loads greater than 50t (as a minimum requirement).

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7. INSTALLATION OF SCAFFOLDING FOR ACCESS

- Erect scaffolding based on sufficient structural integrity to ensure a safe working environment, including anticipated wind force and soil bearing capacity of the location of erection. Comply with Scaffolding Procedure of JGCS.

- Only trained and experienced personnel for erection and dismantling of scaffold, and aware of all safety requirements.

- Tag of scaffolding and control system shall be used to erection and dismantling of scaffold structures, for displaying the status of erected structures, as per the scaffolding procedure of JGCS.

- Pre-assembled scaffold on the frame for erection purpose would be inspected by certified scaffolding and shall be inspection by JGCS prior to use.

- Scaffolding tubes will be used as life lines, for erection purpose if necessary.

- Scaffolding would be arrange, like sketch drawing below and right angle, end to end coupler shall be used for joined tubes.

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8. IMPLEMENTATION

8.1. Preparation

8.1.1. Material Check and Preservation

Prior to the arrival of equipment on site, Contractor's MCS and Subcontractor shall review the manufacturer's requirements and the requirements of this specification regarding on-site storage of the Air finned cooler.

These requirements shall be incorporated into the preservation plan and adhered to in all respects.

Contractor's MCS and Subcontractor shall carry out the preservation in accordance with manufacturer's manuals and apply lubricants and preservative compounds at site upon the requirement to all equipment periodically.

When the equipment arrived at site, shop preservation shall be checked by Contractor's MCS. Where necessary, damage to preservation shall be rectified without delay.

All openings on motors and tube bundles shall remain closed during construction stage. If there are some openings remained, they shall be closed with normal plugs of steel or malleable cast iron or with blind flanges applying corrosion inhibitors.

After handover of the equipment and components to Subcontractor for site installation at Contractor's MCS including storage and laydown yard all the necessary preservation activities shall be taken and maintained by Subcontractor.

8.1.2. Construction Tools

It shall be the responsibility of the Subcontractor to ensure that proper tools are available and used during the installation work of Air finned coolers.

Tools shall be stored in a tool room/warehouse when not in use. Such tools shall include but are not limited to the following:

Corrective size wrenches, keys, and sockets

Torque wrenches cover all required range and size

Certified slings, shackles and hoists

Hand held tachometers

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Calibrated alignment dial indicators with calibration certificate, which cover all required size

Alignment jigs which total sag is smaller than the maximum allowable value

Alignment mirrors

Calibrated Precision levels and required length of stretch with calibration certificate

Belt Tensioning equipment

Hydraulic bolt tensioners of required size range and size

Pyrometers suitable for measuring bearing temperatures

Portable Vibrato meters

All Special Tools provided by the manufacturer other than those listed above shall be inventoried and tracked by the CONTRACTOR. Upon requisition, the necessary tools shall be issued to Subcontractor and shall be turned over to the CONTRACTOR in the original working condition

Valid calibration documents must be present for calibrated instruments.

8.1.3. Foundation

Work Release between disciplines shall be in accordance with the procedure.

When receiving the foundation the following points shall be checked with the latest relevant drawings:

Distinct position (centre) marking and height (level) marking on the deck, it will be referred for alignment work of level and position.

Size and numbers of anchor bolt and nuts, position of bolts with projection.

Existence of damage and rust of threaded parts of bolts and cleanliness.

Prior to the installation work, the deck shall be checked for the following points:

Distinct marking on deck (centre marking and level marking)

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Level of pads and Bolt.

Complete freedom from foreign matters.

The bottom of equipment bases shall be cleaned and free of laitance, loose particles, oil or grease.

8.1.4. Shim Plate

Shim material shall be in accordance with client specification and shim shall be prime-coated on the surface other than the machined faces. The thickness of liners shall be at least 10mm.

Pads shall be made using flat liners in accordance with manufacturer's drawing, basically just under the levelling jack bolts. The setting elevation shall be determined considering the length of jack bolts supplied by the manufacturer and sufficient covering with grout material.

