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Project name

Document name
Document number
Rev. no / Page

PNG LNG Plant Project


ERECTION OF PIPE AROUND EQUIPMENT
PGLN-YF-KPMTH-90K010-021
0 / 1 of 20

SC NO.
REQ NO.
IDENT NO.
ITEM NO.

PNG
PNG LNG Plant Project
CHIYODA-JGC JOINT VENTURE
:
: DW-PIPE-011
: PGLN-YF-KPMTH-90K010-021
Rev.no :
:

A-Reviewed with
No comments

Section :

B-Reviewed with
Comments as noted

Signature :

C-Do not proceed with


Construction work
D-Received as information
CJJV Internal Use
Category
A
DFO Requirement

Date :
B

CJJV(CONTRACTOR)PERMISSION TO PROCEED OR REVIEW


TAKEN ON SUBCONTRACTOR DOCUMENTS SHALL NOT NOT RELIEVE
UNDER SUBCONTACT AGREEMENT.

Doc. name

Doc. no

ERECTION OF PIPE AROUND EQUIPMENT

Rev. no

Date of rev. Description

PGLN-YF-KPMTH-90K010-021

Prepared
by

Checked
by

2
1
0

03 Jan.2011

Issued for
review

C O N T E N T S

1.0

PURPOSE

2.0

SCOPE OF WORK

3.0

CONSTRUCTION REFERENCE AND DOCUMENTS

4.0

RESOURCES
ORGANIZATION CHART FOR PIPING ERECTION
RESPONSIBILITIES
MANPOWER
TOOLS AND EQUIPMENT

4.1
4.2
4.3
4.4
5.0

GENERAL ACTIVITIES

6.0

ACTIVITIES DESCRIPTIONS AND DETAILED METHOD


PIPING INSTALLATION AROUND EQUIPMENT WORK-FLOW
AROUND HEAT EXCHANGER PIPING
AROUND AFC PIPING
OTHER EQUIPMENT PIPING

6.1
6.2
6.3
6.4
7.0

ERECTION AND INSTALLATION INSTRUCTION

8.0

TEMPORARY FACILITIES

2 of 20

Rev.

Approved
by

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PGLN-YF-KPMTH-90K010-021

9. 0

QUALITY CONTROL REFERENCES

10.0

TASK ANALISYS AND HSE REFERENCES

11.0

ATTACHMENTS

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Rev.

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1.0

PURPOSE
The purpose of this Work Method Statement is to control installation activities of piping
erection around equipment, especially around E-1411,E-1412,E-1415A/B and AFC
undertaken by SUBCONTRACTOR, and to ensure that the required quality is achieved
to Project Specification Codes and Standards, Russian codes and standard.

2.0

SCOPE OF WORK
This Work Method Statement describes the erection methods for pipes that shall
be erected around equipment except on pumps and compressors of Sakhalin
LNG Project.

3.0

CONSTRUCTION REFERENCES AND DOCUMENTS


DOC. NO.
DEP 30.10.60.18
DEP 31.38.01.31
DEP 31.38.01.11
ANSI B31.3
7000-E-90-10-S-0001-01
7000-E-90-10-S-0006-01
7000-E-90-10-S-0008-01
7000-E-90-38-S-0001-01
7000-E-90-38-S-0002-01
7000-E-90-38-S-0004-01
7000-E-90-38-S-0006-01
7000-E-90-38-S-0010-01
7000-E-90-38-S-0012-01
7000-E-90-38-S-0013-01
7000-E-00-10-S-0227
7000-E-00-10-S-0429
7000-E-90-38-P-1006-01
7000-E-90-38-P-1011-01
7000-E-90-38-P-1012-01

DOC. TITLE
Welding of Metals
Shop and Fabrication of Piping
Piping General Requirement
Process Piping
Technical Specification for General Welding
Requirement
Technical Specification for Prevention of Stainless
Steel Zinc Embrittlement
Technical Specification for Welding-Quality Control
Requirements During Site Construction
Piping Class Summary
Piping Material Specification
Technical Specification for Valve Locking And
Interlocking Devices
Technical Specification for Sequencing Ball Valves
Expansion Joint for Cryogenic Service
Technical Specification for Shop and Field
Fabrication of Piping,
Specification for Piping General Requirements
Material Identification and Traceability
Scaffolding Procedure
Inspection and Test Plan Piping field Erection
Inspection and Test Plan Piping(Adjacent to Rotating
Equipment) Alignment Check
Inspection and Test Plan Installation of Strainer
Element
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RESOURCES

4.1

Organization Chart for Piping Erection.


