Work Method Statement For Column Internal

Sensitivity: MZN Internal
ALMUZAIN
(AL MUZAIN GULF SAUDI CONTRACTING
COMPANY
Jubail Industrial City, Saudi
Work Method Statement
Work Method Statement for
ATMOSPHERIC COLUMN 011-C-0002
(Column Internal Replacement, Cleaning, and

Inspection Job)
Note: This Work method statement is the property of ALMUZAIN and shall not be duplicated,
copied or otherwise reproduced, without prior consent of General Manager
ISSUE NO: 01 REV NO: 0 PREPARED BY: REVIEWED BY: APPROVED BY:
ISSUE DATE: REV DATE: UDAY KHAPARE GURURAJ SATORP

(INDUSTRIAL SUPERVISOR) (PROJECT MANAGER)
DOC.NO.MZN-MED-WMS-041
Page 1 of 12
ALMUZAIN
COMPANY
Contents
1.0 Purpose
2.0 Scope of work
3.0 References & Procedures
4.0 Safety Precautions
5.0 Health safety & Environment Measures
5.1 Preparation
5.2 Lifting Equipment
5.3 During Site Execution
5.4 Safety Inspections
6.0 Responsibilities
7.0 Quality
8.0 Tools and Equipment to be used
9.0 Site Activities
9.1 Pre-Shutdown Activities
9.1.1 Jobs at Site
9.2 Shutdown Activities
9.2.1 Column Entry
9.2.2 Activities inside the column
9.3Post-shutdown activities
10.0 Housekeeping
Page 2 of 12
ALMUZAIN
COMPANY
1.0 Purpose
 The purpose of this work method statement is to describe in detail all required
measures taken to execute the Column jobs in SATORP.
 This document is applicable to all employees and sub-contractors working for
Columns Inspection and Modification carried out in SATORP.
2.0 Scope of work
SL Column Column Colum

Description Column Internal details Scope of work
No Number Dia. Height
5400/ 1. EL. to EL. – 1. Feed Pipe 09 NOS. (Nozzle A1(36”), 1. Replacement of tray no. #57 - #45
011-C-0002 ATMOSPHERIC 7800/ 2. Replacement of missing tray
1 COLUMN
60950MM A2(12”), A4(10”), A5(10”), A7(8”),
4800 A8(12”), A10(8”), A11(12”), A13(6”) valves, fasteners etc.
MM 2. Nos. of Trays #01 to #57 3. Tray #44-#01 tray manway
3. 03 Nos. Chimney Tray (CT tray #44, opening, cleaning and inspection
#30, #15) 4. Collector tray (01 no’s) and
4. 01 Nos. Collector tray above tray #06 Chimney tray (04 no’s) cleaning
5. Vapour Horn at nozzle (A1) & weir and inspection
plate 5. External/Internal Scaffolding
erection as applicable and
inspection recommendation
6. All Feed pipe cleaning and
inspection
7. Vapour horn cleaning and
inspection
8. Hydrojeting inside column shell
and tray (if required)
9. If any repair, based on inspection
recommendation (additional job
like tray straitening or welding)
3.0 References & Procedures
3.1 General Engineering Practices.

3.2 SATORP standards.
3.3 OEM Installation Manual/guidance
3.4 RFC Drawings.
4.0 Safety Precautions

4.1 JSA (Job Safety Analysis) should be prepared based on the
method of statement. Four basic stages in conducting a JSA are:
4.1.1 Selecting the job to be analyzed
4.1.2 Breaking the job down into a sequence of steps
4.1.3 Identifying potential hazards
4.1.4 Determining preventive measures to overcome these hazards
Page 3 of 12
ALMUZAIN
COMPANY
5.0 Health, Safety and Environment Measures

5.1 Preparation
Coordinate with SATORP Safety Department for access routes.
5.1.2 Ensure all workers involved in the hauling operation put on PPE all times.
5.1.3 Brief individual worker the roles and responsibilities of each.
5.1.4 Ensure transporters route is cleared of obstruction.
5.1.5 Work execution shall be monitored, witnessed, and supervised in
accordance SATORP specifications, requirements and HSE rules.
5.1.6 AL-MUZAIN employees shall be well informed especially concerning in-
plant working Conditions, recorded Daily Toolbox Meeting is required.
5.1.7 All activity shall be supervised by safety officer at site.
5.2 Lifting Equipment

Ensure safe work procedure for lifting operation is observed.
5.2.2 Ensure proper lifting method - with the correct equipment are used.
5.2.3 Ensure the equipment are firmly placed on the designated location before
releasing the hoisting hook.
5.3 During Site Execution

