UMM WU’AL PHOSPHATE PROJECT

GULF ASIA SOP PRODUCTION PLANT

CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 Rev. Date :31-JAN-2017
METHOD STATEMENT FOR
Doc. No.: MD-512-5300-
CN-ME-MST-4002 STATIC EQUIPMENT ERECTION Rev. No.: A01

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

MD-512-5300-CN-ME-MST-4001

Rev. Description Approved By

Rev. Date Prepared By Checked By Approved By
No. of Revision (Employer)
UNNI KRISHNAN G.K.PILLAI G.GOPINATH
A01 31-JAN-2017 For Approval
(QDM) (PM)

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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Doc. No.: MD-512-5300-CN-ME-MST-4002
 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION

TABLE OF CONTENTS

1. SCOPE

2. PURPOSE

3. KEY TERMS AND DEFINITION

4. REFERENCES

5. RESPONSIBILITIES

6. LIST OF TOOLS AND EQUIPMENTS

7. RECEIVING AND STORAGE OF EQUIPMENTS

8. STORAGE SYSTEM

9. HANDLING OF EQUIPMENT FROM STORAGE TO SITE

10. EXECUTION OF WORKS

11. INSPECTION

12. SAFETY PLAN

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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Doc. No.: MD-512-5300-CN-ME-MST-4001
 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION

1. SCOPE
This Method Statement covers Receiving, Storage, Installation, Alignment, Grouting and
preservation Procedure for Static Equipment as per the project engineering specification &
standards for UMM WU’AL PHOSPHATE PROJECT, SOP PRODUCTION PLANT

2. PURPOSE:

This method statement is made to enumerate the procedure in the erection of Static
equipment in UMM WU’AL PHOSPHATE PLANT PROJECT, SOP PRODUCTION PLANT.

3. KEY TERMS AND DEFINITIONS:

MPC - Ma’aden Phosphate Company

FLUOR - PMC

GAC - Gulf Asia Contracting Company.

ITP - Inspection and Test Plan

RFI - Request for Inspection

IFC - Issued for Construction

WPS - Welding Procedure Specification

ASTM - American Society for Testing and Materials

AWS - American Welding Society

ASME - American Society of Mechanical Engineers

ASSE - American Society of Safety Engineers

AISC - American Institute of Steel Construction.

API - American Petroleum Institute

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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Doc. No.: MD-512-5300-CN-ME-MST-4001
 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION
4. REFERENCES:

4.1 MD-101-SMEM-EG-ME-SPC-0002 –Mechanical Equipment Installation

Specification

4.2 MD-101-SMEM-EG-ME-CRT-0001-Design Criteria-Mechanical Stationary

Equipment

4.3 MD-101-SMPM-PM-LS-PEI-0001-Equipments and Material Protection

Requirements.

4.4 MD-101-SMEM-EG-GE-SPC-0002 – Welding.

4.5 MD-101-SMEM-EG-ST-SPC-0002 –Steel Erection(For Platform & Ladder

installation)

4.6 MD-101-SMEM-EG-ME-SPC-0002 – Mechanical equipment installation

4.7 MD-101-SMEM-EG-PI-SPC-0005 –Piping Installation and Testing.

4.8 MD-101-SMEM-EG-ST-SPC-0003 – Grout.

4.9 AWS D1.1 – Structure welding code -Steel

4.10 MD-101-SMEM-EG-ME-SPC-0006 – Hot Insulation

4.11 MD-101-SMEM-EG-ME-SPC-0010 – Cold Insulation

4.12 MD-101-SMPM-PM-QA-PEI-0001- Contractor Quality Requirements.

4.13 API-650- Welded tanks for oil storage

4.14 MD-101-SMEM-EG-ME-SPC-0013 Metallic storage Tanks

4.15 MD-512-5300-QD-QC-ITP-3010- ITP for Static equipment erection

5. RESPONSIBILITIES:

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION
5.1 Construction Manager / Superintendent

Ensure that all workers, equipment operator, and other craftsmen associated with the
work are properly oriented and in compliance to this Material Submittal, QA/QC Plan
related ITPs, and other related work procedures and project specifications. Ensure
that work is done in a safe manner.