Please refer to Attachment #1 in General Work Method Statement.
(Doc.No. 7002-E-00-38-P-3101-01-01)

4.2

Responsibilities
Construction Manager is responsible for:
1) Implementation of this work procedure
P/Erection Superintendent is responsible for:
1) Implementation of work activity including preparation of work, delivery of
material, welding, storage, etc.
2)Control of welder and daily welding report and submission to Contractor.
3)Implementation the latest revised drawing and design change.
4) Review of NDE requirements, requisition of NDE and maintenance of NDE
report.
5)The implementation of PWHT, and maintenance of report concerned.
6)Preparation of Material Requisition for field materials
7) Control of storage, handling, preservation of materials received from the
Material Control Team for the process of installation.
8)Clearance of Pre-Test/ Post-Test Punch Items
QA/QC Team Manager is responsible for:
1) Inspection of installation in accordance with relevant ITP.
2) Preparation of inspection record.
3) Handing over QA records to the CONTRACTOR Quality Assurance Manager.
4) Reporting Non-Conformance item(s).

4.3

Manpower
The installation work shall be controlled and coordinated by supervisor.
The basic manpower shall include but not limited to
4.3.1 Pipe Foreman
4.3.2 Pipe Fitter
4.3.3 Pipe Welder
4.3.4 Rigger
4.3.5 Scaffolder
4.3.6 Helper
4.3.7. Equipment Operator
1) Crane Operator
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2) Manlift operator

4.4

Tools and equipment


4.4.1 Mobile Crane 200 ton
4.4.2 Hydro Crane 30 ton
4.4.3 Low Bed Trailer
4.4.4 Lifting accessories
4.4.5 Chain Blocks
4.4.6 Air Compressors
4.4.7 Welding Machines
4.4.8 Hand Tools and Fixtures as required
4.4.9 Fixing Jig, Supports

5.0

GENERAL ACTIVITIES
Please refer to Attachment #1 in General Work Method Statement
(Doc. No. 7002-E-00-38-P-3101-01-01)

6.0

ACTIVITY DESCRIPTION AND DETAILED METHOD

6.1

Piping Installation Around Equipment Work-flow


Please refer to attachment # 10.1

6.2

Around Heat Exchanger (E-1411.1412.1415A and B) Piping

6.2.1
Preparation
6.2.1.1 After release or hand over of the equipment to piping erection group,
depressurization of the purging gas (Nitrogen) thru a valve shall be conducted
under Contractors supervision and control. The pressure cap on the nozzle shall
be removed only immediately before connecting the nozzle to the piping system.
6.2.1.2 To explain how to control do not exceed the nozzle load include back charge for
welding refer to Erection and Installation instruction.
6.2.1.3 Arrange the order for pipe installed around heat exchanger, the crane location and
capacity as well as arrangement of workers shall be checked. (Refer erection and
installation construction to the Doc. No. 7001-E-14-21-P-0317)
6.2.2
Scaffolding
6.2.2.1 Scaffolding work shall be done in a position that are essential for rigging and
welding work and fully concerned with safety and shall be approved for use and
inspection by safety manager.
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6.2.3
Fabrication of pipe spools
6.2.3.1 Pipe spool shall be fabricated in accordance with order of pipe installation and
construction schedule of heat exchanger and all related inspection shall be
completed

6.2.4
Permanent and Temporary Support Installation
6.2.4.1 All pipe support shall be fabricated and installed and be completed inspection from
the top before pipe spool installation
6.2.4.2 When installation of temporary support inevitably, installation in concerning with
safety and damage shall be recovered after removal
6.2.5

Rigging

6.2.5.1

Pipe spool shall be arranged around heat exchanger and pipe spool storage on
the wood, and touch-up painting shall be done if there is a damage in pipe surface

6.2.5.2
6.2.5.3

Rigging should be done by using sling belt according to weight for pipe spool
Crane for rigging shall be set in safe place and appropriated capacity of crane
shall be used by calculating height of heat exchanger and weight of pipe spool

