Aux Boiler_karan REV.03

7/28/2019 Aux Boiler_karan REV.03

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METHOD STATEMENT

FOR

INSTALLATION OF AUXILIARYBOILER PAGKAGE

Contract No. JI-194

SAUDI ARAMCO OIL COMPANY

KARAN UTILITY AND COGENERATION PROJECTKhursaniyah, Saudi Arabia

Signature

03 29-Dec-10

Print Name

R.M.Serrano N. Umbal R.A. DimatatacP.

Ranzenbacher

Rev. Date Prepared byMMG

Checked byMMG

Approved by MMG Approved byPSAL


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I. PURPOSE:

To ensure that equipment installation is carried out safely, and in accordance withgood working practice, as per PSAL/SAUDI ARAMCO Job Specification. Theprocedure is intended to provide recommended practices, general applicationguidance and establish controls during preparation and execution of equipmenterection.

II. SCOPE:

This Method Statement is applicable for the installation of Auxiliary Boiler Package.Any single equipments with a weight of 40MT (Metric Tonne) and above is not part

of scope. PSAL will provide lifting/Installation plan. Execution of work shall becarried out in accordance with the relevant project specifications.

III. REFERENCES:

PIP VEFV1100 : Process Industry Practices; Fabrication/ Installation DetailsVessels / S&T Heat Exchanger Standard Details.

P8926-F-004 : Typical Erection Procedure MVF boiler in Field.

1007-C-766 : Boiler Big Block Installation Procedure.

1007-Q-155 : Preservation Procedure for Boiler Big Block.

PIP REIE 686 : Recommended Practices for Machinery Installation andInstallation Design.

SACSM : SAUDI ARAMCO CONSTRUCTION SAFETY MANUAL

IV. RESPONSIBILITIES:

Mechanical Superintendent / Supervisor:

Ensure full compliance by all millwrights, mechanical foremen and labour regardingexecution of the work in accordance with PSAL/SAUDI ARAMCO projectrequirements and specifications. Confirm the availability of all materials, tools,equipment, and required personnel who will carry out the work.

Quality Control Inspector:

Conduct inspection in accordance with this procedure and approved Quality

Inspection and Test Plan. Monitors daily mechanical activities and verify complianceto PSAL/SAUDI ARAMCO Specifications. Prepares quality records and finalacceptance documentation where required.


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Safety Supervisor:

Monitor the work is carried out in accordance with PSAL/SAUDI ARAMCO projectsafety procedures.

Engineering Department:

Prepare and submit method statement together with all related documents forengineered lift, such as crane capacity chart, spreader beam calculation, etc (whichare specified in Saudi ARAMCO specification & safety requirement for PSAL/SAUDIARAMCO review and approval. Provide latest revision of AFC drawings andtechnical support to MMG site operation group.

V MANPOWER CATEGORY

- Foreman- Millwright- Mechanical Fitter- Fabricator- Helper- Scaffolder- Surveyor- Rigger

- Permit Coordinator and Other Involve Manpower

VI. WORK SEQUENCE / PROCEDURE:

A. Required Tools and Equipment:

- Appropriate Crane for Specified Lift- Wire Slings / Nylon Web Sling / Soft Tag Lines- Shackles / Beam Clamps / Blocks / Wrenches- Spreader Bar or Frame / Chain Hoist

- Wrenches / Levelling Tools / Filler Gauge- Welding Machine with Accessories- Measuring Tools / Precision Scale- Theodolite.- Equipment shall be maintained & check prior to use for safe work insurance.

Equipment shall be approved & certified by ARAMCO. For equipments:Mobile/Crawler crane, man-lifts, Certified Man-Basket etc.