5.2 Site Supervisor/ Foreman

The Site Supervisor shall be directly involved in the planning and execution of the activities
involved in the Static equipment installation. He shall be responsible for the preparation of
the lifting plan, Safety action Plan and safe work plan application for the work permits if
required prior to the commencement of any activities.

The Foreman shall be responsible for the direct execution of works involved in the
equipment erection process according to the plan and shall directly control and give
instruction to the working personnel .He shall also ensure that works are performed with
proper tools and equipment, PPE and good housekeeping around the area.

He should raise inspection request to the QC department, at appropriate stages of works as

detailed in the ITP. RFI should be raised at least 24 hours in advance to the required time
of inspection.

5.3 QC Department / Engineer / Inspector / Manager

PQM Manager is responsible for all required Quality control activities such as test and
inspection for this desired Works. All inspections will be carried out in accordance with
approved ITP.

The site QC inspector will have the responsibility for making RFI, necessary inspection and
witnessing with Client and preparing necessary documents and he will submit it to PQM
(Project Quality Manager). Conduct inspections in accordance with QA/QC Plan, approved

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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Doc. No.: MD-512-5300-CN-ME-MST-4001
 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION
ITP and Method Statement with proper documentation for construction and inspection
record preparing and maintaining.

5.4 Safety department / Supervisor / Officer

Ensure that the safety requirements have been adequately addressed and work is being
carried out in a safe manner. Conducts safety inspections, monitor and address any unsafe
acts and unsafe conditions.

6. LIST OF TOOLS AND EQUIPMENT:

1. Crawler Crane and Hydraulic Crane

2. Trailer, Man lift, Fork lift & Man Basket

3. Lifting tools and tackles

4. Scaffold items (1 lot)

5. Power Tools (Generators, Cutting, Grinding, Welding, Drilling M/C etc.)

6. Plates & structural (Temporary supports) ( 1 lot)

7. Survey instruments

8. Lifelines Hand Tools

9. Hand tools (Hammer, spammers, wedges, torque wrench etc.)

10. All types of precision tools (Micrometer, dial gauge, level, calipers etc.)

11. Timber, Steel and other temporary materials.

12. And PPE’s for the project safety requirements.

7. RECEIVING AND STORAGE OF EQUIPMENTS:

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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Doc. No.: MD-512-5300-CN-ME-MST-4001
 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION
7.1 The equipment shall be offloaded by GAC at their own Laydown yard or site with
Preservation.

7.2 Visual inspection shall be carried out and Overage/shortage/damage, if any, shall be
recorded in OSD report by Material Controller with respect to packing list when received
by GAC.

7.3 All other types of discrepancies shall be handled through NCR’s and SSR’s.

QA/QC inspectors shall be informed to perform this inspection as per the agreed list of
items required “Receiving inspection record”. Inspection will be carried out as per the
attributes in attachments.

7.4 All the equipment shall be received and stacked as per the Drawing/Document
recommendation at the predetermined compacted area with clearly marked for access to
Crane, Trailer & Forklift movements. Proper sign board displaying equipment storage area
& sub area shall be provided.

7.5 Adequate barricades are to be provided around the storage area with warning sign
boards.

7.6 Provide proper protection during handling the equipment or the wooden packing to avoid
any damage on the coating of the equipment or the packing.

7.7 Wooden boxes containing small and loose materials like equipment accessories shall be
stored with proper packing list affixed on outside the packing in order to identify the
material easily.

7.8 Proper receiving & issue log shall be maintained by GAC material controller for all
materials.

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 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION
7.9 Lifting shall be carried out using Nylon slings of sufficient capacity or wire rope slings,
spreader beams(If required) which meets requirement of Safety control under the
contract.

7.10 Precautions shall be taken for handling of bolts, nuts and Washers during transporting and
storage to preserve the threads and prevent coated surfaces from damaged.

7.11 Use long size ladder when rigger need to get on material packages ladder need to hold by
support

8. STORAGE SYSTEM

8.1 The levels of storage and protection requirements to be agreed with client in the material
delivery status report.

8.2 Specific storage instructions from the manufacturer /drawings such as protection of flange
faces shall be verified before taking custody.

