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Project : Zohr Development Project - Phase I Contract No. : 032195

Owner : Eni - Petrobel Document No. : C-PTJ-PTB-T-0168

Contractor : The Petroleum Projects and Technical Consultations (Petrojet) Date : 14/06/2017

Transmittal
From PETROJET To Petrobcl
Position Chairman Assistant for Zohr Project Position
Name U: ng. : Kacfry Osman Attn.

Subject :I Method Statement of Static Equipment

• Approval • Review and Comment D Information

Issue for
D Others
Submittal Description

No. Of
S.N Description Rev. Remarks
Copies
Method Statement of Static Equipment
0 1
(Doc. No.: PTJ-ZH-MS-0012)

6 1I
7
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~

9 l

10
-
Remarks:

Prepared By:

Position DC
Name: Mr. Ibrahim Elhaddad
Signature:
Date: 14/06/2017
Action bv Petrobel

0Approved D Revised & Res ubmit 0 Rej ected

D Approved with comments

Position Name Signature Date

Page 1 of 1
 Project ZOHR Onshore Development Project

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METHOD STATEMENT OF
STATIC EQUIPMENT 0 13/06/2017 PAGE 1OF18
The Petroleum Projects and

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METHOD STATEMENT OF STATIC EQUIPMENT

Doc. No.: PTJ-ZH-MS-0012

Prepared Approved CLIENT

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Job
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Document description I Rev. I Date
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The Petroleum Projects and

METHOD STATEMENT OF
Port soid I STATIC EQUIPMENT I a I 13/06/20171 PAGE20F18 I Technical Consultations Co.

Table of Contents

1. Scope ................................................................................ . 3

2. Purpose ....................... . 3

3. Reference ........................................................... . 3

4. Responsibility . . . .. . . . . .. . . . . .. . . . .. . .. .. . .. . . .. .. . . . . . . . ....................... · 3

5. Procedure ........................................................................... . 5-13

6. Internals .................................................................................. 13

7. Documentation ........................................ . 14

8. Safety Requirement.................... . .. . .. . . . .. . . .. . . . . . . . .. . . . .. . . . . .. . . . . .. .. . 14

9. Attachments . .. .. . . .. . . . .. . .. . .. . . . . . .. . . . .. . . .. . . . .. . . .. ... . . . . . .. . . .. . . . . .. . . . . .. . . . 15
 Project
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ZOHR Onshore Development Project
PETROBEL /ENI
Document description Rev. Date Page
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··-·· PETROJET

The Petroleum Projects and

''.';!~.·~, METHOO STATEMENT OF

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Port said STATIC EQUIPMENT 0 13/06/2017 I PAGE 3OF18 Technical Consultations Co.

1. Scope

This Method Statement applies to the project ZOHR ONSHOR Project installation and alignment of static
equipment in compliance with project specification. This also covers foundation check, fixing of shims,
bolting inspection. Installation of equipment shall also include preservation of installed equipment from
storage to commissioning stage.

2. Purpose

The purpose of this method statement is to set the minimum requirements for the installation and alignment
of static equipment to meet the specific specification and requirements of the project.

3. Reference

• SATIP-D-001-01- Pressure Vessel Installation

• SATIP-E-004-0-1- Heat Exchanger Installation -shell and tube.
• SATIP-F-001-01- Fire heater I package Equipment Field Installation.
• SAEP-20- Equipment inspection schedule.
• PIP- VEFV 1100- Vessel/S & T Heat Exchanger Standard details.
• PIP-REIE 686- Recommended Practices for Machinery Installation.
• PIP- RESE 001- Specification for General Purpose Skid Mounted Equipment.

4. Responsibility

4.1 Construction Manager

• Responsible for implementing procedures of this method statement through different stages of the work
process.

4.2 Construction Supervisor

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METHOD STATEMENT OF
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The Petroleum Projects and

Technical Consultations Co.