Ensure workers are distributed to each designated place.
5.3.2 Always ensure workers to be in proper gear where required.
5.3.3 Ensure all workers assigned are involved in its task.
5.3.4 Brief individual worker the roles and responsibilities before start work.
5.3.5 Ensure support systems are installed accordingly as required.
5.3.6 Ensure all tools to be used have been inspected and tag by Safety Dept.
5.3.7 Ensure work areas are clearly marked (Crane Radius area) to restrict
access to authorized personnel only.
5.3.8 Ensure that equipment to be used are properly tagged and checked.
5.3.9 Al Muzain to provide qualified welders, who are well versed on the job at
hand with the approved welding procedure (If required)
5.4 Safety Inspections
5.4.1 It shall be responsibility of the Supervisor to routinely inspect the physical

areas under their control. This inspection shall include determining if
Equipment, Rigging, supports, scaffolds, and ladders are appropriately
installed or use, and if the job site is cleaned up after the day’s work.
Page 4 of 12
ALMUZAIN
COMPANY
6.0 Responsibilities
6.1 The Site Engineer/Supervisor will be responsible to manage and direct project
construction activities and ensure efficient implementation of work in accordance with
the Project Specification and standards.
6.2 The QAQC Representative shall witness all activities and tests performed and ensure
that all works are carried out to client satisfaction.
6.3 Supervisor shall monitor the execution of the work.
6.4 Foreman shall lead the work force during the execution of the work.
7.0 Quality
7.1 All the Quality related documents / Procedures shall be submitted and get it approved
before proceeding of any work.
7.2 (If Required) Submission of weld map / location map identifying the welding works
(Obstruct Piping cutting & welding) shall be prepared by the QA/QC Engineer.
7.3 Submission of ITP (Inspection Test Plan) shall be prepared by the QA/QC Engineer.
7.4 The Quality department (QAQC representative) shall ensure that the alignment is
done to client satisfaction.
7.5 The required materials shall be checked before use.
7.6 All the calibrated inspection tools to be used.
7.7 AL-MUZAIN QC inspector & Third-party NDT technician shall co-ordinate with client
inspector. They shall be responsible to assure, monitor & control quality activities for
the Column internal replacement/repair work. (If any NDT Required)
7.8 Observe the stage wise inspection as per the approved inspection and test plan (ITP)
for the job.
7.9 Get clearance from client representative(s) at site before proceeding for the
subsequent stages.
7.10 Inspection report shall be prepared and get it signed from Client inspector.
8.0 Tools and Equipment to be used:
 The below mentioned tools are tentative and required tools will be mobilized as required.
8.1 Air Compressor
8.2 Forklift / Trailor / boom truck
8.3 Hydro Jetting Machine
8.4 Vacuum truck / super sucker.
8.5 Air winches
8.6 Chain Block / Lever Block – as per requirements
8.7 Grinding / buffing Machine
8.8 Slings & shackles
8.9 Tower Light, Halogen lights, electric panel board, extension board, transformer, 24volt
light, 110v power tools, power cable etc. (as column required)
8.10 Hand tools etc.
 All the Equipment and tools will be inspected by SATORP before taking to job location.
Page 5 of 12
ALMUZAIN
COMPANY
9.0 Site Activities
9.1 Pre-Shutdown activities

9.1.1 Complete safety orientation for personnel.
9.1.2 Preparation of Entry ID
9.1.3 Training completion for Permit receiver / Standby / firewatcher etc. as per
the SATORP standards.
9.1.4 Mobilization tools, tower lights and cleaning equipment and personnel to site.
9.1.5 Complete Permit Requirement.
9.1.6 Mobilization (location) of Tool containers, Offices & equipment etc. will be
near the workplace. Temporary Facilities Location Plan shall be provided
for SATORP concurrence and same shall be followed at site.
9.1.7 Unload equipment at prescribed place.
9.1.8 Equipment and tools inspection by SATORP.
9.1.9 Receive and check Free Issue Materials as per BOM and drawings. In case
materials have any discrepancy, same shall be informed to SATORP, for
notification purposes without delay. The free issue materials to be kept at
site within direct radius of mobile crane to avoid double handling.
9.1.10 The trays are to be clamped (periphery) and segregated trays wise. Each
type one tray will be trail assembled (mock-up) at site.
If different metallurgy of the bolts/nuts are used in column, then the

same will be color coded at site to avoid mix-up of material.
9.1.11 Preparation of permit and installation of external scaffolding as per

approved scaffolding plan.
9.1.12 Mark the locations for insulation removal in columns as per SATORP
inspection worksheet.
9.1.13 Prepare metal bins for collecting or safekeeping of loose items (bolts, nuts
& washer) during the removal of any obstruction.
9.1.14 Column davit capability & possibility of utilization of Air-winch for
lifting/lowering of column internals to be certified by SATORP.
9.1.16 Position the air winch to facilitate the removal and installation of old and
new materials to lower or lift to and from the location.
9.1.17 Blind list to be checked with SATORP operations and all blinds to be
made available in location and same to be secured properly.
9.1.18 Locate ventilation air movers, near designated manway/blind nozzle.
Page 6 of 12
ALMUZAIN
COMPANY
9.2 Shutdown activities
9.2.1 Column Entry
9.2.1.1 Blinding to be done as per the blind list provided by SATORP.