6.2.5.4 Arrange a skilled rigger and set rigger in place for pipe spool installation and near
crane
6.3

Around AFC Piping

6.3.1

Pipe header fabrication


Pipe header must be reinforced enough to protect the deformation and damage of
header from much weldolet for branch, before hole cutting and fit-up, and also be
welded in accordance with welding sequence in case of welding.
Please refer to Attachment #10.2

6.3.2

6.4
6.4.1

Fabricated pipe spool should be installed as attached sequence.(attachment #10.1)

OTHER EQUIPMENT PIPING


Before installation of piping to perform depressurizing. Dust protection such as thin
plate is required with gasket between equipment nozzle and piping

6.4.2

Flange Face Inspection

6.4.2.1 Surface of flange gasket face shall be free from rust, weld spatter, scars, paint,
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dent, arc strikes, corrosion pitting and other imperfection.


6.4.2.2 The criteria of acceptable surface damages shall be as per ASME B16.5 para. 6.45
Flange Facing Finish imperfection, and apply also for pipe sizes above DN
600(24).
6.4.3

Flange Parallelism Check

6.4.3.1.1

All pipe-flange fabrication shall be inspected and dimensionally checked

prior to welding to determine their alignment and perpendicularity with respect to


pipe/spools centerline.

6.4.3.1.2

Measurement of flange alignment shall follow the procedure stated

below:
1) The line that shall be developed by connecting the two uppermost points of two
opposite bolt holes equidistant from flanges vertical centerline shall neither develop
an angle of depression nor an angle of inclination
2) The four projected lines tangent to the four quadrant points of flange face, and
parallel with pipe or spools horizontal line shall be of equal distances when
measured perpendicularly using an L-square from pipe/spools outer surface
3) When pipe/spools centerline is at zero degree from the horizontal, the x and y-axis
of the flanges face shall also be at 0 and 90 degree, respectively. Otherwise, the
flange is not aligned and squared.
6.4.3.1.3

Alignment and perpendicularity of two connecting flanges during

installation of flanged pipes to pressure vessels, heat exchanger, valves, control


valves, inline instruments, relief valves, and other similar flanged equipment shall
be verified by inspection to ensure that no external stresses shall be left acting
against the equipment after welding due to misalignment. Forced fit-up shall not be
allowed, and any misalignment that may be discovered during fit-up shall be
rectified accordingly.
6.4.4

Gasket Setting

6.4.4.1.1
Prior to fabrication of gasket, an inspection shall be conducted to check
its size, dimension, and ratings that it conforms to its required specifications.
6.4.4.1.2
Gasket shall be handled very carefully, and inspected from any signs
and/or occurrences of corrosion and damage. Gasket they could prejudice quality,
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safety and integrity of the piping installation shall be rejected and promptly
replaced.
6.4.4.1.3
Order of Flange Bolt Tightness, Refer to procedure for bolt up attachment
#10.3
7.0

7.1

ERECTION AND INSTALLATION INSTRUCTION


HP- Precooler E-1411
LP- Precooler E-1412
Main Cryogenic Heat Exchanger-1415 A/B
And all static equipment
Installation

7.1.1 General Instruction


Pressure vessels are normally purged with Nitrogen (N2) gas, an inert gaseous
element used to prevent corrosion from within the vessel. This gas is entered into the
vessel to get rid of oxygen from coming into direct and prolonged contact with the