• Responsible for day to day execution of work, implementing PTW system, work method statement, Job
Safety Analysis and all applicable safety rules.
• To ensure that all required manpower are available and materials to be used are prepared. Proper tools
and equipment shall be ensured and available for use.

4.3 Site HSE Manager

Responsible for all safety matters and safety monitoring.

• Ensure that permit to work and risk assessments prepared by our site HSE and construction engineers
are carried out where necessary and work programmed to ensure compliance with COMPANY HSE policy
and procedures reference to the COMPANY specifications.
• Tool box meeting for whom they are responsible, with regard to responsibilities and the necessary
information, instruction and training is provided to subcontractors and the necessary information provided
to visitors.
• All practical steps are taken to include a safe working environment including the reduction of noise and
sound levels to an acceptable degree.

4.4 Site HSE Supervisor

• Follow up and revise this HSE plan at suitable intervals

• Participate in major HSE studies and audits
• Maintain a systematic log of non-conformances and Corrective actions related to HSE audits.
• Preparing and issuing HSE deliverables.
• Reviewing/auditing the work of other disciplines to ensure that HSE requirements are addressed and
documenting these reviews. Actions arising will be tracked via the established Tracking System.

4.5 Quality Control Supervisor

Responsible for monitoring all QC aspects Relevant to construction process in various Stages. Ensures
all required for inspection are approved and instruments used have valid calibration certificates, Method
statements are available at Construction site.

4.6 Quality Control Inspector

• Ensures that the Inspection test plan is followed and Intervene in case of any violation. Performs Inspection
to the different activities to ensure its compliance with standard requirements.
• Assure that all relevant quality documents are properly prepared and correct for submitting to
SECUCLIENT when the works are ready for final Inspection.
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4. 7 Construction Engineer

• To keep records of production and also oversee the procedure is implemented.

• To raise RFI notifying readiness for QC inspection to all Parties via QC department.

4.8 Rigging Supervisor

To ensure that rigging and heavy lift activities are performed rigger in a safe and efficient manner. Rigging
is engineered, performed & inspected to satisfy the Customer's requirement in accordance with the issued
Project Drawings and Specifications.

5. Procedure

5.1 GENERAL REQUIREMENTS

5.1.1 Work Execution

i) Where the permission and/or inspection by the authorities concerned are required, Contractor shall
perform all cares and preparations for such permission and/or inspection.

ii) When required by laws or regulations, qualified persons shall do the works with license required.

5.1.2 Special Crew

i) During heavy equipment installation, a special crew shall be organized.

ii) The crew shall comprise a rigging supervisor, signal/flag man, hoist operator, crane operator,
rigger, safety supervisor, etc.

ii) The function of each individual of the crew shall be clearly defined.

iii) Job safety issue to be explained to crew and only trained crew is allowed to work.

5.1.3 Precaution for Installation

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i) Where equipment is roped for lifting, pads shall be applied on the corners, finished surfaces, etc. of the
equipment for preventing damage resulting from wire ropes.

ii) The operators of the crane shall be prohibited from leaving their post under loading.

iii) Construction equipment, machines, tools and measuring instruments to be used in the works shall be
thoroughly inspected, prior to use.

iv) Where the use of fire is prohibited, flame-free tools and devices shall be prepared.

v) When lifting up or down the equipment by the use of a sling, due care shall be taken to its location and
center of gravity in order to avoid unbalancing of the equipment.

vi) Where the crane is used in hauling, drawing-in, etc., the stretching route of wire ropes shall be determined
after careful examination and shall be distinctly marked in order to avoid injuries to the workmen.

5.14 REQUIRED TOOLS

Calibration period of any device shall not Exceed SIX (6) Months.

• Appropriate Crane for Specified Lift.

