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‘Sabcorractor Doe
SAIH NIHAYDA CONDENSATE No. Rew,
1N-6070-00002. | =
CONTENTS
1.0 Purpose 30f9
2.0 Scope 30f9
3.0 References 30f9
4.0 Manpower, Equipments & Instruments 3of9
41 Manpower 3o0f9
42 Equipments & Instruments 3o0f9
5.0 Responsibilities 40f9
6.0 Prerequisite 4o0f9
7.0 Procedure 5of9
7.1. General Requirements 5 of 9
7.2 Installation of control panels 6o0f9
73 Installation of Inst. local panels and Junction Boxes 7of9
8.0 Earthing and Bonding 8of9
9.0 HSE Boffo
10.0 Records 90f9Smaumavonconnercars, | Ne o
ALDI mneaimen [aes [nce
FAD ooo ae | |
ieee
3.0
4.0.
PURPOSE
The Purpose of this Method Statement is to identify the methods, procedures, resources,
plant, equipment, quality control and HSE measures to be planned, prepared and
implemented to ensure proper installation of instrument panels and junction boxes as per
Project Specifications / PDO standards installation practice. /d\
SCOPE
This Method Statement applies to the above purpose of work for the specific Saih Nihayda
Condensate Stabilization Plant Project (C-311194).
REFERENCES
3.1 Instrument Signal Lines: SP-1090
3.2 Electrical Installation Practice: SP-1099
3.3 Earthing and Bonding: SP-1109
3.4. Human Factors Engineering - Control Room Design: DEP 30.00.60.15
3.5 Human Factors Eng, - Human/Machine Interface Design for Situation Awareness:
DEP 30.00.60.16
3.6 Instrumentation for Equipment Packages: DEP 32.31.09.31
3.7 C&A Standard Drawings: SP-1206
3.8 Corporate Philosophy for Control & Automation: SP 1243
3.9 Quality Control Pian
3.10 Instruments for Measurement and Control: DEP32.31.00.32
3.11 Inspection and Functional testing of Instruments: DEP 62.10.08.11 /\
3.12 AFC Drawings.
MANPOWER, EQUIPMENT & INSTRUMENTS.
4.1 Manpower
Allocation of manpower shall be in line with the Site Organization Chart, as a minimum the
following personnel shall be available depending on the activities:
* Instrumentation Engineer
+ Instrumentation Foreman/Supervisor
‘* QC Inspector-Instrumentation
* HSE Advisor
* Inst. Technicians, Riggers, fitters, welder and HelpersSAIH NIHAYDA CONDENSATE | no >™™TO | Rev
STABILIZATION PLANT (SNCP) | it.coz ae
METHOD STATEMENT FOR
COM, | mstaitanonorinsraumenr | 200%" ROT Sheet
Sivtassan PANELS & JUNCTION BOXES
‘sNG-69.919100- | gy 409
1N6070-00002
4.2 Equipment & Instruments.
+ Tool Box with complete set of tools.
* Drilling Machine with Accessories.
+ Welding machines.
19 gears, Crane, Boom Truck.
+ Hydraulic manual lift trolley.
5.0 RESPONSIBILITIES
* Instrumentation Engineer shall be responsible for the following.
> Ensure that Instrument panels and junction boxes are in accordance with project
specification, standards and AFC drawings before stating the works.
> Construction will be carried out as per project specifications, standards and AFC
drawings.
> PTW required for installation of Instrument panel, console / desk and junction
boxes.
> Notify Quality Department when portions of the work are ready for inspection, as
depicted in the relevant QCP’s.
> Ensure that notification time to Quality Department is sufficient to allow
processing of the Request for Inspection.
> Issue Request for Inspection (RFI) to Quality Department upon completion of
installation works.
+ The QC Inspector shall be responsible for the following.
> Receive the construction RFI and determine construction work status i.e. check
installation conformity to project specification.
> Ensure that installation activities are ready for inspection prior to ABB / PDO
witness.
> Inform ABB / PDO representatives by the official application of inspection (RFI)
and arrange the joint inspection according to relevant QCP.
> Ensure that inspections are performed in a timely manner and recorded as per
specification and standard detail drawings.
+ HSE Advisor.