8.3 If sensitive/delicate items such as instrument gauges, control valve components, etc. are
likely to get damaged during transportation shall be additionally protected or removed prior
to equipment handling. Any removal of parts shall be approved by PMC

8.4 Machined surface will be protected from rust and damage. Gauges and instruments will be
protected from construction fall and other damages.

8.5 Flanges and openings open to atmosphere will be temporary blinded with plywood or
plastic sheets. Special preservations for equipment, which are not coming in general
category, will follow vendor instruction.

8.6 The equipment preservation record shall be maintained by GAC QC inspector.

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION
9. HANDLING OF EQUIPMENT FROM STORAGE TO SITE

9.1 The loading / transportation of equipment from storage area to site shall be done by using
proper capacity nylon slings/wire rope slings/shackles/tools/spreader beams (if
necessary).

9.2 Lifting hooks are to be provided for handling and transportation, by the Fabrication agency.

9.3 Lifting instructions on the manufactures manual or marking on the equipment shall be
carefully noted and followed.

9.4 All obstacles shall be removed from transportation route. Coordination with proper
authorities and other agencies kept informed well in advance.

9.5 Underground piping system shall be considered while surveying transporting route and
proper precautionary measures shall be taken.

10. EXECUTION OF WORKS

10.1 Pre-installation checks

Prior to starting installation the following shall be verified to be satisfactory.

10.1.1 Structural support

The following condition of the concrete foundation and/or steel supporting structure shall be
checked against the relevant drawings and construction records.

 Fabrication agency shall confirm that dimensional inspections as nominated on the ITP
have been completed and should cross check critical dimensions. The development of
the foundation dimensions shall have considered the layout of the equipment, the piping
arrangement, the concrete cover required by the anchor bolts, the minimum outside
dimensions recommended by the equipment vendor, including space for the maintenance
access.

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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Doc. No.: MD-512-5300-CN-ME-MST-4001
 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION

 GAC shall confirm that the construction quality records for the supporting concrete/steel
structure as required by the applicable ITP are on the file. The foundation shall be cured
at least 7 days as per ACI 301 prior to loading with equipment and/or grouting. Concrete
shall also be exposed to a drying out period of at least 24 hours to ensure that the
capillaries are free of moisture and will provide proper grout bonding. A minimum of 28
days curing time is required before tightening the foundation bolting.

 The supporting structure shall be marked out to facilitate ready positioning of the
equipment including: Marking of centerline, elevation line and height accuracy.

 Flatness and levelness shall be checked at the points where pads and/or liners are to be
installed.(If required)

 The surface of the concrete foundation shall be checked to see that it is chipped for
grouting.(If required) Chipping shall be to a depth to provide for a minimum grout
thickness of 25-50 mm between the bottom of the base plate and the top of the
foundation to be specified on the construction drawings.(If required) The final chipping
operation shall be done just prior to setting and grouting of the base plate to avoid
contamination of the chipped surfaces.(If required) The chipped surface shall be cleaned
with compressed air.

 GAC shall confirm that the top of the concrete foundation is lower than the finished height
by the grout thickness indicated on the foundation drawings. It shall also be elevated a
minimum of 100mm above the finished elevation of the floor slab or grade to prevent
damage to the machinery from run-off or wash-down water.

10.1.2 Anchor Bolts

The anchor bolt placement in the foundation shall be checked against the drawing or
with a steel template for major equipment. Tolerances shall be in accordance with the
requirements of Ma’aden Standard Specification-MD-101-SMEM-EG-ST-SPC-0005-
Concrete works.

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION
When anchor holes are used for anchor bolts, the anchor bolts shall be installed in the
anchor holes after the equipment is temporarily placed in the correct position. GAC shall
ensure that appropriate provision has been made in the foundation design for the
placement of the anchor bolts after placement of the equipment. After the grouted mortar
has sufficiently hardened in accord with the applicable ITP, leveling work shall be
commenced.

Anchor holes shall be cleaned before temporary installation of the equipment.

Before installing equipment, cut out top of anchor bolt sleeve as per drawing.

10.1.3 Condition and Protection of Equipment

After being thoroughly inspected the equipment shall be transported to site. The
condition of the machined surfaces shall be checked, and if necessary, shall be coated
with a suitable rust preventative. Temporary covers on all openings shall be tightened
firmly and shall not be removed during installation until the piping or other attachment is
connected.