In the case of anchor boxes, temporary pads or liners may be installed under the base frame and at the next of anchor boxes. After filling the anchor box with grout material, permanent padding shall be made in correct position, then the temporary pads or liners shall be removed. Liners shall not be used under machinery which is provided with levelling jack bolts.

Size of the padding plate shall be determined considering the allowable load (max. 30kg/cm2) and numbers of required pads.

The load to be supported shall be calculated in accordance with the equation shown below. However size of liners shall be minimized and sharp edges of the liner plates shall be rounded because they are buried in the grout.

L = W / N x A x B

L : Load Supported by liner (kg/cm2)W : Lifting load of equipment (kg)N : Number of linersA : Width of pad plate (cm)B : Length of pad plate (cm)

In case special leveling devices are provided with the machinery, they shall be set in accordance with manufacturer's instruction.

If the equipment installed on steel structure, the liners shall be welded after base alignment work and full seal welding of liners on floor structure or other

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countermeasure method to minimize vibration can be done upon manufacturer's requirement.

8.2. Setting and Alignment

8.2.1. Rigging and lifting

Rigging and lifting shall be carried out generally in accordance with Lifting and Rigging Operations Procedure (S-000-1654-0530V) by a competent lifting crew.

Rigging and lifting for the specific items shall be done in accordance with the manufacturer's recommendations including the use of spreader bars and slings and so on.

8.2.2. Setting and alignment

Machinery shall be set and aligned at the proper position, elevation and level-ness within the tolerance.

When the "driver" is shipped separately from the equipment common bed, the "driver" shall be installed after the common bed is aligned.

When leveling jack bolts are not provided on the equipment shims may be used for leveling. All shims shall straddle the hold down bolt. If the machine is foot mounted, the shims shall be the full size of the foot. When shims are used directly under channel or "H" beam sub bases, the shims shall cover the entire width of the channel or 'H" beam and shall be a minimum of 4 (four} times as long as the diameter of the bolt.

When jacking screws are used for leveling pads are not necessary to remove after grouting. It is required; however, that the jacking screws are backed off two turns or fully removed depending on the Employer instruction at site and the hold down bolts shall be re-tightened after the grout has adequately cured.

After installation of the equipment and up-to grouting commencement, foundation chipped surface shall be protected from harmful contaminations for grouting with a suitable way.

Any abnormal wear and tear on equipment and parts during installation and assembly shall be corrected by the Subcontractor. Prior to commencement the corrective action written work procedure shall be prepared and approved by Contractor/Company.

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8.2.3. Alignment Tolerances

Location ± 3 mm

The installation position of machinery shall be measured with reference to the centre marking of the foundation.

Elevation ± 3 mm

The bottom of the base plate shall be measured with reference to the level marking of the foundation.

Levelness ± 0.2 mm per meter for API 610 pumps± 0.4 mm per meter for general purpose equipment and ASMEPumpsManufacturer’s levelness criteria shall be followed for machineryother than mentioned above.

The measurement planes used for alignment shall be machine finished planes.

Levelness shall be checked from two directions, which are at 90°. to each other, minimum 4 points of the skid. The levelness of the pump side of the common bed may be checked on the surface of the top oriented pump nozzle.

Before grouting, it's required to confirm the shaft alignment to avoid future trouble of shaft alignment.

8.3. Grout

8.3.1. Types of grout and materials

The summary extracted from D-000-1320-1001V is shown below.

GROUT TYPE APPLICATIONMINIMUM

COMPRESSIVE STRENGTH

TYPE G1:SAND-CEMENT GROUT

MINOR STEEL WORKS (e.g. MINOR PIPE SUPPORT, INSTRUMENT STAND)

20 MPa AT 28 DAYS13 MPa AT 7 DAYS

TYEP G2:NON-SHRINK CEMENT-BASED GROUT

MAJOR STEEL WORKS, STATIONARY EQUIPMENT, ROTATING EQUIPMENT (NOT COVERED BY TYPE G3)

75 MPa AT 28 DAYS*

TYPE G3:NON-SHRINK EPOXY-

WHERE SPECIFIED BY VENDOR

95 MPa AT 28 DAYS*

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BASED GROUT

* 50mm CUBE IN ACCORDANCE WITH BS1881 OR EQUIVALENT

Note 1: Grout fill for anchor boxes (as required) shall be done with TYPE G2 regardless the type of grout material use beneath the base frame.