9.2.1.2 All the Manhole (M1, M2, M3, M4, M5, M6, M7, M8, M9 - 24
Inches #150 Rating) opening to be done after the flushing and
cooling of the columns.
9.2.1.3 Clean gasket seating surface area for manway covers/nozzles
and offer for inspection and Install face protector in all manholes.
9.2.1.4 After Opening of all Manholes, the pneumatic air movers to be
installed for proper ventilation.
9.2.1.5 Sufficient lighting (24V) arrangements to be done.
9.2.1.6 Complete necessary O2 Testing and temperature tests for safe
entry.
9.2.1.7 Get the applicable work permit from the operation.
9.2.1.8 Safe entry inside the confined space.
9.2.1.9 All the confined space entry will be monitored by Hole
watch and register to be maintained.
9.2.1.10 Every one-hour gas test to be done.
9.2.1.11 Every New entry, gas test to be conducted like lunch break, shift
change over time etc.
Work shall not be started until necessary required permit is obtained.
ATMOSPHERIC COLUMN – 011-C-0002
9.2.2 Activities inside the column
9.2.2.1 Offer client initial inspection for as open condition column

9.2.2.2 Install hard cover to bottom nozzle (B1-20” #300)
9.2.2.3 Erection of internal scaffolding for initial inspection and hydro-
jetting cleaning of column shell & above tray (If required)
DOC.NO.MZN-MED-WMS-041 ALMUZAIN
(AL MUZAIN GULF SAUDI CONTRACTING COMPANY Page 7 of 12
Jubail Industrial City, Saudi Arabia)

M8, Air Mover location

during entry through M9
NOTE: - When we change the

place of working in the
confined space, we will also
change the location of the air
mover if needed.
 Entry Through MH 9 and MH 8

 (BDH Valve Tray #57 - #45 Tray Replacement job)
9.2.2.4 Install air mover in manhole no M8 for good ventilation.
9.2.2.5 Preliminary “as found “inspection by client
9.2.2.6 Remove the distributor pipe for cleaning and inspection (if
required)
9.2.2.7 Clean distributor pipe with high water pressure.
9.2.2.8 Old Tray no #57 to #45 full tray remove and shift to scrap laydown
9.2.2.9 Clean shell internally and offer for inspection
9.2.2.10 NDT activities as per SATORP recommendations
9.2.2.11 Based on the recommendation from inspection, repair points to
be attended.
9.2.2.12 New tray installation and assemble start form tray #45 to #57 as
per drawing and new tray material supply by SATORP/OEM.
9.2.2.13 Distributor pipe re-installed.
9.2.2.14 Replace the damaged or missing clamps, bolts etc. for pipe.
9.2.2.15 Final inspection by OEM/SATORP/ALMUZAIN
9.2.2.16 After inspection tray manway box-up
9.2.2.17 After complete column internal activity, Manhole box-up with new
gasket in presence of inspection by OEM/SATORP/ALMUZAIN
9.2.2.18 Manhole bolt torquing.
9.2.2.41
Page 8 of 12
ALMUZAIN
COMPANY
M5, Air Mover location during

entry through M6 or M7

NOTE: - When we change the place

M1, Air Mover location of working in the confined space,
during entry through M2 we will also change the location of
the air mover if needed.
Page 9 of 12
ALMUZAIN
COMPANY
 Entry Through MH7 to MH 2
 (BDH Valve Tray #44 - #07 and SVG Valve Tray #06-#01 and chimney
tray/collector tray/Vapour horn) for cleaning and inspection
9.2.2.19 Install air mover in manhole no M1, M3 and M5 for good