• Slings/ Non Metallic Ropes/soft tag lines.
• Shackles/Beam Clamps/Blocks/Wrenches.
• Spreader or frame/Chain Hoist.
• Welding Machine for Tacking of Liners/wedges.
• Wrenches/leveling Tools/Feelers GaugeNernier Caliper's and calibrated Dial Gauges.
• Calibrated THEODOLITE.
• Grouting Tools and equipment/Survey Equipment.
• Equipment shall be maintained and checked prior to use for safe work assurance. Equipment shall be
approved and certified.

5.2 Material storage and handling

5.2.1 Unpacking
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i) Upon arrival of the equipment in the field, the number and external appearance of packing's shall be
checked against the packing list.

ii) After unpacking, the specification of the equipment such as dimensions and weight, quantity shall be
checked against the packing list, purchase order and/or invoice. Whether or not there is anything
defective in appearance such as rust, flaw or distortion shall also be checked.

iii) Centering markings, orientation markings, markings of center of gravity and sling point markings, if used,
shall be checked according to the drawings.

5.2.2 Safekeeping

i) The safekeeping shall refer to the storage instructions and requirement preservation and storage
documents of each individual item. Equipment preservation shall be maintained until the time when it will
be opened for piping connection or internal parts installation.

iv) The place and method of safekeeping until the installation shall be determined by taking the following
items into consideration.

• Types of the equipment, parts accessories and spare parts, if any.

• Property of material used and finished surface.
• Period of storing (temporary placing) and weather conditions.
• Environmental condition, such as whether or not rain, sand storm and corrosive gas in this area.

iii) Cleaning, anti-corrosive treatment or sealing, if necessary, shall be made. Where inspection is required
for the insides of the equipment such as vessels, manhole covers shall be opened after taking necessary
measures such as confirmation of content, air supply and ventilation, for the prevention of danger.

5.3 LIFTING METHOD

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5.3.1

The following items shall be considered for the determination of a lifting method and the erection of lifting
equipment.

i) Space of installing location.

ii) Space and ground condition of erection point of the lifting equipment.

iii) Buildings, stFUctures, equipment, etc. existing nearby, and whether or not those can be used without
damaging or overstressing the same.

vi) Buried objects such as underground piping and cables, and open trenches existing in the place where
the lifting equipment is erected.

v) Operating conditions of existing plants facilities and equipment.

vi) Condition of roads as to whether or not they can be used.

vii) Existing lifting equipment, and whether or not it can be utilized.

viii) Space of dismantling or taking out of the lifting equipment.

ix) Performance and maintenance condition of the lifting equipment.

5.3.2

For the heavy weight equipment, the installation manual including specification of the lifting· equipment,
routing and method for taking-in (hauling) of the equipment from temporary place, the direction and
sequence of installation, etc. shall be evaluated before starting the works.
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5.3.3

The Rigging/Lifting plan shall be approved before starting the works.

5.4 PREPARATION FOR INSTALLATION

5.4.1 Foundation

i) Equipment foundation shall be checked for the following items:

• Period of maturing of foundation concrete

1- Foundation curing period
2- Foundation handover documents

3- Elevation and center line markings

4- anchor bolts are thoroughly cleaned

• Dimensions
• Position (center marking) and height (level marking)
• Disorders in the foundation concrete, such as honeycombing.
• No of bolts, bolt circle diameter, size of anchor bolts, and damage or rust of threaded parts.
• Dimension and cleanness of anchor boxes, if anchor box type is applied

ii) Treatment for the foundation surface preparation, such as chipping and fitting liner plate, shall be carried
out as follows;
• Foreign matters are to be completely removed and surface shall be thoroughly cleaned.
• Portions which come in contact with liners are chipped and fitted shall be fully contacted with liner plate.
• Surface, if grouting is to be done after centering, is chipped and then cleaned completely with
compressed air, etc. so as to give good adherence and avoid cracking, peeling-off, etc. of grouting
mortar.
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5.4.2 Liners

i) Liners to be used shall be, in general, made of carbon steel (hot dip galvanized should be used). In case
of corrosive environment, liners made of anti-corrosive material shall be used.

ii) Liners shall be so arranged that the load of the equipment is uniformly and exactly distributed to the
foundation within allowable load. In general, the liners shall be placed as near as possible to both side of
each anchor bolt. Where distance between the anchor bolts is more than 800mm, additional liners shall
be set in between them to prevent the base plate from deformation.

iii) Oil and other foreign matters stuck on surface of liners shall be entirely removed.

