Method Statement for Instrument Field Installation - 005

SADARA MIXED FEED CRACKER PROJECT METHOD STATEMENT FOR FIELD INSTRUMENT INSTALLATION (FOR INSTRUMENTATION WORKS)

Document No. A554-E-103-IC-GEN-DOC-005 Revision:

0

Prepared by:

J.U. Saguagan

Reviewed by:

J.H Lee

Checked by QA/QC:

K. K. Akhter

Approved by:

S.H Joo

1

2

3

Owner Approved by: Revision Date:

19 FEB 13

Issue Purpose:

IFA

This document contains technical information that may be subject to the export control regulations of the United States and/or other jurisdictions. It may not be exported or re-exported except as authorized under applicable U.S. or other export control regulations.

Contains Confidential Information of SADARA Page 1 of 13

SADARA Mixed Feed Cracker 005

Document No: A554-E-103-IC-GEN-DOC-

Document Title: Method Statement For Field Instrument Installation Purpose: IFA

SUMMARY OF DOCUMENT REVISIONS Rev. No.

Date Revised

0

19 FEB 13

Section Revised

Revision Description Initial Issue


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Table of Contents

Section

Topic

1.0

Purpose ……………………………………………………………………………. 4

2.0

Scope ………………………………………………………………………………. 4

3.0

Responsibilities ……………………………………………………………………. 4

4.0

References ……………………….…………………………………………………. 4

5.0

Method of Preparation ……………………….….………………………….……. 5

6.0

Safety Requirements …………………………………………………….………. 6

7.0

QA / QC Requirements ……………………….….…………………….…………. 6

8.0

Procedure ……………………….…………….………………………….…………. 7





1.0

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PURPOSE The purpose of this method statement is to ensure that all works regarding Field Instrument (Flow, Level, Pressure, Temperature and Analyzer Shelter) Installation for Instrumentation Works shall be done in accordance with the SADARA standards and all other applicable international codes and standards.

2.0

SCOPE The scope covers the steps to be followed for the installation of Field Instrument (Flow, Level, Pressure, Temperature and Analyzer Shelter) for Instrumentations intended for permanent installation in the plant. DAELIM and AIC shall ensure that the method statement is adhered to the SADARA Standards with reference to SADARA specifications.

3.0

RESPONSIBILITIES: The DAELIM Instrumentation Construction Manager is responsible to plan and schedule activities for the installation execution in co-ordination with client personnel. It is the responsibility of the materials personnel; to receive & visually inspect instrument, before handing them over to SADARA Instrument Department and shall be responsible for the safekeeping and its reservation that received. It is the responsibility of the Instrument QC inspector to carry out inspection. Check the physical condition of the instrument after calibration before installation. Any damages found must be reported immediately to their immediate supervisor. After Field installation, all instruments shall be protected by means of plastic covering or any mode of protection applicable against from dust, rust, scratches, denting, and other external factor that can cause damaged to the unit.

4.0

REFERENCES: A554-O-PRG-IC-GEN-BOD-003 : SADARA Instrument Basis of Design A554-K-PRG-IC-SPC-ID7-005

: Design Engineering Criteria Instruments

A554-K-PRG-IC-SOW-CON-001 : Instrumentation EPC Project Instructions





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A554-O-PRG-IC-GEN-BOD-003 : Instrument Basis of Design For EPC G6A-0002-00 G6A-0041-00

5.0

: DOW Global Instrument Administrative Guideline : DOW Global Instrument Job Specification Master Dictionary

G6C-7002-00

: Design Criteria – Temperature Instruments Rev.1

PIP PCCGN002

: General Instrument Installation Criteria

PIP PCCFL001

: Flow Measurement Design Criteria

PIP PCCLI001

: Level Measurement Design Criteria

PIP PCCPR001

: Pressure Measurement Design Criteria

PIP PCCTE001

: Temperature Measurement Criteria

PIP PCCPA001

: Process Analyzer System Design Criteria

METHOD OF PREPARATION 5.1)

The Instrument Construction Manager / Superintendent shall plan and schedule activities for the installation of the instrument field installation in coordination with Mechanical Construction group.