inside surface of the vessel. Once the purging process is completed the nozzles of the
vessel shall then be sealed tightly with pressure caps to prevent the gas from
escaping into the atmosphere. These pressure caps shall only be removed at a time
prior to connecting the vessels nozzle to the piping system. Exposure of the vessel
inside walls/chambers to open atmosphere shall be kept as short as possible.
Duration to nozzles being open shall be kept as short as possible , i.e. cut the cap,
inspect and weld the piping consecutively whenever possible. The pressure caps,
protection or cover, on nozzles shall be remove only immediately before the
connection of nozzle to the piping system. Removing of blankets is only allowed
after depressurizing the connecting chamber from nitrogen-over-pressure by
installed gauge / valve.
Refer to Nitrogen let down procedure(7001-E-14-21-P-0311) for safety aspects
To avoid ingress of swart it is recommended that the pressure caps shall be cut at
horizontal Nozzle position.
During all work around the vicinity of an open nozzle, care must be taken that no
particles like slag, scale, rust, welding residues, oil, grease, salt, or moisture etc. can
get into the nozzle and thus inside the CWHEs. In case that particles get into the
nozzle, it is necessary to remove them (e.g. with vacuum cleaner). The CWHEs are
accessible via manholes and visible via handholes according to Dimensional Outline
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Drawings.
If the CHWEs are installed in the plant, but not yet completely piped, all open
nozzles have to be covered by ply wood. And Foil is not sufficiently secure to ensure
avoidance of ingress. Securely fitted blind or other secure means should be used.
This is important for nozzle open to the top. In any situation the CWHEs have to be
protected from ingress of moisture (rain!) to avoid freezing during operation!
All piping has to be carefully cleaned by purging and dried before connecting to
CWHEs. Due to the small pipe diameters the CWHEs may easily be blocked through
ingress of slag. This can result in in safety problems due to blocking of the free
passage to the safety valve and in operation problem because the heat transfer
surface would be partly inactive.
To avoid ingress of the soil particles during start-up and operation it is recommended
To install strainer in the let pipes to the CWHE
7.2

Removing of Pressure Caps from Transition Joint Stubs

7.2.1 Check and record that no pressure in inside the nozzles / chamber.

7.2.2 Removal of pressure caps shall be done only by using a cutting disc. At no instance
shall the surface temperature of the cap, measured at its heat-affected zone,
exceed 350 degree for 30 minutes (for Asahi Transition Joints) to minimize heat
transfer by conduction, or the development of an excessive thermal gradient on the
base metal of vessels connecting nozzle.
7.2.3

For the limitation of temperature at the transition joint there are the following
possibilities.
-. Continuous cooling during welding with cooling water and application of a spray
protection sleeve (Ref: Welding Procedure Specification No.:TW 108 Rev.5 in
Appendix 3)
-. Early interruption of welding before the temperature comes up to the maximal
tolerated values. Inter-cooling with pressure air (oil free!) down to a temperature
of approx. 40

7.2.4 Only medium size grinders using medium size cutting disc shall be used during the
cutting or removal of pressure caps.
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7.2.4.1 Cutting is only allow on the blanket.

cutting line

After cutting remove


by grinder

DETAIL A
7.2.4.2 Cutting and grinding has to be done very carefully in order not to damage transition
joint stub. The following shall the steps that shall be followed to avoid slag and fine
cuttings from entering into the bore of pipes.
1. Cutting shall be performed in such a manner that the penetration of cutting discs
shall be gradual, uniform, and evenly distributed throughout the outside
circumference of the cap and inwardly towards the center of its axis. Cutting discs
penetration shall proceed until 80% of caps total thickness shall be removed.
2. At 0.20 t remaining, cutting shall be done more gradually, uniformly and
tangentially until the cutting disc shall be able to penetrate the entirety of the caps
thickness.
3. After removal f the cap, the inside surface of the nozzle shall be cleaned of the
fine cuttings by using a clean and dry cloth. Cleaning shall be done thoroughly and
completely.
4. The nozzle, removed of its cap, shall be sealed tightly with plastic or wooden
covers to prevent incursion of dusts and other foreign particles that could be a
cause to corrosion.
7.2.5 Check that the transition joint are not damaged after cutting the pressure caps.
7.2.6 Paint on the surface must be removed before welding.

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7.2.7 Edge preparation at the pipe for welding according WPS(by other)
Inspect and report cleanliness of pipe internal.
7.2.8 Welding of the pipe of the transition joint stubs.(Doc.No.7001-E-1421-P-0317
Appendix 3)
After completion of welding NDE(PT,RT,UT) as require by local rules and
By Contractor has to be performed.
7.2.9

Alignment and perpendicularity between the vessels nozzle and the connecting
piping component shall be thoroughly checked and measured. Forced fit-up shall
not be allowed at all times. Any misalignment that shall be discovered during fit-up
of the connection shall be rectified immediately and appropriately in order to make
the vessel free from excessive external stresses after welding.