B. Pre-Installation Work Activities:

1. Obtain the AFC Drawings.

2. Review construction drawings by identifying the following requirements.


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a. Prepare a specific heavy and multi-crane lift plan and procedureconsidering weight, size, and shape of the equipment to be installed, when

required. Preparation of heavy and multi-crane lift plan / procedure.

b. Arrangement of lifting, hoisting, and construction equipment during lift.

c. Issue the correct AFC Drawings to all personnel associated with the work.

d. Review the construction drawings and check availability of the following.

e. Lifting, hoisting and construction equipment / tools. Check validity ofcertification and inspections.

f. Temporary facilities and consumables to be used for the installations.

g. Visit the installation location and consider the following items.

h. Feasibility of lifting plan/procedure and provision of access.

i. Installation of safety equipment / facilities (scaffolding, safety nets andsafety ropes) at strategic locations.

j. Preparation for the provision of firefighting equipment.

k. Removal of obstructions such as structural beams and braces (wherenecessary).

l. Ensure appropriate protection for the equipment and its surrounding areas;i.e., pipe protection for the existing piping.

3. Visually check equipment / accessories are free from damage.

4. Obtain the necessary work permit before the commencement of work activities.

5. Install lifting brackets and temporary bracings / stops in accordance withspecific drawings.

6. As a minimum, the following items shall be checked prior to installation of anymechanical equipment. After which raise RFI for QC Inspection.

7. Provide touch up to any damage paint.

9.1. Concrete Foundation:

The following conditions of the concrete foundation shall be checked

against the relevant drawings.

a. Whether the centerline is marked.


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b. Accuracy of height and whether elevation line is marked.

c. Dimensions

d. curing time

e. Ensure

f. The top of the concrete foundation shall be lower than the finishedheight of the grout thickness indicated on the foundation drawings.

9.2. Anchor Bolts:

The following conditions of the anchor bolts embedded in the foundationshall be checked against the drawings or with a steel template for majorequipment

a. Tolerance shall be in accordance with project specification

b. Projection The projection of the bolts above the foundation surfaceshall be of a proper length relative to the final level of the foundationfinish.

c. Inclination There must be no inclination of the bolts which mayprevent the equipment base plate from fitting accurately.

d. Condition of the bolts and nuts Threaded parts shall be completelycoated with grease or machine oil allowing the nuts is unscrewedsmoothly.

e. Anchor bolts with pipe sleeves to allow adjustment of the final boltposition shall be checked with the following.

f. Sleeve as specified in the instruction manual.

g. Inside Sleeve Inside space of sleeve should be free from sand, dustand debris.

h. Unless otherwise specified in the Instruction manual, pipe sleevesshall be approximately 50 mm larger in diameter than the anchorbolts.

i. When pockets are used for anchor bolts, these shall be installed inthe pockets after the equipment is temporarily placed in the correctposition.


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j. Unless otherwise specified in the Instruction manual, pipe sleevesshall be approximately 50 mm larger in diameter than the anchor

bolts.

k. When pockets are used for anchor bolts, these shall be installed inthe pockets after the equipment is temporarily placed in the correctposition.

8. After the grouted mortar has sufficiently hardened, leveling work shallcommence.

9. Pockets shall be cleaned before the installation of equipment.

10. Ensure that equipment foundations should be released from civil QCdepartment prior to installation of equipment.

11. Delivery of mechanical equipment to site shall be in accordance with SiteHandling and Identification of Mechanical Materials.

12. Boiler package materials received shall be preserved in accordance withvendor Preservation Procedure and Project Material Preservation and Storageprocedure.

C. Installation Activities:

1. Installation of Boiler Big Block, PSAL

1.1 Instal lation of Boi ler Big Block s hal l be carr ied out by Heavy Lif t

Contractor assigned by PSAL.

1.2 Boi ler shal l be instal led l i f t ing by crane and posit ioned on

foundat ion p edestals P1 P10.

1.3 Before the lay-down of the boiler on the plinths, carry out the

positioning and levelling of the slide base plates on the foundation P1 &P2 drum saddles and P3 to P10 for side walls with relevant Teflon padsaccording to drawing M-021 (SP No. PB-A-97039), M-025 (SP- No. PB-B-97043). For the levelling operation, sheets of metal of variousthickness to shim base plates must be used only. Do not use channelsor beams. The shims shall be located in correspondence of the saddlesstiffening.