5.2) The work shall be performed, following good workmanship practices, by personnel in compliance with established safety regulations. All work shall be performed using only the correct tools. Field instruments are subject to inspection and witness by the client after work. 5.3)

Forms, procedures and sign off sheets for activity shall be prepared and submitted for review and approval of the client prior to beginning of any activity.

5.4)

All instrument works and supports shall be in accordance to standard details of IFC drawings and Typical Installation Drawing. Technical query shall be submitted officially for any amendment from the approved IFC drawing, prior to start any work.

5.5)

Necessary clearances shall be taken from other group, (like piping and structural group) before proceeding with the works to avoid any overlapping/interference of work executions.

5.6)

The Safety Work Permit shall be prepared based on the schedule of field instrument erection activities, or in daily base activities. Contains Confidential Information of SADARA Page 5 of 13




5.7)

6.0

7.0

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Ensure that all work/activity are in full compliance with SADARA Standards and approved Project Specification.

SAFETY REQUIREMENTS 6.1)

Safe work permit requirement is mandatory. All personnel involved in the activities shall wear complete personal protective equipments (PPE) in accordance with the safe work requirements.

6.2)

Conduct job safety tool box before starting the work, and issue daily JSA. And the safety officer shall verify that all the necessary and applicable documents, related to the safest operation are in possession before commencing the job.

6.3

Place barricade and warning sign boards in applicable locations. Restrict Personnel/equipments entering the work area.

6.4)

Check adequacy and availability of all tools, before commencement of installation activity.

6.5)

If the weather conditions turns bad, (like sand storms, wind storms raining or hailstorms) shall immediately coordinate to safety officer and all works shall be stopped.

6.6)

Safety procedures shall be followed at all times.

QA/QC REQUIREMENTS 7.1)

The Quality Control Program shall be as per DAELIM Project Procedure in conjunction with the SADARA Engineering Standard. The detailed inspection stages and methods shall be as per the Approved Inspection and Test Plan.

7.2)

Prior to commencing the installation work, the Field Instrument shall be inspected visually for any damages during and after the transportation.

7.3)

All installed field instrument shall be inspected for elevation as per the IFC drawings.

7.4)

Inspection and test plan must be submitted ahead of time for PMT & DAELIM approval.

7.5)

All RFI’s shall be submitted 24 hours ahead of scheduled date of inspection.





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7.6)

All relevant attachments including IFC Drawing must be attached on all submitted RFI’s.

7.7)

Work execution, material approval and testing shall be monitored witnessed and recorded on documents in accordance to the inspection list, QC form given by applicable ITP field installation and its support.

7.8)

Instrument inspector shall carefully check against IFC drawing for the following items: a.) b.) c.) d.) e.) f.) g.)

Check Check Check Check Check Check Check

for correct elevation the correct size and materials. for proper grounding. for correct mounting for adequacy of supports. for adequate sunshade installation. for the correct polarity of the instrument supply.

8.0 PROCEDURES 8.1

Handling Every Items delivered shall be inspected to ensure compliance to specification, Data sheet & free from damages. Offloading shall be in responsible & Safe Manner.

8.2

Issue of Document and Drawings Ensure receipt of all related documents and IFC drawings from the client before proceeding with transportation & installation.

8.3

Field Instrument Installation – General Requirements 8.3.1.)

Field Instrument shall be installed as per IFC drawing and typical installation details drawing. And instrument prior installation using as a reference shall be oriented so that the scale faces the direct access approach to the equipment with them is associated.

8.3.2)

Where the process variable can be manually controlled at a control valve station, the process variable indicator shall be clearly visible from the valve hand wheel or valve bypass location.

8.3.3)

Instrument shall be accessible for use, calibration and repair without requiring the removal of piping, grating or other structure. This requirement also applies to the removal of any Contains Confidential Information of SADARA Page 7 of 13


Document No: A554-E-103-IC-GEN-DOCRevision: 0 Issue


covers or housing that is part of the instruments or its installation. Also ensure that the installation shall not be subjected to shock excessive vibration or temperature extremes. 8.3.4)

Location of instruments shall permits easy access from grade, permanent platforms or stairways for operation, inspection and maintenance. All vent valves or tubes connected to vent ports shall be directed away from the normal personnel access position.