ventilation
9.2.2.20 Open all tray manways from #44 to #01 (include chimney tray)
9.2.2.22 Remove the distributor for cleaning and inspection (if required)
9.2.2.23 Clean distributor with high water pressure.
9.2.2.24 Clean all the trays manually or by water as suitable
9.2.2.25 Clean all the chimney trays manually or by water as suitable.
9.2.2.26 Clean Vapour horn manually or by water as suitable.
9.2.2.27 All nozzles shall be cleaned and de-plug all drains and vents as
applicable.
9.2.2.28 Remove any remaining sludge, debris found inside the column.
9.2.2.29 Clean thoroughly and dispose the waste safely in drums properly
labeled as per waste disposal procedure
9.2.2.30 Vacuum trucks/super sucker (as required) to vacuum
sludge/remaining hydro jetting water from bottom sump which
can’t be drained directly to sewer
9.2.2.31 Clean shell internally and offer for inspection
9.2.2.33 Replace the damaged or missing tray valves, clamps, bolts etc.
9.2.2.34 Based on the recommendation from inspection, repair points to be
attended.
9.2.2.35 Distributor pipe re-installed
9.2.2.36 Final inspection by OEM/SATORP/ALMUZAIN
9.2.2.37 Chimney tray/collector tray manway box-up with new gasket and
inspection.
9.2.2.38 After inspection tray manway box-up from the #01-#44
gasket in presence of inspection by OEM/SATORP/ALMUZAIN
Page 10 of
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ALMUZAIN
COMPANY

NOTE: - When we change the place

of working in the confined space,
we will also change the location of
the air mover if needed.
 Entry Through MH1
 Bottom (Scaffolding Erection and Hydrojeting)
9.2.2.41 Install hard cover to bottom nozzle (B1-20” #300)

9.2.2.42 Erect scaffolding from dish end to below tray
for cleaning and inspection.
9.2.2.44 Column inside shell and Dish end Cleaning to Hydrojeting
9.2.2.45 Post Cleaning Inspection
9.2.2.47 Final inspection by OEM/SATORP/ALMUZAIN.
9.2.2.48 Remove internal scaffolding after completing all activity with
inspection
9.2.2.49 Remove nozzle cover for bottom outlet before box-up
gasket in presence of inspection by OEM/SATORP/ALMUZAIN.
Page 11 of
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ALMUZAIN
COMPANY
9.3 POST-SHUTDOWN ACTIVITIES
9.3.1 De-blinding of the columns.

9.3.2 Insulations to be restored wherever removed.
9.3.3 Inspection of the same.
9.3.4 Proper House Keeping of the area with satisfaction to SATORP.
9.3.5 Demobilization of Equipment and Manpower.
9.3.6 QC Dossier Submission.
10.0 HOUSEKEEPING
10.1 Maintain cleanliness and orderly stocking of materials & tools.
10.2 Pick up and dispose wastes & other debris prior to leaving site area.
10.3 Remove safety yellow tape or other warning devices that were used to
control access to Work area.
10.4 Store tools, equipment, and unused materials properly at the end of
the workday.
***** End of Method statement *****
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Work Method Statement For Column Internal

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Work Method Statement For Column Internal

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Sensitivity: MZN Internal

Work Method Statement for

ATMOSPHERIC COLUMN 011-C-0002

(Column Internal Replacement, Cleaning, and

ISSUE DATE: REV DATE: UDAY KHAPARE GURURAJ SATORP

2.0 Scope of work

SL Column Column Colum

3.0 References & Procedures

3.1 General Engineering Practices.

4.0 Safety Precautions

5.0 Health, Safety and Environment Measures

5.2 Lifting Equipment

5.3 During Site Execution

5.4 Safety Inspections

5.4.1 It shall be responsibility of the Supervisor to routinely inspect the physical

8.0 Tools and Equipment to be used:

9.0 Site Activities

9.1 Pre-Shutdown activities

If different metallurgy of the bolts/nuts are used in column, then the

9.1.11 Preparation of permit and installation of external scaffolding as per

9.2 Shutdown activities

9.2.1 Column Entry

9.2.1.1 Blinding to be done as per the blind list provided by SATORP.

Work shall not be started until necessary required permit is obtained.

ATMOSPHERIC COLUMN – 011-C-0002

9.2.2 Activities inside the column

9.2.2.1 Offer client initial inspection for as open condition column

Work Method Statement

M8, Air Mover location

NOTE: - When we change the

 Entry Through MH 9 and MH 8

M5, Air Mover location during

M3, Air Mover location

NOTE: - When we change the place

 Entry Through MH7 to MH 2

9.2.2.19 Install air mover in manhole no M1, M3 and M5 for good

M2, Air Mover location

NOTE: - When we change the place

 Entry Through MH1

 Bottom (Scaffolding Erection and Hydrojeting)

9.2.2.41 Install hard cover to bottom nozzle (B1-20” #300)

9.3 POST-SHUTDOWN ACTIVITIES

9.3.1 De-blinding of the columns.

***** End of Method statement *****

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* End of Method statement *