auxiliary boiler ms

7/16/2019 Auxiliary Boiler MS

http://slidepdf.com/reader/full/auxiliary-boiler-ms 1/10

MS-P-003 REV.0

of 10

METHOD STATEMENT

FOR

INSTALLATION & ASSEMBLY OF

AUXILIARY STEAM BOILER PACKAGE

Contract No. JI-194

Karan Utility and Cogeneration Project

Khursaniyah Kingdom of Saudi Arabia

Signature

00 03/28/10 Print M.N. TASI E C. Barawid R. A. Santos P. Ranzenbacher

Rev. DATE Name Prepared ByMMG

Checked ByMMG

Approved ByMMG

Approved ByPETROFAC



MS-P-003 REV.0

of 10

TABLE OF CONTENTS

1. SCOPE OF WORK

2. REFERENCES

3. DEFINITIONS

4. RESPONSIBILITIES

5. EQUIPMENTS & TOOLS

6. EXECUTION / PROCEDURE

7. QUALITY CONTROL & INSPECTION

8. SAFETY PRECAUTIONS

9. ATTACHMENT/S



MS-P-003 REV.0

of 10

1. SCOPE OF WORK

To ensure that the assembly and installation of Auxiliary Steam Boiler Package lines are

carried out safely by MMG personnel, in accordance with good working practice and in

compliance with the applicable codes, standards, approved drawings and manufacturer’s

installation procedures. This procedure is intended to provide general application

guidance and establish controls during preparation, installation and inspection.

2. REFERENCES

a) Typical Erection Procedure “MVF” Boiler in Field. Rev. 0. By MACCHI

Steam & Power Generation.

b) Boiler Big Block Installation Procedure. Rev. A. By MACCHI Steam &

Power Generation

3. RESPONSIBILITIES

A. Construction Manager

Ensure the full implementation of this Construction Method Statement (CMS) andidentifies the requirements and add on resources for the effective accomplishment of the installation of HDPE Underground Pipe.

B. Construction Supervisor:

Ensuring that all construction activities are being carried out in accordance with theProject Specification, Procedures, IFC Drawings and with the approved ITP. Tocoordinate with the contractor execution team and QC department for proper executionof work and to follow each check point as per quality requirement.

C. Section Engineer:

Responsible for the safe and effective execution of installation and testing of HDPEpiping, in order to ensure that the work criteria is maintained by the staff under his



MS-P-003 REV.0

of 10

control and report to Construction & Civil Manager.

D. Site Engineer / Foreman:

Responsible for obtaining work permits and ensure all safety requirements are metwhile doing the work and report to Section Engineer.

E. Welding Supervisor:

Ensure proper handling of the fusion machine, welding operation and work performed

as per safety working plan.

F. Quality Control Inspector:

Quality Control Inspector has to monitor daily activities and verifies as per ProjectSpecification. He has to conduct activities and inspection as per approved ITP andQCP and has to record all quality documents and reports in appropriate forms. He willbe responsible for notification (Request for Inspection – RFI) to the company/contractor. After completion of all inspections & tests, all reports & documents shall besubmitted to Company for final review and approval.

5. EQUIPMENTS AND TOOLS

Fusion MachineCraneTrailer Loader

Dumping TruckCompactor GeneratorsPumpsWater TankersHand ToolsGrindersSupport Stand & Temporary Shelter (if required)



MS-P-003 REV.0

of 10

6. EXECUTION / PROCEDURE

6.1 Foundation Preparation

6.1.1 Foundation preparation shall be in accordance to MACCHI “Boiler Bigblock Installation Procedure” and Approved for Construction Drawing.

6.1.2 Prior to Installation of all equipments, ensures that all the foundation areinspected and approved by Contractor/Client.

6.2 Lifting, Installation and Alignment

6.2.1 Boiler Big Block lifting and setting and alignment to foundation refer to“Boiler Big Block Installation Procedure by MACCHI” .

6.2.2 Erection of economizer block according to

Jointing can be performed inside and / or outside the trench to suit site conditions.

1) The inside and outside of pipe ends that are to be fused shall be cleaned and allforeign materials on the exterior area that will be clamped are to be removed.

2) Open the upper jaws and insert pipe in each pair of jaws and let the ends of the pipeextend about 1” past the face of the jaws.

3) The pipe ends shall be faced to establish clean parallel flat surfaces for heating and joining.

4) The facing tool will be installed between the component ends and facing shallcommence until continuous shaving are produced from both ends, the distancebetween the component ends is the gap specified by the equipment manufacturer.

5) All shaving chips to be clear from both ends.

6) Move the carriage to the right to open a gap large enough to insert the heater.



MS-P-003 REV.0

of 10

7) Check heater tool surface at prescribed temp. (204-232°C) periodically with apyrometer and make necessary adjustments.

8) Install the hot clean tool between the component ends together and against the heatingtool surface and a complete contact between pipe ends and heating tool surface shallbe assured.

9) Force contact shall not be used during heating, only small amount of force can be usedat the beginning to establish initial contact.

10) Heating time ends when melt bead size shown in Table 1 page 7 of 10 has formed allaround both ends.

11) After removing the heating tool, the melted ends shall be inspected quickly for acceptable criteria (flat, smooth and completely melted, no bubbly or concave meltedsurface).