> Ensure all the safety aspects are taken care of during loading, lifting operations
and during installation.Saco Oe
SAIH NIHAYDA conDensaTe | <2 ov.
STABILIZATION PLANT (SNCP) | ts. o02 we
InstaLianon or nsraument | POD: No Por | Sree
PANELS & JUNGTION BOXES
8N0-68-919100- | gp s/9
1n-6070-00002
6.0 PREREQUISITE
6.1 Control panels
+ All material received at site shall be inspected, handled and stored upon receipt at the
storage and handling area, the equipment shall be inspected for mechanical damage.
Any damage shail be recorded on “O.S.D. Report” and reported to supplier.
Check all drawings and certificates are available.
+ Prior to installation of control panels, the control room shall be inspected to ensure the
architectural works and finishing are complete; the area is clean, free from debris and
any obstructions.
Ensure that the control panel, local panel, console and JB shall be clearly labeled
according to the relevant drawings.
After inspection the equipment shall be resealed to prevent ingress of moisture or dust. A
6.2. Field Panels and JBs
* Check the location of Field Panels, JBs and ensure that the accesses for these are free
from obstructions. In case of any obstruction, the same will be brought to the notice of
CONTRACTOR / COMPANY for re-location
+ Ensure that the field panel and JB shall be clearly labeled according to the relevant
drawings.
Ensure all ATEX certificates are available for control panels, local control panels and 38's. AN,
7.0 PROCEDURE
7.1 General Requirements:
7.1.1 Control Panels
+ All material received at site shall be inspected, handled and stored upon receipt in
accordance with project requirements.
+ Check the access to auxiliary room is clear and the location of panel entry to
building is defined and necessary platforms are made to unload the panels nearer to
entrance of control room.
+ The control panels should be planned as possible feasible to be transported and
offioaded directly to the auxiliary / control room. This is to minimize the risk
associated with loading and unloading the equipments,
+ The transporting and handling of panels shall always be with correct tools and
equipment with full protection provided for the panel finish.SAIKNIHAYDA CONDENSATE | NaN P | ow.
STABILIZATION PLANT (SNCP)
ts.o02 we
‘METHOD STATEMENT FOR
oe ustaltanion or strument — | POOD%!No. | Re | Shoot
‘asso PANELS & JUNCTION BOXES
SNG-69-919100.
wN-6070-00002 | ° e9
7.2
For unloading of the system panels, a scaffolding platform should be prepared in
front of the control/auxillary room main door.
Lifting certificate with weight details shall be provided prior to applying the work
permit.
Panels shall have an engraved name plate of laminated plastic or SS (White
background and Black text) tag plates shall be provided by manufacture. A
Ensure that panel general arrangements drawing are available.
7.1.2 Field Panels and JBs
All material received at site shall be inspected, handled and stored upon receipt in
accordance with project requirements.
Support should be installed as per approved installation drawings.
Support should be right with proper alignment and dimension.
Junction boxes shall be shifted as per the site installation requirements on daily
basis.
Field Panels/Junction Boxes should be correctly installed as per the approved project
drawings, specifications and vendor instructions.
Nut-bolts and washers used for the rigidity for the support and junction boxes must
be as per installation details and vendor instructions.
Installed junction boxes / panels shall have an engraved name plate of laminated
plastic (White background and Black text tag plates shall be provided by ABB) or as
per project requirements,
Alll terminals in junction boxes and local panels shall have facilities to protect them
from accidental damages.
All the cable shall be provided with brass and nickel plated cable glands located at
the bottom of the junction boxes and local panels for glanding purpose.
Spare entries for future purpose at the bottom of the junction boxes / local panels
shall be provided by certified blind plugs.
For the termination inside the junction boxes / panels are proper crimping and
ferrules for cable shall be provided.
All junction boxes / panels shall have the internal earth bus-bar should be connected
to instrument earth.
Installation of Control panels.
Make sure that no loose - shipped items are mounted on the equipments until it has
been moved to the final inspection area.
Whether proof wooden packing will be removed before to install on the base frame.‘Sabsarvadior Do
SAIH NIHAYDA CONDENSATE — | so Fev
STABILIZATION PLANT (SNCP) | eso oe
TWETHOD STATEMENT FOR | poo pon no how —
INSTALLATION OF INSTRUMENT Sheet:
'PANELS & JUNCTION BOXES.
sne-6o.01e100- | gy 19
16070-00002
Secure all cabinets doors closed.
