Method Statement for Erection of Ccr Reactor Module

NGHI SON REFINERY AND PETROCHEMICAL PROJECT

Document Title :METHOD STATEMENT FOR ERECTION OF CCR REACTOR PACKAGE

Contractor Doc. No:VV3160-001-C-015 REV – 0

METHOD STATEMENT FOR CCR REACTOR PACKAGE

DOCUMENT CLASS: X

0 11 - Nov - 2014 Issue for Approval

Rev. Date Description Prepared by Checked by Approved by

Responsible Company Prepared by: Checked by: Approved by:

WEC Nava Nava

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Issue Purpose For Approval




TABLE OF CONTENTS

1. SCOPE 3

2. PURPOSE 3

3. REFERENCES 3

4. RESPONSIBILITY 5

5. EQUIPMENT 6

6. LIFTING CATEGORIES 7

7. INSTALLATION SCAFFOLDING FOR ACCESS AND TEMPORARY PLATFORM 12

8. PLANNING 13

9. CRANE SETUP 13

10. EQUIPMENT PREPARATION 14

11. INSTALLATION METHOD 14

11.1 FOUNDATION 1411.2 ERECTION / LIFTING OPERATION 1611.3 MODULE ERECTION 1711.4 EQUIPMENT INSTALLATION 2011.5 CONTINUATION OF PLATFORM 22

12. ERECTION OF PIPINGS & MISC PIPE SUPPORT 24

13. ALIGNMENT 25

14. GROUTING 26

15. LOOSINING SLIDE AND ANCHOR BOLT 26

16. INSPECTION & RECORDS 26

17. SAFETY 26

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1. SCOPE

This document covers the sequence of activities for erection of CCR reactor module package and to

ensure the compliance to the above activities with the contractual applications and HSE

requirements in Nghi son refinery and petrochmecial Project.

2. PURPOSE

The purpose of this document is to establish the sequencial method of activities for erection

procedure for CCR reactor module package and to ensure the compliance to the above activities with

the contractual applications and HSE requirements in Nghi son refinery and petrochmecial Project.

3. REFERENCES

The requirements contained in the latest editions of the following standard shall form an integral part

of the requirements of the procedure.

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

- 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

- 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

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- S-000-1654-0500V Excavation Procedure

- S-000-1654-0510V Working at Heights- ASME B30.5 Safety Code for Mobile Locomotive Cranes.

- ASME B30.6 Safety Code for Derricks.

- ASME Safety Standard for Sling.

- S-000-1330-1002V Specification for Steel Structure – Erection

- S-000-1520-0107V Supplementry welding requirements to API RP 582.

- ASME American Society of Mechanical Engineers

- ASME B31.3 Chemical Plant and Petroleum Refinery Piping Code

- ASME B16.25 Butt Welding Ends

- ASME Section IX Welding and Brazing, Qualifications

- ASME Section V Non-Destructive Examination

- ASTM American Society for Testing and Material

- AWS American Welding Society

- S-000-1320-1001VA for Grouting for Machinery

- 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

- 3550-8820-TN-0009 Guidelines On Application Of Mandatory Vietnamese Standards/Statutory Regulations.

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

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

3.3 Manufacturer’s installation standard

3.6 Equipment drawing

3.7 Equipment foundation drawing.

3.8 The alignment work shall furhter comply with the requirements of the applicable codes or regulations in force at the locality of the jobsites.

4. RESPONSIBILITY:

CCR reactor installation work organisation shall be headed by project Manager supported by whole

of people involved in site key personnel construction organisation below.

Project 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 EngineerResponsible 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 OfficerResponsible for monitoring that all activities are carried out in asafety manner and compliance with the established safety procedure.

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 foreman

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MechanicalFitter/Millwright

To do Fit-up work under supervision mechanical

General Worker To do mechanical work under supervision

5. EQUIPMENT:

5.1 Monorail & Hoisting Equipment

5.1.1 Mobile Crane

1. Mobile crane operators shall be qualified by statutory board or other approved authorities.Manufacturer’s lift table must be placed conspicuously in the operator’s cab. Capacities given shall be adhered to strictly. Additional boom, if required, shall be compensated with additional counterweights in accordance with the instruction manual. Outriggers and jacks shall be also provided on the mobile crane in case of sudden tire failures or other failure.