The bottom face of the base plate shall be cleaned. When oil, grease, dirt or any other
loose particles are found it shall be washed off by water or other suitable solvents before
installation.

10.2 Pre-Planning of Lifts

Rigging plan shall be prepared by GAC and approved by PMC prior to lifting operations for
those classified as critical lifts.

Rigging interference drawings must be required when necessary to show foundations and
equipments that must be removed or not installed until after a heavy lift operation.

The drawings must include the followings as a minimum.

 Total weight to be lifted including load blocks and rigging gear

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION

 A scale plan view showing the location of the lifting equipment, lifted items, and their
relationships with any potential obstructions.

 A scale elevation view shows clearance between lifting equipment, lifted items, and their
relationships with any potential obstructions.

 A description of the configuration of the cranes indicating model number, boom length,
boom type, auxiliary counter weights, parts of load line, jib length, type, offset etc.

 Crane capacities based on actual working radius and crane configuration.

Lifting crane load shall not exceed 75% of the SWL. If the available soil compaction
strength is not adequate, proper compaction shall be carried out in order to increase the soil
compaction strength.

10.3 Checks before Erection.

The following shall be completed before erection.

 As per project specification the necessary permits like crane lift permit, permit to work
(Road close, near overhead electrical line, over underground system) Lift check list,
engineered design and drawing for engineered lift shall be made and got approved.

 The foundation surface is roughened (chipped) and cleaned. (If required)

 Level padding is completed and released for erection protocol. (If required)

 Heavy lift plan shall be approved by PMC and shall be available at the time of erection.

 Verify that no interferences /obstructions are existing during swinging.

 As far as possible the tall equipments will be dressed up prior to lifting.

 Must follow all safety requirements such as PPE, area barricading, sign boards etc.

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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Doc. No.: MD-512-5300-CN-ME-MST-4001
 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION
10.4 Preparatory works prior to erection
 The area preparation like backfilling and compaction shall be done for main crane.

 Crane positions shall be as per approved drawings. All areas involved for lifting activity
shall be barricaded and warning signboards shall be placed.

 The lifting assembly/Rigging attachment shall be verified by PMC and GAC Lifting
supervisor together and visual inspection shall be carried out by GAC safety personnel
and ensured with the requirements.

 Cranes, Crane operators, lifting tackles certification shall be checked and ensured the
validity by GAC safety personnel.

 Pre-lift tool box meeting shall be conducted and explained the erection procedure, risks
involved and precautionary measures to be taken for the risk assessment by GAC for all
crane operators, Rigging foreman, Riggers, Safety stewards etc.

 GAC safety personnel shall ensure the PPE and other safety precautionary measures as
prescribed in the risk assessment and clearance shall be given for lifting.

 The erection plan shall be informed well in advance to the nearby working people and
people those who are all working inside the lifting area shall be evacuated and the same
shall be monitored by GAC safety till completion of erection.

10.5 Erection of Equipment on the foundation/Structure

 For Vertical equipment- Initially the main crane hoist rope shall be tightened by giving
20% load and check the uniformity by checking all the lifting points of rigging
attachments fixed on equipment.

 Now the main crane will be under the control of lifting supervisor will gradually increase
the load till it lift the equipment up by 0.5M from the ground level and it shall be hanged
for some time.

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION

 Acting load shall be checked from LID on the main crane and ensure the total load with
reference to the main crane capacity and erection scheme, and then the erection activity
shall be allowed to proceed further.

 2 Nos. of wire ropes shall be used as tag lines at the bottom of the column in order to
arrest the movement of the load during lifting and swinging.

 The equipment shall be lifted under the control of lifting supervisor and rigger by hoisting
the main crane slowly tilt it lifts up to required height in order to remove the
saddles/packing/trailer bed.

 No personnel should be allowed to go under the suspended equipment .But in some

cases during removal of saddles shall be permitted under strict supervision after
verifying stability of the crane and the equipment.

 The main crane lifting hook will be hoisted slowly at the Pre-determined radius to swing
towards the lifting end. Once the equipment becomes vertical the minimum height from
the ground level shall be maintained in order to remove the shackle and slings from the
equipment is made ready for the swinging operation.