8.3.5)

On remote mounted I/P transducers, tubing length between the transducer output and their final control element shall be as short as possible to minimize the effect on control loop stability.

8.3.6)

Field instruments shall be installed in individual project Specifications Standard.

8.3.7)

All Instruments shall be correctly leveled and aligned before fastening to the supports.

8.3.8)

All necessary preparation, instrument and associated supports must be according to the IFC drawing.

8.3.9)

Supports, brackets, hangers etc. for equipments and materials should be installed so as not weaken the structure to which they are attached.

8.3.10)

Before installation of all the instruments, it should be calibrated / pre-installation calibration.

8.3.11)

All instrument shall not be mounted on a handrail, adjacent to process vents, exhausts or where it obstructs a walkway.

8.3.12)

Instruments shall be installed manufacturer’s instruction.

8.3.13)

Vents open to atmosphere should be protected against entry of foreign matters.

8.3.14)

If more than one instrument is connected to the process, each should be able to be independently isolating without affecting the other.

8.3.15)

Tubing should be formed with exact size bender and installed so that no stress is exerted up on the installation. Tube fitting make-up should be checked with correct size gauge. For

in


accordance

conformance

with

with




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changing direction use bends rather than fittings as far as possible. Tubing laid closely together shall be offset to allow spanner access to the union. 8.3.16)

After instrument installation sunshade should be installed.

8.3.17)

Fastening hardware like bolts, nuts screws, washers shall be stainless steel.

8.3.18)

The instrument cable shield should be earthed in control room, field side should taped and isolated.

8.3.19)

Field mounted instrument such as transmitters. Control valves, and controllers, shall have name plates displaying the field tag number. Name plates shall be attached to instruments at a salient position, if practical. Name plates shall be engraved in English. All Instruments should have a shutoff (root) valve that is readily accessible. All instruments and connecting lines shall have allowance for movement of equipment caused by temperature changes.

8.3.20)

8.4

8.3.21)

Instrument shall not be supported by process connections unless it is of the direct mounting or direct connecting type.

8.3.22)

All unused conduit entries in fittings, and equipments shall be plugged using manufactured threaded plugs or caps. Cable and air entries of all equipments shall be made weather tight temporarily and make it permanently after test, if any.

8.3.23)

The support type, sunshade type, sunshade size and installation should be according to the typical detailed drawing.

8.3.24)

Clean the job site after installation.

8.3.25)

All traps, vent valves and tubes connected to vent ports should be directed away from normal personal access position.

8.3.26)

Installed material shall be protected in the field from dust and foreign material.

8.3.27)

All unused holes shall be plugged with stainless steel blind plugs.

Flow Instruments





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8.4.1 Manufacturer’s installation requirements shall be followed as a minimum. 8.4.2 Meters in liquid service shall be installed so that meters are always full of liquid and trapping of gases is avoided. 8.4.3 In gas service, liquid trapping shall be avoided. 8.4.4 The use of strainers and eliminators shall be considered and evaluated to protect metering devices whose performance or integrity is compromised without such protection. 8.4.5 Thermowells shall be located a minimum of five nominal pipe diameters downstream of a meter. 8.4.6 For Weather Protection, the impulse legs of differential pressure transmitters to head type flow meters shall require appropriate freeze protection. 8.4.7 Meter installations shall be in accordance with the specified electrical area classification. 8.4.8 Head (Differential Pressure) Type Meters  Square root operation in calculating flows from head type meters shall be performed in only one device (i.e., transmitter, flow computer, control system, etc.).  For liquid, steam and heat transfer media services, pressure taps shall be located on the horizontal side of the piping or 45 degrees down from horizontal. The pressure tap sensing lines (impulse lines) shall be sloped down to the transmitter (minimum of 1” per foot).  For gas and vapor services, pressure taps shall be located on the vertical from the top of the piping, horizontal, or 45 degrees from vertical. The pressure tap sensing lines (impulse lines) shall be sloped up to the transmitter (minimum of 1” per foot). 8.5