1.4 Lay down boiler on P1 to P10.

1.5 Remove all temporary devices.

Note: Anchor bolts for plinths P1 to P10 shall be located in positionbefore final boiler block lay down onto foundation. Final Castingof the said anchor bolts shall be done after boiler positioning andlevelling as stated on MACCHI drawing ref. 1007-M-021. In order


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to assure matching of said anchor bolts with boiler base-plates, aproper adjustment of anchor bolts shall be foreseen before final

casting.

1.6 After the boiler lay-down of boiler on the plinths, check the level and theplumbing of the boiler.

1.7 Check if the slides pads are in perfect contact with the support saddles.If not shim the base plates up to the slide pads are in contact.

1.8 Carry out grouting for the plinths P1 to P10 as per drawing M-021 (SP-No. PB-A-97039).

1.9 Removing of the boiler transport structures and the transport stiffeners.

1.10 Positioning and welding of all plates and profiles on the base plates forboiler guides and fixing point as per drawing M-532 (SP No. PB-97180)

2. Positioning Air Ducts and Air Foil.

2.1 Ensure foundation of air ducts are inspected and approve.

2.2 Verify withdrawn material from warehouse against AFC drawing.

2.3 Plan the insertion of Air foil, AD3 and AD4 at the bottom of the boiler. Seedrawing M-400 (SP No. PC-A-97062).

2.4 Position AD1, AD2, AD3 and AD4 according to drawing M-400 (SP No.PC-A-97062).

2.5 Provide temporary support between AD2 and AD3 for the Air Foil, prior topositioning.

2.6 Prior to connecting the AD1, AD2, AD3, AD4 and Air Foil, check the X and

Y alignment and elevation as per AFC drawing.

3. Erection of steel structures, stairs ladders and platforms with canopy forburners front according to drawing (M-701).

3.1 Receive the fabricated structural components and check all members ofthe structure to be erected. Damaged fabricated steel should becorrected or replaced prior to erection.

3.2 Deposit the material on wooden dunnage supports to clear steelsurfaces from ground contact.

3.3 At all times protect structural components during handling andinstallation to prevent damage or deformation.


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3.4 Ensure that all temporary bolts and welds are of sufficient strength to

withstand erection loads incidental to the construction operation.Foundation anchor bolts are to be set within specified tolerances,levelled and held firmly in position during all setting operations.

3.5 Ensure rigging is performed in accordance with the approved liftingplan/procedure.

3.6 For equipment platforms, check and secure that contact surfaces ofsupports have been painted accordingly prior to installation.

3.7 Install columns to their respective foundation as per AFC drawing.

3.8 Install supporting beams and other supports by means of welding orbolting.

3.9 Provide scaffolding if required.

3.10 Check for plumb and square of support against the columns.

3.11 Carry out QC inspection and obtain approval.

3.12 Fabricate all frames for gratings and platform near the erection area

3.13 Install frames and gratings, ladders, stairs and hand rails as perdrawing.

3.14 Touch up if any paint damaged was found.

3.15 Carry out QC inspection and obtain approval.

4. Installation of economizer block as per AFC drawing. PSAL to erecteconomizer block.

5. Piping installation

5.1 Obtain the latest revision of AFC drawings / specifications andconstruction procedures and distribute to those personnel supervisingthe work.

5.2 Review AFC Drawings, confirm installation feasibility in the field andcheck availability of pertinent materials.

5.3 When discrepancies in the field exist relating to AFC drawings or field

condition, raise technical queries and submit to the PSAL.


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5.4 Confirm procedures and AFC drawings are available to personnelassociated with the work.

5.5 Check spool installation locations and determine the need forscaffolding / work platforms and rigging / lifting equipment. Co-ordinatewith both scaffolding and rigging sections.

5.6 Install scaffolding where required.

5.7 Rigging shall be in accordance with approved rigging Instruction. Assignsuitably qualified personnel to assist with the installation work.

5.8 Verify lifting procedures and tools are approved / certified in accordancewith customer and MMG project safety regulations (recommended 1/3rd rotation).

5.9 Review AFC drawing, determine spool and material availability.Determine sequence of spool installation based on constructionschedules, availability of equipment / access and materials.