7.3 Pressure Test


After piping the pressure test has to be done:
Warning : Connecting piping must be designed for the pressure to be pressurized for
CWHEs circuits. The test pressure of the connecting piping and the
CWHEs in the circuit to be pressurized must not exceed the allowable
value.
Please note : Pneumatic pressure tests are dangerous!
7.3.1

7.3.2

Pressure-testing of the CWHEs on site had to be carried out at 1.25 maximum


allowable working pressure of the respective pressure circuit. The maximum
allowable working pressure should be indicated on the nameplate.
The metal temperature and the pressure test medium temperature shall not be
higher than 50C of design metal temperature. According to ASME UG-100
Pneumatic Test, the metal temperature during pneumatic test shall be
maintained at least 17C above minimum design metal temperature.

7.3.3 Any deviation require the prior written approval of Linde.


7.3.4

Only a pneumatic test with dry and oil-free air shall be carried out due to difficulties
to remove hydraulic test liquid after installation. Residual test liquid might freeze
during operation and cause severs damage.

7.3.5 The pressure test shall therefore be carried out under supervision of a responsible
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person by observing the local applicable protective labor and safety regulation. And
contractor procedure for pneumatic pressure testing(7000-E-00-10-S-0431-01)
7.3.6 In there are any indications for a leak in the CWHEs, Vendor has to be informed
immediately.
7.3.7 Testing Pressure shall be recorded as per contractor procedure(7000-E-00-10-S0431-01) recording /chart record No. withness persons / calibration sheet
8.0

TEMPORARY FACILITIES
Refer to General Work Method Statement

9.0

QUALITY CONTROL REFERENCES


Refer to ITP 7000-E-90-07-P-1006-01Piping Field Erection, ITP 7000-E-90-07P-1011-01Piping(Adjacent to Rotating Equipment) Alignment Check, ITP 7000E-90-07-P-1012-01Installation of Strainer Element, ITP-7000-E-90-07-P-101301Installation of Valve Interlocking Devices

10.0

TASK ANALISYS AND HSE REFERENCES


1.
Before commencement of work
- Worker shall pass physical examination.
- Every body shall be inducted at Contractors training center.
- Subcontractor worker also shall be inducted by HSE team.
- Only qualified, certified and trained workers shall be assigned in the work.
- Worker shall wear PPE required in accordance with his work activity.
- Safety supervisor shall monitor the compliance of entire work crew.
- Equipment shall be certified and inspected before using.
- Appropriate tool shall be used and color coding shall be done and recorded.
- Tool box meeting shall be held by supervisor/foreman every morning before
work.
- Adequate access shall be provided and maintained
- Suitable lay down area shall be provided for storage of materials and safe
rigging operations.
- Wood for pipe and fitting shall be laid at lay down area before receiving
material.

- The area of lay down shall be prepared separately as LTCS pipe, SUS pipe,
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LTCS fitting, SUS fitting.


- Material receiving and handling shall be under the supervision of a competent
person who is present at the worksite.
- Trained workers of bolt tensioning/torquing shall be working only on bolt
tightening.
2.
-

Loading and Unloading of Piping Material and Pipe Spool


A qualified and trained rigger shall be assigned.
Banksman shall be nominated when crane or trolley is working.
Rigging equipment and rigging gear shall be inspected prior to work
Rigging gear shall be certified and inspected before using and shall be color
coded and recorded.
Tag line shall be used to control the suspended material.
Wire sling and hook shall be used for LTCS pipe and web sling shall be used
for fitting for loading and unloading
Barricade and warning signs shall be installed around working area especially
pipe stacking area before the commence of work.
Routes for suspended loads shall be preplanned to avoid endangering
workers.
The crane shall be located on fully compacted area and all of the outriggers
shall be fully extended equally on both sides using suitable grillage as
required.

3.

Handling of Material
- Good access of equipment to work site shall be secured.
- Speed Limit shall be kept during driving.
- Pipe should be stacked on wood on firm and horizontal ground/place and
shall be anchored by using tri-angled wood.

4.

Manual Handling
Manual handing shall be minimized during loading and unloading, if possible.
In case of manual handling, worker shall keep good postures(keeping arm
close to the body, correct grip/hold, chin in, head up, use of check the heavy
load body weight), check rough surface and be careful to crushing.
Workers shall wear PPE, especially long-sleeved coverall and hand gloves.
Worker shall be trained before work.