Note 2: Grout fill of void space inside base frame may be done with TYPE G2, however the following method with the 2 steps is also acceptable.

- 1st Step: Concrete Mix Type “MIX E” may be filled up to 25 mm ~ 30 mm lower than the final level.

- 2nd Step: After cured the first filling with concrete, TYPE G2 shall be used as final layer of grout fill.

Note 3: If not specified which type of grout to be used, shall subject to Contractor approval.

8.3.2. Application

Prior to installation of TYPE G3 epoxy and TYPE G2 non-shrink cement-base grouts a certification of compliance from a third party laboratory showing test results of compressive strength and shrinkage test shall be provided. The test shall be conducted according to the relevant code.

Approved TYPE G3 and TYPE G2 grout material with the valid shelf life only can be used and shall be stored in accordance with manufacturer's recommendation and follow the manufacturer's instruction in use.

TYPE G3 epoxy grout shall be applied for the equipment required in Vendor's specification and/or drawings.

TYPE G2 non-shrink cement-base grouting shall be basically applied to all Compressors and Air Finned coolers based on Vendor recommendation.

Both mixing and pouring of TYPE G3 epoxy grout or TYPE G2 non-shrink grout shall be in accordance with the grout manufacturer's instruction.

Water for mixing grout Type G2 and TYPE G1 shall be fresh and clean, and free from injurious amount of oil, acid, alkali, salt or organic materials.

Foundation bolt sleeves shall be filled with the specified material, if any, prior to grouting the base.

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Grouting of one continuous area shall be completed without interruption.

Grout openings and vent holes on the drip pan/top plate of the base plate shall be sealed to prevent contamination of grout by oil or chemicals. Sealing materials shall be adequate to protect against the expected contaminant (such as acids)

TYPE G1 sand cement grout shall be applied to all other portions such as minor steel structure clarified in Para. 5.3.1.

TYPE G1 sand cement grout shall be mixed with cement and fine aggregate (sand) in the proportion of 1:1 by volume and the weight percentage of water and cement shall be 40% or less, and grout shall be stiff consistency.

After foundation cleaning, when using cement-base grout, water shall be sprinkled over the foundation tops, and grouting shall be done in a moisture condition.

Remaining puddles shall be removed before grouting. If epoxy grout used, the surface must be dry.

TYPE G1 grout materials shall be rammed in and tamped sufficiently with iron bar or the like to eliminate any air pockets.

The surface of grouting shall be finished so as to be smooth by using a steel trowel, etc.

Upon completion of grouting with TYPE G2 and TYPE G 1, grout shall be properly cured for 7 days or longer by covering it with continuously wet mats or sprinkling it.

8.4. Shaft Alignment

8.4.1. Preliminary alignment

Prior to grouting and before piping work (or with all piping disconnected), the driver and speed change gear if any shall be adjusted for preliminary shaft alignment and it shall be confirmed that the equipment can be finally aligned within the limit of tolerances.

The reading of indicated gauge shall be demonstrated to be repeatable. A minimum of three rounds of the shafts shall be made with the indicators going to the zero point at the top position each time.

Alignment shall be adjusted by inserting 300 series stainless steel shims under each support foot. Shim requirements in API RECOMMENDED PRACTICE 686 shall be followed.

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8.4.2. Final alignment

The final alignment of the shaft shall be carried out, after the lines are connected to the suction and discharge nozzles of the equipment.

The maximum shaft movement in either the vertical or horizontal directions after the flanges is tightened shall be 0.05 mm or less.

If the effect of pipe strain exceeds this value, corrective action must be taken to improve pipe alignment.

This limit shall include the effects of setting piping supports.

8.4.3. Hot alignment (If Required )

The hot alignment shall be done on a case-by-case basis, taking into consideration the design operating temperature of the equipment and the manufacturer's recommendation.