5.10 Ensure correct materials, tools and personnel are available to performinstallation work.

5.11 Handling and transportation of pipes and components from the projectwarehouse and fabrication area to the work area.

5.12 To prevent damage to pipe spools which have been coated. Handlingshall only be carried out with non-metallic slings following full curing ofthe coating system. Chains or wire ropes shall not be used. Themanufacturers recommendations shall be followed for curing ofcoatings at all times.

5.13 Coated spools shall be stored on soft standings (wood dunnage, sandbags etc.).

5.14 Loading and handling of coated pipe spools shall be carried out in sucha way that coating damage is kept to an absolute minimum. Soft linesshall be attached to spools, where necessary, to prevent swing andpossible damage during loading / unloading.

5.15 During transportation, spools shall be adequately secured with soft linesto prevent movement and damage. Where practicable, end caps / bevelprotectors shall be installed to prevent the ingress of foreign objects anddamage to weld preps.

5.16 To prevent the entry of debris and damage to flange faces, flangecovers shall be left in position on valves and spools until the time ofinstallation.


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5.17 Obtain work permit (when required).

5.18 Prior to installation the following items shall be observed.

a) Check the location and orientation of spools to plan north on AFCisometrics / plans

b) Identify permanent supports (trunnions, guides, anchors, dummysupports and pipe shoes).

5.19 Install permanent pipe supports in accordance with the AFC isometric,support drawings or when practical, provide temporary supports ofsufficient capability to withstand applied loads.

5.20 Establish good reference point and commence installation in aprogressive manner.

5.21 Fit up and other installation activities shall be accordance to approvedmethod statement of Piping Above Ground and Erection ProcedureMVF Boiler in Site by MACCHI.

6. For NDE Requirements refer to: Approved QCIP

7. For Hydrotest Requirements refer to approved method statement for Hydrotest.

8. Erection of air windbox with relevant support structure and spring hangersaccording to drawing 1007-M-410 (SP No. PC-A-97064), 1007-M-414 (Macchiinternal doc.)

9. Positioning of burners according to drawing 1007-M-200 (SP-No. PY-B-97150),1007-M-201 (SP No. PY-B-97047), 1007-M-202 (SP No PY-B-9748)

10. Execution of refractory casting for burner throat by means of proper template

according to drawing 1007-M-504 (Macchi InternDWal Doc.)

10.1 Positioning of refractory tiles in the furnace floor and the bricks in theinspection doors according to 1007-M-540 (SP-No. PC-A-97068).

11. Erection of the gas ducts from boiler to economizer according to drawing 1007-M-400 and 1007-M420.

12. Erection of Gas ducts from economizer to stack according to drawing 1007-M-400 and 1007-M420.

13. Erection of Stack

13.1. Review AFC drawing.


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13.2. Stack delivered in four parts ST1, ST2, ST3 and ST4.

13.3. Use suitable crane for pre-assembly.

13.4. Lay all stack sections ST1, ST2, ST3 and ST4 on the ground. Align andweld as per WPS and AFC drawings. Assemble all steel structure suchas platforms, ladders, grating and hand rails, personal protectionstackers etc., along with cable trays with cabling complete with paintingon the ground.

13.5. Install in one piece as tandem lift by PSAL.

14. Positioning of F.D. fan drivers (electric motors or steam turbine) and silenceraccording to drawing 1007-M-211 (SP steam No. PC-A-97050), 1007-M-715(SP No. PC-A-97195)).

15. Erection of sand filter for FD fan suction on relevant support structureaccording to drawing 1007-M-412 (SP No. PC-A-97063), 1007-M-700 (SP No.PC-A-97070).

16. Installation of insulation materials, fabrication and installation of lagging on the

economizer casing on the ducts according to the drawing 1007-M-605 (Macchiinternal documents).Moreover has to be carried out the completion of insulation on the lower partsof steam boiler after the removal of the shipping frame according to drawing1007-M-600 (SP No. PC-A-97069), 1007-M-601 (macchi Internal doc.)