2. Cranes and monorail shall be inspected in accordance to statutory requirements and/or requirements by clients at various jobsite.

5.2 Wire rope, Slings, Chains and Fittings

5.2.1 Wire ropes shall be of suitable construction in order to withstand the maximum load to be imposed and length of wire rope in the main hoisting system shall be of ample length for the entire range of movement specified. It shall also have at least two full wraps of wire ropes on the hoist drum at all time. Wire ropes shall be visually inspected and shall be removed if any of the risky condition below is found.

1. Wear of one-third of the original diameter of the outside individual wires.

2. Any damages that resulting to distortion of rope structure.

3. Evidence of any heat damage from any cause.

4. Reductions from nominal diameter of rope exceeding:

3/64 for Ø up to 3/4 inch inclusive1/16 for Ø 7/8 inch to 1 1/8 inches inclusive3/32 inch for Ø 1 1/4 inches to 1 1/2 inches inclusive

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5. In running ropes, six randomly distributed broken wires in one rope lay, or three broken wires in one strand in one rope lay.

6. In standing ropes, more than two wires in one lay in sections beyond the end connection or more than one broken wire at end connection.

5.3 All equipment required will mobilize, included listed as follows :

- Calibrated Inspection Tools/Instruments - Steel plate for crane (defend on crane size)- Crane (to be finalized and mut have approved lifting plan)- Forklift- Man Baskets and Man lift- Crawler and Hydraulic cranes to be used- Lifting Gears Accessories- Mechanical hands Tools- Scaffolding materials - Electrical hand Tools.- MEWP.- Corrective size wrenches, keys, and sockets Torque wrenches cover all required range and size

Certified slings, shackles and hoists- Calibrated alignment dial indicators with calibration certificate, which cover all required size- Alignment jigs which total sag is smaller than the maximum allowable value- Calibrated optical laser alignment tools- Alignment mirrors- Calibrated engineering levels and required length of stretch with calibration certificate- Belt Tensioning equipment- Magnet stand drill, drill bite and reamer for dowelling 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 tumed over to the CONTRACTOR in the original working condition

Valid calibration documents must be present for calibrated instruments.

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. Page 7 of 26




To Provide safely work when CCR reactor, there are consideration which take according to weight

of the module and equipments. The lifting categories are shown on list below:

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

lifting operations.

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

utilised.

JGCS shall produce and maintain a project specific Lifting Study Schedule. This

shall be initiated, distributed and maintained by the WEC’s Lifting Engineer and shall incorporate a

listing of all classified lifts.

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 SCAFFOLDING FOR ACCESS AND TEMPORARY PLATFORM

7.1 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.

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

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

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

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

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

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8 PLANNING

After investigating the job site and prior to the commencing of work, the following items shall be

reviewed for the any alignment & leveling works:

1. Shape, dimension, weight and material of equipment

2. Alignment sequence and procedure for each modules.

3. Schedule for alignment of equipment.

4. List of temporary equipment and tools to be prepared

5. Ground condition for construction equipment

6. Confirming the latest vendor draiwings information to riggin plan.

7. Checked crane swing radius, crane movements and work space around the lifting area.

9 CRANE SETUP

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9.1 Selection of the crane for erection shall be calculating the total weight to be lifted and radius operation

9.2 The crane positioning area shall be cleaned up & all unnecessary material shall be removed from the area before locating the crane

9.3 Only certified crane operator with valid licences shall used for the operations

9.4 The counter weight swing radius of the crane shall be adequately barricaded and checked for fouling before the actual operation

9.5 The lifting/ erection area shall be barricaded while erection members/ pre-assembeled frame/ portal. Comply as per doc. S-000-1654-0405V Site Barricades.

9.6 During assembling/erection, man lift can be used if required as a support for bolting, sling removal. Comply with document.No. S-000-1654-0425V.

9.7 Checking ground condition where crane will be placed. Ground reinforcement will be done if ground bearing pressure not reaches requirements.

9.8 CBR test will be done And ground compactness test result will be reviewed for adequacy lift. If required, crane mat will be used. (see picture for crane mat will be used for each crane)

10 EQUIPMENT PREPARATION

10.1 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.

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

10.3 Chequred plate or gratings and temporary lifting element must be stitch welded at the top the modules, as shown below.

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10.4 All documents related to the ccr reactor package should be at job site with the concerned crew following erection.