 Now the equipment will be lifted to the required elevation to top of foundation
bolt/structure as per the erection drawing. There will be enough skilled workers to keep
the equipment on correct orientation by using 2Nos.of tag lines.

 Equipment shall now be lowered until it reaches the top of embedded anchor bolts on
the top of foundation /pedestal/base structure.

 If required chain block shall be used for adjusting equipment to bring its correct
orientation.

 Chain block shall only be used for alignment and not for hanging too long line

 Once all the bolts are entered in to the base plate hole, the main crane shall now be
lowered till it rests on the padding liners / prepared concrete, which is fixed on top of the
foundation/pedestal.

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Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
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 Nuts for the embedded anchor bolts shall be put and tightened by using spud wrench
alternatively.

 Up on completion of erection, main crane rigging attachments shall be removed by using

man lift or auxiliary crane with man basket.

 The elevation and verticality of the equipment shall be surveyed and & recorded.

 If necessary, the adjustment shall be made by using shims between the base plates and
the padding liners provided on the foundation for alignment. Unless otherwise not
mentioned in project spec or vender documents, Carbon steel Wedges and shims shall
be used as packers to installation supports and alignment.

 After ensuring the elevation and the verticality, the nuts shall be snug tightened
alternatively as per specifications.

 The field inspection shall be offered for verticality check prior to grouting.

 Unless noted otherwise Cement base non-shrink grouting shall be carried out as per
project specification MD-101-SMEM-EG-ST-SPC-0007

10.6 Bolt tightening

The anchor bolt will be tightened at 4 points in criss-cross manner and the inclinations of the
equipments to be monitored using theodolite. If the magnitude of inclination is within the
tolerance level all of the anchor bolts are fully tightened by using spud wrench. Spot welding
will be made on the liner sets, or packing shims if mentioned in vendor data.

10.7 Alignment

10.7.1 General

 All installed equipments shall be aligned by plumpness and/or level check.

 Tanks/stacks shall be aligned by plumpness and shall satisfy the requirements given in
10.7.2

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 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION

 Horizontal equipments shall be aligned level and satisfy the requirements in 10.7.3

10.7.2 Plumpness
Plumpness shall be checked by viewing from two directions 90 o apart with a transit.

The check of plumpness of very tall equipment shall be done when all equipment
surfaces are at a uniform temperature.

Out-of-plumb of the equipment installed shall not exceed 1mm per 1M of height or a total
of 25 mm for the entire height, whichever is smaller, unless otherwise specified in the job
specification MD-101-SMEM-EG-ME-SPC-0002.

After alignment is finished and the lock nuts of the anchor bolts are tightened firmly, the
shims and wedges shall be tack-welded to each other and any excess in the shims and
wedges shall be cut off with a gas cutter. (If required)

10.7.3 Leveling
The alignment level shall be made using a spirit level instrument or a transit at four
points based on the center line marked on the equipment in the shop.

Shims shall be sized such that they will not protrude beyond the base plate. Once the
shims are installed and equipment leveled, the lock nuts of anchor bolts shall be
tightened firmly.

10.7.4 Grouting
The grouting of base will be done after leveling and verticality inspection completion.
Unless noted otherwise Cement base non-shrink grouting shall be carried out as per
project specification MD-101-SMEM-EG-ST-SPC-0007

10.7.5 Welding and Flame cutting

Normally no welding or hot work is allowed in the equipment pressure parts area
(PWHT zone).

All welding shall comply with the requirements of Ma’aden standard specification - MD-
101-SMEM-EG-GE-SPC-0002 Welding of plates and sections. Approval from the

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Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION
employer shall be sought prior to performing welding.

All welding should be done as per approved WPS and qualified welders should be used.

10.8 Auxiliary items:

The auxiliary items such as Ladders / Handrails shall be assembled once after the
inspections of main equipment are over.

11. INSPECTION
 The QC inspector of GAC, PMC shall carry out the necessary inspections in various
stages of the work including the material, pre-erection, erection and alignment as
mentioned in ITP.

 RFI shall be submitted 24hrs before for the next day inspection on the stage wise
activities described in the approved ITP.