17. Erection of pressure safety valves according to drawing 1007-M-276 (SP No.PC-A-97069).Note: Check if the plugs for hydrostatic test are installed in the safety valves ifyes, they must be removing before commissioning activities.

18. Positioning of sampling system according to the drawing n 1007-S-307 (SPNo. PC-D-97108),1007-M-021 (SP No. PB-A-97039).

19. Positioning of steam vent silencers on relevant support structures according tothe drawing 1007-M-271 (SP No. PC-A-97051), 1007-M-272 (SP No. PC-A-97052), 1007-M-700 (SP No. PC-A-97070).

20. Positioning, assembling and welding of non-boiler external piping, the relatedvalves and supports up to battery limit. The piping with DN =< 2 will besupplied loose in commercial length and shall be pre-fabricated on siteaccording to the routings shown on assembly dwg.1007-M-300 (SP No. PB-A-

97054) and materials list 1007-M-326 (SP No. PA-E-97059).


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Note: that these routings are indicative and have to be verified on site beforethe erection to avoid interference. The piping erection shall be according to the

following documents:P&ID 1007-S-002 (SP No. PD-A-97007), 1007-S-003 (SP No. PD-A-97008),1007-S-006 (SP No. 23. PD-A-97009), 1007-S-007 (SP No. PD-A-97010),1007-S-011 (SP No. PD-A-97073), 1007-S-019 (SP No. PD-A-97136) [1007-S-018 (SP No. PD-A-97140) and 1007-S-019 (SP No. PD-A-97139) for boiler C].Lines list 1007-M-001 (SP No. PD-A-97139)Valves list 1007-M-002 (SP No. PA-E-97038)Piping assembly and details dwg. n 1007-M-300 (SP N o. PB-A-97054), 1007-M-316 (SP No. PAE-97055), 1007-M-321 (SP No. PA-E-97057), 1007-M-326(SP No. PA-E-97059). Piping supports 1007-M-330 (SP No. PC-A-97060),1007-M-350 (SP No. PC-A-97061)During the activities special care has to be taken to prevent that any foreignmatters, shaping, dirty enter into the pipes/boiler. All pipe connections must beclosed with temporary protections up to assembling and welding the joints.

21. Spreader bar will be used with nylon sling that shall carry Boiler Stacks asshown in the procedure plan drawing.

22. Carry out of N.D.E. on non-boiler external piping according to applicable codesand QCIP.

23. Installation of insulation material and lagging on piping and relevant auxiliariesup to battery.

24. Limits according to the dwg. 1007-M-610 (Macchi internal doc.), 1007-M-615(Macchi internal doc.).

25. Installation of textile expansion joints between the air duct and the windbox,between the boiler. outlet connection and flue gas duct, between the F.D.FANSand the air duct according to dwg. 1007-M-410 (SP No. PC-A-97064), 1007-M-420 (SP No. PB-B-97165) and the installation manuals provide by theexpansion joint supplier (see Attachments 3 and 4).

.

VII. INSPECTION & / QUALITY RECORDS:

1. Inspection shall be conducted and recorded in accordance with the JobSpecific Inspection and Test Plan, QC detail activities along with references forchecklist according to SATIP-F-001-04 - BOILER - Packaged Type and Vendorapproved ITP.

VIII. SAFETY PRECAUTIONS:

The work shall be executed in accordance with the approved job safety analysis(JSA). Permit shall be obtained prior to any commencement of the work whenrequired


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IX. ATTACHMENT:1. 1007-M-420 - Air Duct Assembly and Details.2. 1007-M-431 - Stack Details.3. 1007-M-400 - Air and Flue Gas Duct General Arrangement.4. 1007-M-410 - Air Duct Assembly Details.5. 1007-M-700 - Platform Stairs and Ladders General Arrangement Drawing.6. 1007-M-701 - Steel Structure Platform and Stairs /Ladders Assembly Mark STR17. 1007-M-702 - Steel Structure Platform and Stairs /Ladders Assembly Mark STR28. 1007-M-703 - Steel Structure Platform and Stairs /Ladders Assembly Mark STR39. 1007-M-704 - Steel Structure Platform and Stairs /Ladders Assembly Mark STR410. 1007-M-705 - Steel Structure Platform and Stairs /Ladders Assembly Mark STR5

