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Installation Method Statement
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TITLE INSTALLATION METHOD STATEMENT
PROJECT Caustic Tower Modification Project
ITEM LT-01 – Caustic Tower
CUSTOMER Koch-Glitch / Kemya
CUSTOMER’S WO. NUMBER
ISSUED BY
DATE
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Installation Method Statement
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CONTENT PAGE
INTRODUCTION 3
SCOPE OF WORK 3
MAIN EQUIPMENT 3
MATERIAL STORAGE AND TRANSPORTATION 3
LIFTING TO/FROM THE COLUMN 4
WASTE DISPOSAL 4
VENTILLATION 5
INSTALLATION PROCEDURE 7
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Installation Method Statement
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1.0 INTRODUCTION
The following instructions aim to highlight the methodology of how the operations as listed
on the installation method statement XXXXXXXXXX are to be performed. The procedure
for which the work is to be completed as detailed in method statement XXXXXXXXXXXX
2.0 SCOPE OF WORK
To carry out the Modification of Trays in Caustic Tower LT-01 of Dia. 4400 mm ID. As per
the drawing reference attached.
It must be stressed that all the works to be carried out with the importance on safety over
and above all other considerations and is subject to the statutory and mandatory health
and safety regulations pertaining thereto, together with the KG / KEMYA safety Policies.
Prior to commencement, the column is to be fully isolated, washed / steamed through. All
Column Manholes are to be opened and gas free. KG / KEMYA will give the entry to
column after ensuring safe working condition.
Entry will not be permitted until entry permit is obtained from KG / KEMYA.
At all times when men are working inside the column, entry attendant (standby man) is
required at manhole entry location.
3.0 MAIN EQUIPMENT
No. Description Qty. Comments
1 Crane 1
2 Forklift 1
3 Welding Machines 1
4 Grinding M/C 110 V 1
4.0 MATERIAL STORAGE AND TRANSPORTATION
The Column internals shall be delivered on pallets or in closed wooden crates to the
designated preparation area prior to shutdown. The packing cases will only be opened in
the presence of a specialist from KG. Any transport damage has to be reported
immediately to the responsible person. During the pre-shutdown period, all crates should
be checked against packing lists and to be arranged in the sequence of installation.
Missing items to be reported immediately.
Prepared materials will be transported from the storage area to near the column area in
readiness for installation as and when required.
During transporting the material, the traffic regulations and plant procedure must be
followed.
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5.0 LIFTING TO / FROM THE COLUMN
A crane, mechanical / pneumatic winches and chain blocks will be used to facilitate the
removal of old and the installation of new internals and the new or old materials will be
lowered or lifted by using material basket.
The lifting basket will be tested and marked with its safe working load. An experienced
supervisor / men will control all lifting and lowering activities either by radio contact or
hand signals to the crane
A clear working area is required at the point of lifting or lowering the materials.
The lifting area will have a barrier to prohibit unauthorised entry and for
safety precautions during lifting operations.
6.0 WASTE DISPOSAL
Redundant internals will be removed from the column via the respective manholes and
placed into a lifting basket, or slung with certified shackles and slings, then lowered to
ground level using the crane / winch and will be deposited into a scrap.
All the waste materials to be disposed in the designated area as per the instructions of KG
/ Kemya
7.0 VENTILATION & LIGHTING
Air mover or exhaust to be fixed below the working level for better fresh air circulation. For
vast hot work inside the column, localised fume extraction equipment to be provided.
Personal respiratory systems will also be provided for the welder workforce during hot
work activities if required.
Only 24 V or explosion proof lighting must be used inside the confined space. For grinding
purpose use pneumatic grinders are 110V grinders.
8.0 INSTALLATION PROCEDURE
Entry into the column will only be carried out once column is gas freed and the entry
permit issued. The following parameters are very important to confined space entry.
Oxygen 19.5 to 23% vol. Max.
LEL 0%
It is Mandatory that full understanding of the requirements to all involved persons.
Entry attendant should be located near the working manhole and entry into the column
must be strictly controlled by use of signing-in system to check everyone in and out.
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9.0 PRE-SHUTDOWN ACTIVITIES
SITE ESTABLISHMENT
9.1.1 Complete safety orientation for all personnel.
9.1.2 Mobilise equipment and personnel to site.
9.1.3 Site office and store to be established
9.1.4 Complete Permit Requirement.
9.1.5 Meeting / Discussion with client.
9.1.6 Equipment inspection and necessary certification from client.
All the materials and the new internals to be shifted to the designated area for material
identification and segregation. The tray materials to be checked against approved
drawings & packing list. Each one type of tray assembly to be done for easy
understandings and fitment purpose. The loose materials like fasteners to be kept in
stores.
10.0 SHUTDOWN ACTIVITIES
10.1 Vessel Entry Check
Sr. No Description Responsibility
8.2.1 Positive isolation of columns. KEMYA
8.2.2 Chemical cleaning of Column KEMYA
8.2.3 Gas test KEMYA/ ALMUZAIN
8.2.4 Lighting arrangements KG/ ALMUZAIN
8.2.5 Proper ventilation KG/
ALMUZAIN
8.2.6 Standby person outside the column ALMUZAIN
8.2.7 Valid confined space entry permit KG / KEMYA
10.2 Column Details
SL NO SERVICE DIAMETER NO OF TRAYS TYPE OF TRAYS
8.2.1 Caustic Tower 4400 mm 5 – 16 (12 Trays) Bubble Cap
10.3 Job Details
Entry to be done through 1C manhole
ENTRY
INTERNAL MANWAYS OPENING
INSPECTION BY CLIENT
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REMOVAL OF TRAYS # 5 TO 16 - 12 TRAYS
BY GRINDING
INSTALLATION OF TRAYS WITH LEAKTEST
NOZZLE MARKING, CUTTING, FIT-UP
OUTSIDE
BACKCHIPPING OF NOZZLE AND SEALING
FROM INSIDE
FIT-UP AND WELDING OF FALSE
DOWNCOMER AND PWHT ( TWO
NOZZLES AND F/DOWNCOMER AREA)
HYDROTEST AND CUTTING OF
TEMPORARY ATTACHMENTS)
INSPECTION BY CLIENT
10.4 Drawing list for Caustic Tower – LT-01
DRAWING LIST