Make sure that the eye bolts are properly fitted /secured on the cabinet tops, after
unpacking of the cabinets do not remove the polyethylene packs covering the
panels.
Use slings of suitable capacity to lift the control panels considering safety of the
equipment / personnel.
Use “Boom Truck” or a crane to load and fix the equipment so as not to fall during
the movement of the vehicle.
Unload it gently on hydraulic manual lift tro!ley which shall be supported by qualified
rigger.
Move the hydraulic manual lift trolley gently by holding the sides of the panels and
after reaching the destination, release the hydraulic system taking utmost are so
that the panels rest on the floor safely without any shock.
‘After transporting the panels to the location as per the drawing, remove the
polyethylene pack carefully ensuring no scratches on the body and install as per
approved drawings.
To ensure base plate, floor fixing are fabricated with proper level / location in
accordance with the relevant drawing. Cable sleeves and ducts shall be inspected to
ensure correct line and location. Test report to be documented for fabricated floor
level and base plate prior to shifting of control panels.
To ensure that Panel alignment and level are completed before fully tighten of the
bolts.
Where panel instruments are supplied loose, shall be identified, checked against
their data sheet or Bill of Material and installed as per the detailed layout drawing.
The installation shall be checked to ensure the fixing is secure and their vertical and
horizontal alignment is correct.
The Control panel shall be inspected to ensure all identifying labels and tags are
installed in accordance with the schedule and layout drawings. Loose supplied items/
Instrument shall be inspected to ensure all identifying labels & tags are installed in
accordance to the schedule & layout drawings.
Interconnection wiring shail be done as per AFC Drawing / Vendor instruction
Earthing of the control panel shall be checked to ensure it is as per the detailed
panel earthing drawing and installed in accordance with AFC drawings.
Panel doors and detachable covers shall be checked to ensure proper earthing
closure and sealing.
‘As the work progress the Instrument Foreman / Supervisor along with the QC.
Inspector will monitor the work and record it on the said forms as per the QCP.‘Supronaser De
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Sar | FAD INSTALLATION OF INSTRUMENT wen. | OT eae
1N-6070-00002
8.0
9.0
ion of Instrument Field Panels and Junction Boxes.
‘+ Support fabrication and installation according to Project drawing and specification.
+ Field mounted local panels and J8 grounding shall be through external bolts or
internal terminals.
‘+ Field mounded local panels and JBs inspection shalll be recorded as per approve QCP.
+ Local panels shall be installed as defined in the installation drawing and be aligned
horizontally by plumb and level.
+ The transporting and handling of panels shall always be with the correct tool and
equipment with full protection provided for the panel finish.
EARTHING AND BONDING:
Earth resistance of earth pit and grid shall be check to ensure resistance value meets the
project specification
+ Equipment is earthed and bonded in accordance with earthing layout drawings and
standard drawings.
+ All equipments and structural supports shall be earthed and bonded in accordance with
the approved earthing drawing specification.
+ Earth connection shall be checked for correct tightening and resistance value. A
HSE:
PTW system shall be followed as per the field category of the task / activity.
+ Project approved HEMP to be followed prior to the execute activity.
+ Dynamic / Task Risk Assessment to be made / generated accordingly and it shall be
disseminated to the work force.
+ All equipment shall be identified, inspected before it goes to site. Equipment is to be
inspected daily before operations begin.
* Appropriate approved safe system of panel boards shifting to be followed,
+ All lifting equipments, tools/tackles used for the work should have valid third party
certification, should be inspected before use and ensure color coding.
© Equipment & instrument being used for installation shall be formally inspected and tested
with available records. A
* Safe use of specific equipment must be explained to the operator.
+ Competent crane operator, riggers shall be engaged for the job.
+ Hazard of shifting of panels shall be indentified and develop a safe method to shift the
panels.‘Suseonctor Do
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SNG-09-819100-
1n-6070-00002 | oe
10.0
* The lifting area should be barricaded with sign boards to prevent unauthorized entry.
‘+ Proper care shall be taken during handling the equipment and manufacturer instruction
should be followed.
+ All test equipments for use on the site shall be identified with their valid test certificates.
‘+ While working at height safety belt shall be used.