11. 1007-M-706 - Steel Structure Platform and Stairs /Ladders Assembly Mark STR612. 1007-M-707 - Steel Structure Platform and Stairs /Ladders Assembly Mark STR713. 1007-M-750 - Hand Rail & Toe-Plate Plan elevation +104150 (TOS)14. 1007-M-751 - Hand Rail & Toe-Plate Plan elevation +106620 (TOS)15. 1007-M-752 - Hand Rail & Toe-Plate Plan elevation +11327 to 116670 (TOS)16. 1007-M-753 - Hand Rail & Toe-Plate Plan elevation +11327 to 116670 (TOS17. 1007-M-754 - Hand Rail & Toe-Plate Section Stair and Details18. 1007-M-755 - Hand Rail & Toe-Plate for Stack19. 1007-M-760 - Grating & Step Assembly Plan elevation + 104180 (TOG)20. 1007-M-761 - Grating & Step Assembly Plan elevation + 106650 (TOG)21. 1007-M-762 - Grating & Step Assembly Plan elevation form +108780 to +110880

(TOG)22. 1007-M-763 - Grating, Step Assembly Plan and Details elevation form +113000

to +116700 (TOG)23. 1007-M-764 - Platform Stack Grating Assembly.24. JI194-OK030004-MR-C03-001-A - Piping Support Construction details.25. 1007-W-100 - Macchi Welding Book with Welding Map PQR Procedure.26. 1007-S-002 - V86-U-0501 (Train 1) Water Steam P & I Diagram.27. 1007-S-003 - V86-U-0501 (Train 1) Air-fuel Gas and P & I Diagram.28. 1007-S-006 - V86-U-0501 (Train 1) Fuel Supply System P & I Diagram.29. 1007-M-001 - Line List.30. 1007-M-002 - Valve list.31. 1007-M-020 - Boiler Foundation Assembly.32. 1007-M-300- Sh.1 - Boiler Piping Assembly Plan El. 0.00.33. 1007-M-300- Sh.2 - Boiler Piping Assembly Plan El. 4150.

34. 1007-M-300- Sh.3 - Boiler Piping Assembly at elevation 6620.35. 1007-M-300-Sh.4 - Boiler Piping assembly Plan El. 10040.36. 1007-M-300-Sh.5 - Boiler Piping Assembly Plan El. 13270.37. 1007-M301-Sh.1 - Boiler Piping Assembly Right Side View.38. 1007-M-301 Sh.2 - Boiler Piping Assembly Left Side View.39. 1007-M-302 - Boiler Piping Assembly Front View.40. 1007-M-303 - Boiler Piping Assembly Rear View.41. 1007-M-316 - Steam Drum Instrument assembly.42. 1007-M-320 - Isometric Drawing Code Under Code Jurisdiction.43. 1007-M-321 - Isometric Drawing External Piping.44. 1007-M-330 Sh.1 - Boiler piping Assembly plan El. 0.00 support position.45. 1007-M_330 Sh.2 - Boiler Piping Assembly Plan elevation 4150 Support Position.46. 1007-M-330 Sh.3 - Boiler Piping Assembly Plan El. 6620 Support Position.

47. 1007-M-330 sh.4 - Boiler Piping Assembly Plan 10040 supports position.48. 1007-M-330 Sh.5 - Boiler Piping Assembly Plan 13270 Supports Position.49. 1007-M-331-Sh.1 - Boiler Piping assembly Right Side View Support Position.50. 1007-M-331-Sh.2 - Boiler Piping Assembly Left Side View Supports Position.


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51. 1007-M-332 - Boiler piping Assembly Front View Supports Position.52. 1007-M-333 - Boiler Piping assembly Rear View support position.

53. 1007-M-350 - Piping Supports Constructive Details.54. 1007-M-325 -Piping Under Code Jurisdiction Material List

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Aux Boiler_karan REV.03