5.

Rigging
1) Suspended load and Falling material
- Rigging work shall be done by skilled and trained riggers, erectors,
banks-man and crane operator under the control of supervisor.

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Equipment shall be maintained and calibrated so as to ensure its


effective operation and safety function of crane shall be checked daily.

Barricade and warning sign shall be installed around working area


before
commence of work.
Routes for suspended loads shall be preplanned to avoid endangering
workers and lifting location shall be decided by considering the gravity
center.
The crane shall be located on fully compacted area and all of the
outriggers shall be fully extended equally on both sides using suitable
grillage as required.
Hooks shall have self-closing safety latches or equivalent.
Tackles/lifting equipment inspected periodically by competent person
shall be used and also checked before daily activities.

2) Crashing against workers or properties


- Maintain adequate space when objects moving by cranes or trolley.
- In case of crane, the rigger with tag line shall be located minimum 5 m
apart from the edge of suspended material. Other man shall be located
apart from as far as possible.
- Use tag line to control the suspended material.
- Banksman shall be dedicated when crane or trolley is working.
6.

Scaffolding Works
1) Damage on scaffolding structure due to improper installation
-

Well trained, qualified scaffolders only shall do this work.


Certified scaffold materials shall be used.
Scaffold shall be inspected before use by competent scaffold supervisor
and shall also be checked every week by an inspector.

2) Injury due to falling material during installation


- Warning sign and barricade shall be placed at all times during the
erection of scaffolding.
- Scaffold material shall be stocked on firm area/grating far from handrail
and opening.
- Slot and hole shall be closed to maximum of scaffold floor and toe
board shall be installed all the time for prevent material from falling
down.

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3) Falling down of worker


- Scaffolder shall wear full body harness and connect it to fixed scaffoder
or steel structure and then he shall commence work.
- Scaffolder shall use fall arrester in case of suspended scaffold.

4) Scaffolding tag and inspection


- Workers shall use scaffolds bearing green color tags.
Nobody shall be allowed to modify or dismantle any part of the scaffold.
Modification and dismantling shall be undertaken only by trained and
authorized persons under the supervision of a competent supervisor.
- Scaffold shall be inspected weekly, and after downpour of rain or bad
weather.
5) Access through the vertical ladders ( 6 m over length)
- The vertical static line and steps shall be checked daily.
- Prior to using for access, the ladders shall be checked daily by
competent
person.
- The user shall wear safety harness and use sliding chuck during coming
up and down.
7.

Installation around equipment


- Before work, barricade and warning tape shall be installed around equipment
and access to this area should be controlled by watch man or supervisor.
- Crane shall be well positioned on compacted ground and banksman shall
watch out not to contact spool and crane boom to equipment and steel
structure.
- Pipe spool shall be controlled by two tag lines and shall be installed vertically
from upper pipe to lower pipe by one or two web slings.

- All workers who install pipe spool at work at height shall wear full body
harness and fix it to hand rail or structure during the work, if the platform or
scaffold is not inspected and permitted by competent person. In case of
permission, full body harness is not mandatory to every body. But, every body
should wear full body harness in case he works outside platform and scaffold.
- Worker shall pay attention to prevent of falling material such as tool, working
material from platform and scaffold. To prevent falling down of material, worker
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shall have a good house keeping on, platform and scaffold, minimize the
volume and store material inside apart from platform and scaffold in case of
storing material on platform and scaffold.
Do not throw down any material to ground from platform and scaffold.
Lay down material from platform and scaffold by trolley.
Gas inside the equipment shall be removed and then tested by gas tester
before commencing work.
Equipment piping shall be installed from top to down direction.
Welding work, flange bolting and other work shall be done on equipment
platform or scaffold. In case the using of platform or scaffold for equipment
erected by other contractor, the work shall be done by using man lift or
additional scaffold.
Band pipe spool tightly by using web sling before erection of pipe spool to
prevent pipe spool from slipping down to ground
Web sling is a good measures for non-slip of material from banding condition
and protection of pipes surface.
Rig spool after rigger confirm the tightness of banding beam by using web
sling.
The sling shall be inspected by CTSD and color coded before using and user
shall check the condition of sling before using every times
Signalman(banksman) with signal jacket shall be nominated to control the
crane operation and rigging work.
Before work commence, install barricade and warning tape around working
area.
Equipment shall be protected from falling material by covering equipment with
plywood and etc.
Grinding and Welding
1) Fire by spatters
- Flammable materials around cutting area shall be not kept.
- Fire blanket shall be used for flammable materials.
- Fire extinguisher shall be prepared beside working area.
- Watch man shall be nominated and check the working condition
carefully.
2) Injuries by grinding machine
- Only qualified, trained and skilled worker only shall carry on that job.
- Worker shall wear adequate PPE, especially full face shield, retardant
clothes and leather glove.
- The change of grinding disc shall be done by competent person.
- Grinding machine shall be quarterly inspected, color coded. And it shall
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be inspected by user before work commence and have a adequate