10.5 Dress up items, which cannot be erected in horizontal position will be erected in vertical position after make alignment and vertically.

11 INSTALLATION METHOD

11.1 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 foundation, it will be referred for alignment work of level

and position.

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Size and numbers of anchor bolt and nuts, position of anchor

bolts with projection numbers, position and dimension of anchor

boxes when applicable.

Existence of damage and rust of threaded parts of buried anchor

bolts and cleanliness.

Anchor bolts shall be protected properly to avoid damage during

chipping & padding work and keep it up to the equipment

installation.

Laitance shall be removed from the surface of foundations and

anchor boxes by chipping to ensure good adherence of padding

and grout materials to the said surface.

The elevation of the chipped top surface of foundations shall

allow for at least 25 mm of grout under the base plate, if not

specified by the manufacturer. Prior to the installation work, the

foundation shall be checked for the following points:

1. Distinct marking on foundations (centre marking and level

marking)

2. Level of pads on the chipped surface

3. Complete freedom from foreign matters on the chipped

surface and anchor boxes

4. The bottom of equipment bases shall be cleaned and free of

laitance, loose particles, oil or grease.

11.2 ERECTION / LIFTING OPERATION

Tool Box Meeting and Safety Talk Analysis Risk Reduction Talk

(START) would be conducting prior doing the jobs. As per

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

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Prior to commencing the erection work, all modules and

equipment should be thoroughly inspected for any damage that

may have occurred during transportation. The orientation and

center of gravity marks on the modules and equipment, such as

base level from the datum level of the foundation.

To prevent overloading of the equipment, any test water or other

temporary materials remaining of left in the equipment to be

lifted shall be drained or removed.

The bottom face of modules should be thoroughly cleaned.

All required necessary tools should be ready prepared near on

foundation

When modules are dressed up with ladders is to be installed, The

dressed attachment should be fixed securely with the main body

of the module and conform the center marks used for alignment

remain visible.

The safe working load shall be marked in all slings and

shackles.Color coding for lifting tools and tackles shall be

verified as per JGCS Standard.

Load shall be test liftesligthly (300mm) off the ground. if any

abnormality is observed, the modules or equipments shall be

immediately lowered to the ground. After the situation is

corrected, the load shall again be lifted and re-examined. Only

when all checks are satisfied the load shall be slowly and

carefully lifted to test the crane break. The load shall be raised to

sufficient elevation but not more than one meter for the test

brake. After all inspections and tests are completed and all

personnel except those involved with the lift are kept out, the

load may lifted slowly and carefully in a fully controlled manners

to its final location.

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Wind speed shall be checked at site prior to commencing lifting.

if the wind velocity exceeds 10 m/sec. all installation work shall

be stopped.

No modules or equipment should be installed during heavy rain.

During installation work, special care shall be taken so as not to

damage the anchor bolts or their threads.

The protective cover for nozzle and flange of equipment shall not

be removed.

While seating and leveling, use shim and I or pairs of wedges.

As a rule, shim and I or wedges shall be placed on liner plates

fixed on the concrete foundation or the anchor pads, and

leveling shall be done temporarily.

11.3 Module Erection (Set A, From module 1 to 4)

Mark out locations where module is to be installed and conduct

necessary site measurements to note if there is any deviations

from module drawing.

Check the anchor bolt’s dimension, quantity, elevation and the

orientation of the concrete foundation against the CCR reactor

module.

Install the soleplate padding level.

Dimensions of the module are checked and verified, (as shown)

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After lifting the module 1 into position, lock nuts of anchor bolt.

Later, tightened it to the specified torque value.

After lifting and positioned the module 2, 3, &4, welding must

be carried out to connect the modules according the module

drawing and JGCS specifications .

Erection crew should use the ladder and chequred plate to

transfer from one module to another and also mono rail and

mewp if it needed.

The same process is followed until module 4

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After the installation of the module 4, 3 nos. of south side

bracings to be removed for the installation of reactor

As shown in the figure South side of the beams and bracings to

be designed for single lift removal.

With the use of monorail and man basket three side frames

should be removed and Installation of reactor must be done.

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11.4 Equipment Installation

Mark out locations where reactor is to be installed and

conduct necessary site measurements to note if there is any

deviations from equipment drawing.

Check the anchor bolt’s dimension, quantity, elevation and the

orientation of the concrete foundation against the reactor skirt

baseplate.