+ The scaffolding shail be of adequate type erected by trained scaffolders, inspected and
tagged by competent person
+ All personnel must use mandatory & job specific Personnel Protective Equipments (PPE)
according to the activity.
‘+ Tool Box meeting shall be held daily, prior to start of the work,
+ The contractor to prepare specific HEMP and explain to all working crew (especially hand
& finger injury).
Good housekeeping shall be maintained duration work.
RECORDS:
The inspection and testing of construction will be recorded in the relevant check sheets
according to quality control plan. The changes in the construction will be reflected in the
latest construction drawing by red mark-up.
* Construction Sheet- Junction Box Installation Acceptance 1-016A
* Construction Sheet- Panel/cabinets/console Installation Acceptance. T-018A
* Constructions Sheet- Local control panel Installation Acceptance. [-017A
+ Constructions Sheet- Instrument earth system Installation Acceptance. T-021A
+ Constructions Sheet- Analyzer conditioning system Installation Acceptance I-022A
* Constructions Sheet- Analyzer Installation Acceptance 1-023| ABB | acer arms
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serreauinen [No] 4CONSTRUCTION CHECK SHEET
a Vp. INSTRUMENTS
I-016A
pw Junction Box sae
Va Dy Installation Acceptance REV4
PROJECT PROJECT WHS
DuecuPriON ‘SUB-SYSTEM No.
[rac pescmenion ‘TAGNo.
MANUFACTURER "MODEL Ne 1
SERIAL No. EQN. No
IP RATING PERS No.
Wem Description of check Result
Junction Box supplied, complies with Data Shet
“Junction Hox corel installed Dolied and fastened as per Project Drawings
Exterior, Punt Work and Cover undamaged and Tterior clean
Cover Seals undamaged and Unused Cable tries plugged cowestly
‘Nameplate and Tagging oreo as per Project Drawings
“Terminals undamaged, installed and numbered corecty as per Project Drawings
Earth Sts, Bah Bars and Connection installed correctly as pr Project Drawings
Feld / Muli-Core Cables isaied, clamped, terminated and marked corecty as per Project Drawings
1B Tnieral Wiring earth and continuity checks completed and certiied(-O06A/7A)
Power Sand Non LS. Cable and Toxinatons comely segregated as per Project Specifications
Foundation Fieldbus Terminator (where applicable) ied and rated corey as pe Project Drawings
‘Eacosure IP EX ratings comect and suitable fr locaton -
‘Check and Record Ean Bar resistance (Local Earth 2
“As Built drawings erect
REMARKS 7 OBSERVATIONS:
com,
[APPROVED HY CONTRACTOR
aD BY PDO
NAME, NAME, NAME,
COMPANY ‘company, REE. IND.
SIGN & DATE SIGN & DATE SIGN & DATE
DEP 621008.11-GENCONSTRUCTION CHECK SHEET
A INSTRUMENTS
ae Local Control Panel
Installation Acceptance
LO17A
Sheet 1 of 1
REVG
PROJECT
DESCRIPTION
PROJECT WBS No.
‘SUB-SYSTEM.
DESCRIPTION
SUBSYSTEM No.
"TAG DESCRIPTION
MANUFACTURER (MODEL No.
SERIAL Ne, 'REQN. No.
BP RATING PERS.
tem Description of check
Result
Panel supplied, complies with Data Sheet
‘Panel comectly installed, bolted and lastened as per Project Drawings
Exterior, Pent Work and Cover/Door undamaged and Entror clean
Cover Door Seals undamaged and Unused Cable Enues plugged correctly
‘Nameplates and Tagging crret as per Project Drawings
Al instruments comedy installed a per Project Drawings
“Terminals undamaged nataled and numbered covrecty as pee Project Drawings
arth Swaps, Earth Bars and Connections installed coresly as per Projet Drawings
18 Internal Wiring eanh and continuity checks completed and cried (L-006A /7A)
| tncernal Wiring / Cables installed, clamped, terminated and marked comely as per Project Dravings
‘Cables earth and continuity checks completed and verified (L006A)
Power, IS. and Non LS, Cables and Teemintions corooly segregated a pr Project Specifications
“Tubing! Piping “Hookup” cowrectly installed, tested and certified (-008A /94 7 104)
Fire, Gas or Smoke Detection Equipment (F applicable) installed as per Project Drawings |
Heater / Air Conditioning / Pressurisation installed comely as per Projet Drawings
Enclosure 1P/EX ratings correct and suitable for location,
th
‘Check and Record Earth Bar esiance to Local
“As Bul drawings eoroot
| REMAREST OUSTRVATIONS:
‘COMPLETED BY CONTRACTOR "APPROVED RY CONTRACTOR ‘ACCEPTED BY PDO
NAMIE NAME
COMPANY comPANY REEIND.