 The PMC QC will witness the inspection. Inspection shall be based on approved ITP, IFC
drawing, and project specification.

 All inspection data’s/reports shall be recorded in approved inspection forms and shall be
mutually signed by GAC, Vendor (if required) and PMC.

12. SAFETY PLAN:

 Site safety oriented employees will be assigned for the activity.

 All employees will be provided with right PPE for the job and the work supervisor will
assure they are being properly used.

 Prior to work, supervisors assure rest shelters, drinking water and toilet facility were
arranged for the workers.

 All work activities will be done with valid work permits attached with approved JSAs and
other necessary documents.

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION

 Pre-task meeting will be conducted by work supervisor and STA (Safety Task
Assignment) sheet maintained.

 Necessary barricade and signs will be provided at appropriate locations.

 Prior to start of work, the work supervisor and safety officer assure all tools/equipment to
be used for the job are inspected by competent personnel and are having inspection
stickers/color codes.

 All equipment such as crane, man-lift, etc. to be used for the job will have Project
Inspection Stickers, valid Third Party Certifications for the equipment and operators.

 Before work starts each day, the equipment operators will inspect their equipment and fill
Daily Equipment Inspection Checklist. Any defects must be immediately reported to the
supervisor. Defective equipment will not be used for the job.

 Transportation of material by trucks / trailers will be done using safe access roads.

 All material transported will be properly secured.

 All material unloaded at work area will be stacked properly without any access
obstructions and hard barricaded.

 Trained Flag-men wearing visible vest will be assigned to control equipment/vehicle

movement in work area.

 All electrical equipment will be properly grounded and accompanied with necessary
number of inspected fire extinguishers.

 Power tools will be operated by experienced personnel who attended specific training for
safe use of hand and power tools.

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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Doc. No.: MD-512-5300-CN-ME-MST-4001
 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION

 All rigging/lifting activities will be done by 3rd party inspected/certified equipment/tools

 Experienced and trained personnel will be assigned to perform elevated work activities.

 All loads being lifted will be controlled by at least 2 tag-lines.

 During lifting, all lifting equipment will be protected from sharp edges using softeners.

 No personnel will be allowed to stay under any suspended load.

 For any elevated work where there is a potential fall hazard of 1.5 meters or more,
necessary fall protection methods will be applied according to Project requirements.

 100% tie-off policy will be observed for all activities having a potential fall hazard of 1.5
meters or more.

 For elevated work, safe work platforms will be erected by scaffold craftsmen, inspected
and appropriately tagged.

 Proper access will be provided in work area. MSDS copies of all chemicals used will be
kept at work location and instructions in MSDS will be followed.

 Necessary eye-wash facility will be provided near work area for emergency use.

 All chemical spills will be removed from work area and stored at designated storage area.
Inform earlier, prior to mobilize any hazardous chemical on site

 Necessary fire prevention methods will be implemented by assigning trained fire-watch

personnel with necessary number of inspected fire extinguishers wherever necessary.

 Proper illumination shall be provided as per the project safety requirements during the
extended hours /night shift. Overtime PTW request in advance.

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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Doc. No.: MD-512-5300-CN-ME-MST-4001
 UMM WU’AL PHOSPHATE PROJECT
GULF ASIA SOP PRODUCTION PLANT
CONTRACTING
COMPANY LLC.
Contract No.: 14-KB-023 METHOD STATEMENT FOR Rev. Date :31-JAN-2017
Doc. No.: MD-512-5300- STATIC EQUIPMENT Rev. No.: A01
CN-ME-MST-4001 ERECTION

 Emergency Communication Plan and Emergency Evacuation Plan will be included in pre-
task meetings. Emergency contact numbers and locations of Emergency Assembly Points
will be posted at work area.

 First-aid facility will be provided whenever work is ongoing.

 All work activities will be monitored by work supervisors and safety officers. Any deviation
from Permit/JSA requirements will be immediately addressed.

 Good housekeeping will be maintained at all times including material management,

cable/hoses management, etc.

 Any incident during work activity will be reported to Safety Department, investigated and
necessary precautions will be taken to avoid recurrence.

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

METHOD STATEMENT FOR STATIC EQUIPMENT ERECTION

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