5.4.3 Equipment

i) Prior to the installation, the following checks of the equipment shall be made:

• Appearance of equipment, such as absence of damage and rust on other side base.
• The number and appearance of auxiliaries
• Size of the anchor bolts, and absence of damage and rust on the threaded parts, if anchor box type is
applied.
• Orientation marking
• Marking center of gravity
• Sling points

ii) Oil and other foreign matters stuck on the surfaces of legs, bed, frame, etc. which will contact to
grouting mortar shall be entirely removed.

5.5 . INSTALLATION

1. Before installation, all locations, elevations and orientations of the equipment foundations and support
structures shall be checked and verified in accordance with installation drawings and specifications.
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2. Datum marks for checking verticality & horizontally shall be established while the vessels in the
horizontal position.

3. All equipment concrete foundations and support structures shall be respectively released by QC Civil
and Structural Inspectors prior to the erection of equipment. This release is controlled and documented
in the applicable civil and steel structure procedures.

4. For critical and large diameter equipment's an anchor bolt template shall be considered prior to
concreting of foundation and placement of bolts on the foundations. It is also necessary for the
equipment inspector to ensure before the concrete is poured that the required tolerances (including
manufacturer tolerances) are adhered to.

5. Confirm anchor bolts are plumb, and projection is as per drawing requirements. Reference lines of
levels and/or axis shall be marked I identified on the foundations. Before installation of
equipment, chipping shall be done· on all the required surfaces of the foundations in preparation for
grouting and there shall be no remains of curing agents or other substances which hamper grout cure.
Ensure that using chipping hammer with a chisel bit shall carry out concrete chipping. Heavy tool such
as jackhammer must not be used as it could damage the structural integrity of the foundation.

Upon completion of the surface chipping, the foundation shall be thoroughly clean, air blown free from
dust by free oil dry air.

Provide protective sheeting (such as clean polyethylene) to cover the prepared surfaces when work is
not in progress.

6. Shim plates shall be installed preferably by the equipment group or certainly with consultation
with them and as per the required lay-out and on either side of each anchor bolt. The number of shim
plates, size and lay out is decided based upon the size and weight of the equipment load the shim plates
are required to carry. It is essential that shim plates be fixed to the foundation surface using the same
grout material that the foundation will be eventually grouted with. It is recommended that the top of
elevation of the installed shim plate is 1-3 millimeters lower than the required value. This will facilitate
the alignment process to a great degree .

. 7. The elevation difference between top of concrete and top of shim plate shall be (1" - 2") (25-50mm) of
grout under the base plate or more if it is so required by project drawings. In the case of epoxy grouting,
the contact areas of anchor bolts shall be wrapped with waterproof tape. It must be ensured that shim
plate grout is cured prior to loading the foundation.
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8. The bottom of the base plate shall be cleaned by suitable means to remove mud, oil or grease prior to
installation. It shall also be ensured that the mating surface of the shim plate is rust free and free of any
grease or oil.

9. Once it is confirmed that the foundation as a whole is ready to receive the equipment, it shall be
installed in accordance with manufacturer's installation manual, approved method statement and in
accordance with project specifications as applicable. The following shall be noted:

• The height of the bottom surface of the equipment or base plate is within the specified project elevation
and center line tolerances at a minimum of four locations that are diametrically opposite.
• Liners, wedges and jack screws are standard erection aids for use during base plate/skid leveling
operations and shall be prepared for use. Final choice depends upon site requirements and vendor
installation manual.
• Recommended sizes for liners and wedges based on general industrial practices are shown below. These
dimensions may be modified as necessary for each application.