SIGN & DATE, SIGN & DATE SIGN & DATE
eR,
DEP 62.1008.11-GEN,CONSTRUCTION CHECK SHEET.
1-018A
INSTRUMENTS
Sheet 1 of 1
Panel/Cabinet/Console eva
Installation Acceptance
PROIECT PROIECT WOS‘Ne ‘|
Descrirrion ‘SUB-SYSTEM No.
[fcoescurion TAGNo.
[Manuractoren ~ [MODE No.
SERIAL No. REN. No
TPRATING PEFSNo.
Tem Description of check Result
1. | Panel/ Cabinet Console supplied, complies with Data Sheet
2,__| Pancl/ Cabinet / Console corey installed, bolted and fastened ws per Project Drawings
‘Base Dimensions, Location, Cable Trenches and Cable Enis as pr Project Drawings
“| Eateror Paint Work and Door Locks undamaged ad Intevor clean
,___ | Nameplates and Tagging corect as per Project Drawings
| Dus Seas undamaged nd Unused Gland Enis plugged conectly
| ant Sips, Earth Bars and Connections ntl comely a per Project Drawings
3, | Internal Cards, Modules and Texinals undamaged & installed comets per Project Drawings
9, | System Cables installed, supported and tagged comely as pe Project Drawings
10, _| Coding pn on Pig Socket coment
11, _| Data Highway correctly installed and supported
T2.__| tena Wiring / Cables iasalled lamped iat and tagged corel a per Prost Drawings
13, _] MatizCove Cables cart nd continuity checks completed and cei 0-007A)
14, _ | Power Supply and Associated Cables installed as per Project Drawings -
15.) Power 1S and Non LS, Cables and Terminations comely segreqited ss per Project Speciientins |
16, _] Foundation Fieldbus Terminator (wher applicable) fed and ated corey as per Projet Drawings
11, _| Heater Air Condioning Unit installed comely s per Project Drawings
18, _| Tubing/ Piping “Hook op’ corey installed, ested and ened
19, _| Five, Gas or Smoke Detection Bquipment (if applicable) insalled as pr Projet Drawings
20, _ | BrclosureIPIEX ratings corect and stable fo oeaton|
21, _ | °As Bull drawings corect - |
TRENIARRS 7 ONSERVATIONS:
| eourcrtennr commmcton | arewownnnv conmacron ‘AccEPTTD BY PDO
NAME NAME NAN
‘COMPANY comaNy REE. IND,
SIGN & DATE, SIGN & DATE SIGN & DATE
REE, DEP 62.1008.11-GEN.CONSTRUCTION CHECK SHEET
FY Ye. INSTRUMENTS
1-021A
poy Sheet 1 of 1
% a Instrument Earth System Reva
Installation Acceptance
basemen PROJECT WSN,
Descnirrion SUBSYSTEN Na
"TAG DESCRIPTION TAG Ne,
[AREA DESCRIPTION an
tem ‘Description of check Result
1, _[ All Metal Enclosures corey earthed
Z__| Cables Sheds / Serens comely earthed
3, _| Safty Bares, Converters, et, conealy eared
| Dati 16S ah corect
5. _| Isolation ofthe three Earhing Systems from another comect
6. | Earth Cable to central pont corest
7,___| Test each Earth system using low volage tester and veord resus (Tdenity/ Resi Lsues)
| After ening: Tivee Barhing Systems connected ogee comely
9.__| Metal Tay/ Trunking / Conduit corel earthed
10, _ | Computer Foorconectly earthed
TT, _| Frames Suppors For Consoles / Cabinets comely earthed
[i2._[ as Bute drawings comeet
5
i
requirements.