Level Instruments 5.5.1 Externally mounted instruments shall be preferred over internally mounted instruments. 8.5.2 Level instrument installation that cannot be calibrated, tested, and maintained during process operation shall require owner approval (e.g., internal level displacers). 8.5.3 All equipment shall be in accordance with the specified electrical area classification. Contains Confidential Information of SADARA Page 10 of 13




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8.5.4 Level bubble probes, wave guides, and stilling wells shall be situated to allow sufficient overhead clearance for their installation and removal. 8.5.5 Dedicated, independent process connections shall be used for level measurements that are part of safety instrumented systems or if required to enhance reliability.

8.6

Pressure Instruments 8.6.1 Impulse line purging systems, if required, shall be designed and installed such that the purge cannot introduce errors to the process measurement. 8.6.2 For gas and vapor services, pressure transmitters shall be installed as follows: a. Pressure transmitters shall be mounted above and as close to pressure taps as possible while still maintaining accessibility. b. Impulse lines shall slope continuously downward from transmitter to root valve such that they are self-draining. 8.6.3 For liquid or condensing services, pressure transmitters shall be installed as follows: a. Pressure transmitters shall be mounted below the pressure taps. b. Impulse lines shall slope continuously upward from transmitter to root valve such that they are self-venting. c.

Static head in the impulse line shall be considered in the measurement.

8.6.4 For steam services, pressure transmitters shall be mounted in either of the following ways: a. Above the pressure taps with a siphon or pigtail. b. Below the taps with correction for static head in the impulse line.



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8.7

Temperature Instruments 8.7.1 TWs shall be located a minimum of ten downstream of the mixing point for liquids.

(10)

diameters

8.7.2 TWs shall be located a minimum of 30 diameters downstream of the mixing point for gases or desuperheaters. 8.7.3 TWs mounted in horizontal vessels shall have at least an 18-inch insertion length; however, insertion length shall not exceed 1/2 the vessel diameter. Exception: Special requirements such as agitated vessels may require shorter TW installations. 8.7.4 Indicating thermometers shall be designed to install into a TW with a 0.10 inch clearance between the thermometer stem and the TW inside diameter. The stem length of thermometers shall be selected to bottom out in the TW in which they are to be installed. 8.7.5 TWs installed in oxygen service shall meet the requirements of CGA G-4.4 and the engineering standards of the oxygen producer. 8.8

Analyzer Shelter 8.8.1 Civil/Structural Before installing an analyzer or an analyzer system, the following must be verified:  The analyzer system location meets area space, elevation, and orientation requirements. Verify that the foundation or platform preparation meets specifications.  The cylinder rack installation preparation meets specifications, e.g., ramp access for wheeled cylinder carts, paving, and elevation of cylinder connections. 8.8.2 Field Installation (Shelter Installation) 8.8.2.1 Level and secure field-mounted analyzer enclosure or shelter to support foundation. 8.8.2.2 Seal base support structure appropriate sealing compound.

to

foundation

with

8.8.2.3 For installation of a shelter without a floor, ensure that the shelter sealing gasket has been installed. Contains Confidential Information of SADARA Page 12 of 13




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8.8.2.4 Install ancillary shelter equipment such as awnings/rain shields, detached cylinder racks, fresh air intake, sample recovery systems, etc. 8.8.2.5 Connect the heating ventilation and air conditioning (HVAC) condensate drain line to the condensate drain header or sewer. Condensate should not be allowed to drain freely on a concrete pad.

8.9

Receipt and Inspection 8.9.1)

When the unit is received shall be examine, inspected to ensure that it is free from any physical defects or damages and conduct visual inspection as required to established the condition of the materials.

8.9.2)

Receipt of each package items shall be documented with details such as received date, type of parts or fittings, quantity, and avoid loss of parts during storage.


Method Statement for Instrument Field Installation - 005

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