Item Len Wid Thickness Tap

gth th er

Liner 50- 50- 1,2,3,4,5,6,9, 1 -

s 100 75 2,16 & 19 mm
mm mm

Wedg 50- 50- 6,9,12,19 &25 4-5

es 100 75 mm
mm

• Sliding plates greased with graphite or Teflon plates shall be installed as per drawing
requirements.
• When equipment dressed is to be installed; the dressed attachments shall be fixed securely.
Insulated equipment shall be checked prior to erection to confirm the center marks required for alignment
remain visible. All safety precautions involved with lifting of equipment's, heavy lift shall be given due
consideration. Attention shall be paid to rough weather and high winds.
• During lifting and lowering, special care shall be taken not to damage the anchor bolts and their threads.
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18

• After the alignment is finished, the nuts shall be firmly tightened onto all anchor bolts. All remaining
wedges and/or liners shall be tack welded to each other and any excess shall be cut off.
• Nozzles/openings in equipment shall be protected by temporary protective covers. Threaded nozzle
connections shall be protected with threaded plugs. However, telltale holes in reinforcing pads shall be
protected with wooden plugs or packed with rust preventative grease such as Denso paste. Covers shall
be securely attached by a minimum of four bolts equally spaced. For ocean shipment, flanged
connections shall also be covered with heavy-duty plastic bags securely taped to the nozzles. Welds
attaching manways, nozzles and their reinforcement pads and other structural attachments to pressure
components shall not be closer than 20 mm (toe-to-toe) from any welds under stresses due to pressure.
It is the responsibility of the manufacturer to ensure that a nozzle or an attachment weld of a reinforcing
pad or a structural component will either intersect or encroach on a butt weld the following shall be
performed:

1- If the nozzle is installed onto or encroaching on a butt weld in the vessel wall:
a) Radiograph of the butt weld in the vessel wall for a length equal to three times the diameter of the
opening with the center of the opening at mid-length.

b) Where a reinforcing pad is required, the butt weld shall be ground flush and radiographed, prior to the
installation of the reinforcing pad.

2- Where an attachment weld of a reinforcing pad or a structural component will either intersect or
encroach on a butt-weld in the vessel wall:

a) The butt weld shall be radiographed for a length equal to the projection of the intersecting or
encroaching segment of the attachment weld plus a minimum of 50 mm on either side.

b) Perform magnetic particle examination on the vessel side of the joint attaching the reinforcing pad or
structural component.

• All ladders, access platforms and supporting structures shall be assembled on site prior to
mechanical installation of internal equipment
• Installation of internal components in vessels other than columns shall be carried out as per applicable
project drawings and vendor installation guidelines.
• Filling of catalyst, filtering and other mediums shall be in accordance with applicable project drawings
and vendor manuals .
•
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• Installation of equipment internals is discussed in clause 6.4 separately.

• Installation of pre-assembled packaged skids shall be similar to that of individual vessels described
here. The individual .equipments on the packaged skid shall be checked for correctness of
installation in accordance with the requirements of this procedure, vendor manual and project
specifications. The pre-installed rotating equipments shall be checked for coupling alignment applying in
principle the requirements of the QCP for static equipments in consonance with vendor guidelines. It
may however not be always possible to carry out flange parallelism and offset checks prior to carrying
out final coupling alignment.

• Installation of packaged skids that require assembly of individual equipments on site shall be similar to
that of individual vessels and static equipments described here and in the procedure for static
equipment. The individual equipment's on the packaged skid shall be checked for correctness of
installation in accordance with the requirements of this procedure, vendor manual and project
specifications. The static equipment's shall be installed and inspected according to the requirements of
the QCP for static equipments.
• Results of inspections carried out in accordance with applicable SATIP/QCP and including vendor
recommended tolerances shall be documented in respective inspection records.

5.6 Alignment

All equipments shall be aligned either plumb or level. Columns, stacks, towers and plate heat
exchangers shall be aligned plumb and vertical. Horizontal vessels/heat exchangers and packaged
skids shall be aligned and leveled.