8 Alldocumente evidence requiced to support this statement has been completed and accepted.
REMARKS / OBSERVATIONS:
‘COMPLETED BY CONTRACTOR [APPROVED BY CONTRACTOR ‘ACCEPTED BY PDO
NAME NAME aM
COMPANY ‘COMPANY, RE. AND.
SIGN & DATE, SIGN & DATE, SIGN & DATE
REP, DEW 62.10.08.11-GENCONSTRUCTION CHECK SHEET
1-022A
INSTRUMENTS
Sheet 1 of 1
Analyser Conditioning System
Installation Acceptance Reva
re oN PROJECT WBS Ne.
aeSurniow SUB-SYSTEM No,
TAGDISCRIPTION TAGN®
MANUFACTURER MODEL Ne.
SERIAL EQN. No
PERS
Description of check.
‘Equipment supplied complies with Data Sheets
Pre conditioning System corel installed and supported as per Project Drawings
Conditioning System comet installed and supported as per Project Drawings
‘All Relief Valve settings are in accordance with Specifications and have been certified
Rotameters are vertical
Toolating Valves are installed, tagged and functioning corey a per Projeet Specification
‘Drain and Vent System connections (if applicable) are correctly installed as per Project Drawings
8, | Manometers and Thermometers are installed and sealed comectly
9, _| ulated Enclosure (or systems provided with heating) is ited properly andi lockable
10, _ | Laboratory Sample Connections (if applicable) ae properly isolated and identified
11, | Pump installation and Power Supply (i aplicale) ae in accordance with Project Speci
12, _| Cable Trenches and Cable Bases as per Projet Drawings
13, _ | Cable Tray, Conduit and Trunking installed and supported coretly as per Project Drawings
14, | Cables instal |, landed and terminated as per Project Drawings
——
1s, _ | Cable continuity and mcgge tests completed and cot
rectly
16, _ | Spare Cable Provessenres plugged
17. _ | Instrument Barthed in accordance with Project Specifications
18. _ | Power, L5, and Non LS. Cables corellysegroted as per Project Specifications
19, _ | Nameplates and Tagging cont as per Project Drawings
20, _ | *As Built drawings corect
REMARKS/ ORSERVATION
COMPLE
DY CONTRACTOR ‘APPROVED BY CONTRACTOR [ACCEPTED BY PDO
NAME __[ Name: NAME
COMPANY ‘COMPANY REF. IND.
‘SIGN & DATE, SIGN & DATE: SIGN & DATE
er.ai CONSTRUCTION CHECK SHEET
a
INSTRUMENTS
1-023A
LA_A]] Sheet 1 of 1
Van Analyser woe
Installation Acceptance
PROJECT rw
PROWUCT romer wasn |
SUBSYSTEM
[fexcuirnow SUR SYSTEM.
TAG DESCRIPTION TAG.
[MANUFACTURER ‘MODEL N
SERIAL No. EQN. No-
PES No.
Tie Deserpton of check Result
Equipment supplied complies with Data Sheets
2. | Bguipment and Accessories correctly installed and supported as per Project Drawings
3, __ | instrument Calibrations completed and certified
“E__| instruments and Controls are accesible and clear of obstuction
| Sample Probes & Lines are corey installed and supported as per Project drawings
| All necessary Uilities ar installed correctly ax per Project Drawings
}7. | Tubing Piping “Hook-up” (iF aplieable) comet installed, tested and certified
| Cable Trenches and Cable Enis as per Project Drawings
9. | Cable Tray, Conduit and Trunking installed and supported corectly as per Peojest Drawings _|
To. | Cables installed, clamped tagged, glanded and veined as per Projest Drawings
11. _ | Cable continuity and megger tests competed and cetied
12, _ | Spare Cable / Process enuies plugged comectly -
7, _)Insirament Earthed in accordance with Project Specifications
[1a. _ | Power. and Non 1S, Cables eomocty segregated as pe Project Spevifiatons
Fire, Gos ot Smoke Detection Equipment (if aplicable) installed as per Projet Drawings
‘Nameplates and Ta
“As Bull? drawings eomest
‘COMPLETED BY CONTRACTOR [APPROVED BY CONTRACTOR
NAME [ NAME NAME,
company | comrany Cone
| SIGN & pare SIGN & DATE SIGN & DATE,
RUE, DEP 62.10.08.11-GEN,