8.4.4. Tolerances for Shaft Alignment

If not specified by vendor's instruction, + 0.03 mm of the parallel tolerances and + 0.04 mm of angular tolerances for shaft alignment shall be applied.

8.5. Coupling

Couplings shall be inspected on arrival for any damage in shipping and proper corrosion protection before being stored. Couplings and associated components shall be stored in a clean, dry, warehouse atmosphere.

Coupling with flexible diaphragms or flexible disc packs are particularly susceptible to damage and must be protected. Flexible diaphragms are permanently coated to avoid any corrosion and if this coating is damaged, the coupling manufacturer shall be notified immediately to obtain repair procedures.

All couplings shall be installed in strict accordance with manufacturer's instructions. Installation records shall include the following:

Distance between shaft ends or coupling hub flanges.

Installation of hydraulically mounted hubs ( If Applicable )

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- Hydraulic pressure applied- Axial pull up travel- Final position- Amount of pre-stretch on flexible disc or flexible diaphragm couplings.- Thickness and location of shims installed.

Correct torque for tightening coupling flange bolts.

Axial "float" of gear coupling spacers.

Positions of lube oil spray nozzles for continuous lube gear couplings. They shall be effective with the spacer at either end of its float and shall not rub the spacer or hub.

9. PRECAUTION ON PIPING ASSOCIATED WITH ROTARY MACHINERY

All protective covers and plugs on the equipment shall remain in place until the piping is ready to be connected.

Piping fabrication or erection shall not cause uncontrolled forces defined on the vendor's data sheet to be applied to the equipment nozzles. Piping upstream of the equipment shall be erected toward the machinery from the first anchor point.

Piping shall never be firmly connected to the equipment until all permanent pipe supports are in place between the equipment and the first anchor point. This includes fixed, sliding and spring supports.

Welding on piping connected to machinery is not allowed unless the welding machine ground lead is connected directly to the part being welded. This is to avoid damage to machinery by stray electrical currents.

All work on the piping systems shall be complete before the equipment is presented for final alignment check. This includes:

Cleaning (air or steam blowing)

Pressure testing

Insulation installed (Dummy weight to simulate the insulation weight can be placed subject to the Employer, instead of complete piping insulation.)

All permanent support installed

Drain, vent and balancing lines installed

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Temporary suction strainers installed

10. CLEANING OF ASSOCIATED PIPING

10.1. Chemical Cleaning

When specified or required certain portions of the piping systems associated with rotating equipment shall be chemically cleaned.

It shall be the responsibility of the Subcontractor to provide a written procedure for this function, which shall describe:

Extent of piping to be cleaned

Chemical compound to be used for cleaning.

Cleaning sequence

Equipment required (pumps, hoses, temporary storage of chemical compounds, etc.)

Location of vents and drains

Dry out and blowing procedure

Acceptance criteria for cleanliness

This procedure shall be presented to CONTRACTOR for approval prior to performing any chemical cleaning.

The Subcontractor shall provide all equipment, personnel, engineering and supervision to perform the chemical cleaning function subject to review and approval of CONTRACTOR.

10.2. Oil Flushing of Lube Oil and Seal Oil System

Subcontractor shall be responsible for the lube oil and seal oil system flushing to meetVendor's oil system cleanliness requirements.

The Subcontractor shall prepare and submit for approval, a flushing plan including marked up P&IDs to show the patterns required, bypass lines and location of proof screens, and any other parts or materials required to accomplish the program.

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Flushing of lube oil and seal oil systems shall be performed continuously until cleanliness are met the requirements of manufacturer. CONTRCATOR shall have a witness for the final inspection of checking screens in each location.

Flushing oil shall be completely drained, then the system shall be filled with recommended lubricant prior to equipment operation.

11. SCOPE OF INSPECTION / TEST ITEMS

The Field Quality Control Plan and ITP for Air Finned coolers Installation shall be prepared and referred to.

12. DOCUMENTATION

12.1. Inspection Record

The results of alignment including baseplate levelness shall be recorded and submitted to Contractor right after the inspection is completed.

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MS for Installation of Air Finned Coolers

Documents

Transcript of MS for Installation of Air Finned Coolers