Install the soleplate padding level.

After lifting the reactor into position, lock nuts of anchor bolt.

Later, tightened it to the specified torque value.

Conduct the following inspection before and after grouting: : -

a. Plumbness for the vertical shall be made by viewing from two direction 90 deg.

b. Levelness, orientation and interference Page 19 of 26




Installation of guide supports and reinstallation of south

side framing must be initiated for the module 1 to 4

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11.5 Continuation of Platform

Module 5 & 6 will be pre-assembled at grade before lifting

in module form.

The erection of module 5 & 6 is by slotting from top of the

reactor equipment.

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Care must be taken keep the modul clear from the reactor

equipment.

As like modules 5 & 6, modules 7& 8 also be pre- assembled at

grade before lifting in module form.

By using the crane, module 7 & 8 must placed in its positon.

Finally reactor reduction section must be installed using monorail

crane.

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Conduct the following inspection before and after grouting:

a. Plumbness for the vertical shall be made by viewing from two direction 90 deg.b. Levelness, orientation and interference

12. ERECTION OF PIPINGS AND MISC. PIPE SUPPORTS.

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

connected.

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Piping fabrication or erection shall not cause uncontrolled forces defined on the vendor's data sheet

to be applied to the nozzles. Piping upstream of the reactor 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 installation (Dummy weight to simulate the insulation weight can be

placed subject to the Employer, instead of complete piping insulation.)

All permanent support installation

Drain, vent and balancing lines installed

Temporary suction strainers installed

13. ALIGNMENT

1.1 Prior to erection & alignments, the following are to be inspected:

1. Any damage during transportation

2. Orientation of equipment, center of gravity and base level from datum line of foundation

1.2 The Reactors shall be aligned plumbness as follow:.

1. Reactors are aligned & leveled before bolting-up and plumbness of the reactor shall be subsequently checked.

2. Out-of-plumbness shall not exceed 1.00 mm/m of height or a total of 25 mm for the entire height, whichever is smaller or unless specified in client’s job specification.

3. Shims and wedges shall be placed on liner plates fixed on the concrete foundation at both side of the anchor bolts and leveling shall be done temporary. Extra shims and wedges shall be located between the anchor bolts to prevent base plate from bending when the distance between the anchor bolts is larger than 800 mm

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4. When leveling is finished and anchor bolts are firmly tightened all shims and wedges that are to remain in place shall be tack welded in order to prevent them from becoming loose

5. During tightening of the bolting nuts, the specified torque values shall be maintained

14. GROUTING

a. Unless otherwise specified, grouting shall be carried out in accordance with the following:

i. Foundation surface shall be cleaned thoroughly and be removed of any dirt or oily spots. Surface of foundation shall be wetted thoroughly with fresh water prior to grouting.

ii. Portland cement mortar may be used and mixing ratio with clean fine sand shall be approximately 1: 2 in volume and ratio of water to cement shall be less than 40 % in volume.

iii. Grouting on base plate shall be:

a) Space under the base plate shall be packed fully with grout

b) All shims and wedges shall be fully cover with grout

c) After pouring, excess grout shall be trimmed and surface of mortar outside of the base plate shall be finished smoothly.

15. LOOSENING SLIDE END ANCHOR BOLT

a. For any equipment, after grouting has set and hardened nuts of the sliding end of the anchor bolts shall be loosened to allow thermal expansion.

16. INSPECTION RECORDS

a. Results of the following inspection shall be recorded and are to be submitted to the clients. (1) Alignment for plumbness and Leveling(2) Other inspection records as require

17. SAFETY

The Safety Coordinator & Supervisor shall be responsible for presenting a pre-work briefing using the risk assessment / method statement before work starts.

Where work activities may conflict with or impact upon other work activities, steps will be taken to discuss the matter with relevant parties and establish a consensus. It will be ensured that both parties and their teams are fully aware of potential hazards together with appropriate precautions.

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All plant and equipment shall be inspected before work commences and at periodic intervals thereafter. All plant and equipment shall be safe before and during use. Only qualified and appointed personnel (such as riggers) shall do skilled work.

The Safety Coordinator & Supervisor shall immediately correct any hazards observed or reported to him. In the case of major hazards work shall be stopped and appropriate and satisfactory temporary / permanent action to remove the hazard shall be taken.

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Documents

Method Statement for Erection of Ccr Reactor Module