12) The acceptable melt surfaces shall be joined quickly by using fusion joining force untilthe melt beads roll over to the OD surface.

13) Fusion joining force shall be maintained during joint cooling.

14) Fusion joint shall be cooled under ambient conditions without using air blowers or applying water.

15) The fusion bead appearance to be visually inspected with reference to manufacturer bead appearance criteria.

16) Fusion welders shall be certified that they can produce sound joints using the joiningprocedure and equipment.

A. Installation

1) All trenches to be constructed according to approved IFC drawings and related projectspecifications S-0000-1312-002 and to provide adequate and sufficient widthdepending on pipe diameter and other criteria as jointing and testing.



MS-P-003 REV.0

of 10

2) Surveyor to check excavation to confirm the alignment, levelling prior to pipeinstallation.

3) Usually, jointing of HDPE pipes are done inside the trench. Installation of pipe shouldstart at the line’s header.

4) Set-up time is minimized when pipe lengths are fed through the machine and joined intolong strings. Dragging pipe strings along the ground at speeds above a walking pacecan damage the pipe, especially in cold weather.

5) Pipe up to about 8” diameter and weighing roughly 6 lbs per foot or less can usually beplaced in the trench manually. Heavier and larger diameter pipe will require appropriatehandling equipment to lift, move and lower the pipe into the trench.

6) To avoid field damage, large diameter (16” and above), do not join fabricated directionalfittings such as elbows, tees, wyes, and crosses to more than one pipe beforeplacement in the trench.

7) The remaining outlet connections are made with flanges or mechanical couplings after placement in the trench.

8) Connecting pipes to more than one outlet, then attempting to lift, move, and lower theassembly into the trench frequently results in fitting breakage and is not recommended.

9) Field leak test shall be carried out as per recommended standard (ASTM F2164).Backfilling to be commenced after leak test clearance and according to projectspecifications.

TABLE 1Melt Bead Size

Pipe size, in Approximate melt bead size, in

< 1 1/32 to 1/16> 1 to 3 About 1/16

> 3 to 8 1/8 to 3/16

> 8 to 12 3/16 to 1/4

> 12 to 24 1/4 to 7/16

> 24 to 36 About 7/16

Determining Fusion Pressure for Powered Fusion Machine No. 618



MS-P-003 REV.0

of 10

Variable Definitions:

O.D. = Outside Diameter t = Wall ThicknessSDR = Standard Dimensional RatioIFP = Manufacturer’s Recommended Interfacial Pressure TEPA = Total Effective Piston Area

Formulas:

t = O.D. / SDR AREA = (O.D. – t) x t x 3.1416FORCE = AREA x IFP

GAUGE PRESSURE = ((O.D. – t) x t x 3.1416 x IFP) / TEPA + 30 P.S.I. DRAG

Determining Fusion Pressure for Butt Fusion Device No. 14

Variable Definitions:

O.D. = Outside Diameter t = Wall ThicknessSDR = Standard Dimensional RatioIFP = Manufacturer’s Recommended Interfacial Pressure

Formulas:

t = O.D. / SDR AREA = (O.D. – t) x t x 3.1416

FORCE = AREA x IFP

REQUIRED FORCE = (O.D. – t) x t x 3.1416 x IFP + DRAG



MS-P-003 REV.0

of 10

7. QUALITY CONTROL & INSPECTION

1) Ensure that all IFC drawings, approved procedures and other necessary documentshas been issued to the construction supervisor.

2) QCI has to inspect all the check points as per approved ITP, IFC drawings andprocedures. He has to monitor each step of construction during field joining, installationand leak test to get the maximum quality of work and to avoid any mistake or rework.

3) QC Inspector shall submit request for inspection for final inspection of joint, line / slopeverification and leak test as per approved ITP.

4) Correct & proper documentation shall be made by QC department and final handover toJAL for turnover.

8. SAFETY PRECAUTIONS

1) Job safety plan shall be prepared specifically for this scope of work, and shall provide: Fusion machine safe practice, appropriate heat protective cloths. Types of barricades to be provided for excavations and other operations

involved. Safe access to be provided where needed. Notify safety office before hydro testing.

2) All works shall be carried out as per JGC HSE program.

3) Job safe plan and work permit must be implemented.

4) Proper PPE must be provided and worn at all times.

5) All work areas shall be kept in a clean and tidy manner.

6) “WORK IN PROGRESS” safety signboard shall be placed around working area to warnthe personnel.

7) Excavated & trenched area shall be properly barricaded to avoid any accident or incident.



MS-P-003 REV.0

of 10

8) To avoid any fall or injury in excavated and trenched area, proper slope shall bemaintained for personnel to go down.

9) During leak testing, the whole piping area shall be barricaded and “LEAK TEST INPROGRESS” signboard should be posted.

10) Supervisor has to give proper instruction to work team in his daily tool box meetingabout hazardous and toxicity of chemical, which will be used in HDPE piping.

11) Safety officer will ensure that all construction activity is being performed in compliance

with project safety norms.

9. ATTACHMENT/S

1) Job Safety Analysis

2) Images of HDPE Piping Installation

---------------------------------- END --------------------------------------

auxiliary boiler ms

Documents