- guard to prevent broken disc from flying to worker, especially to workers
eyes.
- Grinding machine, especially grinding disc shall be handled carefully
and well earthed to prevent electric shock.
- RPM of grinding disc is higher than that of grinding machine and the
disc shall be fixed tightly.
- Excessive pressure shall not be put on the disc against the working
surface.
3) Fire burns and eye injuries
- Welder shall wear PPE including retardant clothes, welding apron, eye
protection (welding visor) especially.

4) Electric shock
- Electric machine and generator shall be equipped with ELCB and shall
be earthed by 1 m earth stake or to scaffolding
- Welding cable shall be kept dry and free from grease and oil to prevent
breakdown of insulation.
- Welder and fitter shall wear dry coverall, dry safety shoes and dry
gloves.
- Earth cable lines shall properly earthed and well be arranged under
scaffold, platform, working area or arranged 2 meters over from ground
or platform to prevent cable from damage and workers tripping.
5) Toxic Fume
- Adequate exhaust ventilation shall be provided.
- In case adequate exhaust ventilation is not possible, welding should be
carried out by wearing suitable respiratory protection.
6) Bad weather condition
- Secured ladders/man lifts shall be used for main access at heights for
staging.
- SUBCONTRACTOR shall check weather forecast everyday in order to
check the working condition.
9.
-

Back Purging
After welding, the back purged gas shall be removed by compressed air.
Nobody shall enter into the back purged pipe without removing back
purged gas and gas testing.

10.Post Weld Heat Treatment


1) Usage of insulation
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Worker should wear mask when treat insulation.


Used insulation should disposed correctly.

2) High temperature
- Heat area should be barricaded and protected round working area.
- Worker wear adequate PPE, especially gloves around working area.
- Not allow to keep farmable materials around cutting area.
- Prepare fire extinguisher beside working area.
- Do not use damaged PWHT cables and heat band.
3) Fire by over heat
- Not allow to keep farmable materials around cutting area.
- Prepare fire extinguisher beside working area.
- Do not use damaged PWHT cables and heat band.
11.Non Destructive Examination
1) Exposure to radiation
- NDE bunk shall be covered and isolated completely from workers.
- Do not access NDE work area and source.
Permit to work(PTW) of NDE shall be permitted.
The schedule of NDE shall be informed and announced to every
workers in advance.
- NDE work shall be scheduled and executed especially at night or no
work time after workers finish works and go out after work.
- Warning lamp, warning sign and warning tape shall be installed outside
work area before commencing NDE work.
- The source shall be kept well in well protected container if possible far
from working area after operation.
-

11.0

ATTACHMENT

11.1 Piping Installation Around Equipment Work Flow ------------------------- 1 sheet


11.2 Pipe header spool fabrication drawing around AFC-------------------------2 sheets
11.3 Procedure for Bolt up and checking of flange parallelism------------------2 sheets
11.4 Rigging plan for around heat exchanger--------------------------------------38 sheets
11.5 Rigging plan for around AFC -----------------------------------------------------7 sheets
11.6 Task Statement (TS), Risk Assessment (RA),
Job Safety Analysis (JSA), -------------------------------------------------------4 sheets
11.7 Linde lifting limitations / Nozzles and Piping Cleanliness procedure----4 sheets
11.8 Gas Purging Dam Removal Control--------------------------------------------2 sheets
11.9 Instruction on Safety Valve Handing ------------------------------------------ 8 sheets
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11.10 Installation Procedure for heat exchanger--------------------------------- 1 Package

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