5.7 Plumbing & Verticality

5. 7.1 The Equipment shall be inspected visually from two directions, 90 degrees apart with a transit. The
Surveyor shall sight the top, middle and bottom of the vessel shell to ascertain if it is plumb. Very tall
equipment's shall be checked for verticality early in the morning. Reference points shall primarily be
centerline datum markings of the vessel. A side profile reading may be may be taken in some cases.
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5.7.2 The Equipment shall not be out-of-plumb by more than 1.0 millimetres per one meter of height or a total
of 25 millimeters for the entire height OR ACCORDING VENDOR RECOMMENDATION , whichever is
less, unless otherwise specified in the project specification.

5.7.3 After the grouting has set, hardened and cured anchor bolts shall be checked and tightened fully. Bolt &
nut requirements shall be checked.
5. 7.4 Washer plates shall be welded as per drawing requirements.
5.7.5 QC inspector shall prepare the inspection record as per SATIP requirements. The survey report
shall be prepared and attested by the Surveyor followed by QC inspection.

5.8 Leveling·

Heat exchangers and similar other horizontal vessels shall be aligned and leveled as follows:

5.8.1 The equipment shall be aligned with a transit at four points according to the centerlines marked on the
equipment in the fabricator's shop. The equipment shall be leveled with a dumpy level or steel straight
edge and spirit leveling the directions AB or CD and AC or BD along the equipment centerlines as
shown below:

r X A 5

-f,.-,-j-B·-----r---[Jft· LEVELING
INSTRUMENT
l.'xc D J
I C
PLAN
Vl'EW X·X
/\
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5.8.2 "A" The maximum out-of-tolerance shall be as shown below, unless specified otherwise.

Point Tolerance Remarks

.

A and B or C 1 mm per 1
and D meter of length Unless specified
A and C or B 2 mm Max otherwise
and D

5.8.3 Certain types of vessels need to be installed with a gradient and the drawing or instruction shall be
carefully examined to understand and meet the requirement.

6 Internals

6.1 INSTALLATION OF INTERNALS

The internals including demisters, distributors, etc. shall be assembled in accordance with the relevant
drawings, specifications, or instructions provided by the manufacturers. Before start internal installation,
the inside of vessel shall be cleaned and inspected by COMPANY Inspector.

6.2 CLEANING OF EQUIPMENT INTERNALS

All the equipment (vessel and column) internals shall be checked and cleaned before final closing of man-
holes.
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7 Documentation

All inspection and testing documentation from first activity to last activity, such as receiving inspection,
anchor bolt inspection, padding etc, of each equipment work item shall be kept at QC department to trace
the history of each equipment item.

8 Safety Requirement

• All personnel involved in equipment installation and alignment works shall follow all safety procedures.

• Equipment installation and alignment works shall be undertaken in accordance with procedure for
Health, Safety and Environment plan.
• PPE such as hard hats, safety shoes, safety glass (goggles) hand gloves etc. Shall be worn by all
personnel and fall protection devices shall be used when needed as per safety procedures.

• Safety inspections I audit carried out on equipment shall be recorded and maintained.

• Access to working areas for unauthorized persons shall be restricted by barriers warning signs &
controlled close supervision.

• Contractor shall ensure that the working areas are clearly delineated and barricaded, Access to the
working areas by heavy equipment shall be provided in compliance with approved plans, permits and
safety requirement to perform the work.

• Scaffolding Works shall be in accordance with Luberef Safety Procedure.

• Contractor shall maintain good housekeeping standard at all times.

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9 Attachments

JSA for Static Equipment Installation

Padding plan vessel/package

Padding plan reactor/column

Padding plan heat exchanger

Elevation of pad/foundation release

SAIC-D-2006

SAIC-D-2001

SAIC-D-2022

SAIC-G-2001

SATIP-D-001-01