Shell Petroleum Development Company of Nigeria

Classification Status: [Restricted]

August, 2014

DOCUMENT NUMBER:
[SOK-NG01011666-SOKG1-XXXXX-XXXXX]

SOKU NAG COMPRESSION FACILITY INSTALLATION PROJECT

[METHOD STATEMENT FOR INSTALLATION OF COMPRESSOR AFTERCOOLER E-2180]

Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced
without prior written permission from Shell Petroleum Development Company
The Process Manager for this procedure is the Major Projects General Manager, the Process Owner is the Major
Projects Project Services Manager
Revision

R01

Date

Description

Issue for Internal Review

Originator

FELIX
ANYANELE

Checker

ARVIN DO
REGO

Approver

IKENNA ONYEKONWU

ADDITIONAL AGREEMENT/APPROVAL RECORD

PARTY

REF IND.

NAME

SIGN

DATE

Revision Philosophy
All revisions for review will be issued at R01, with subsequent R02, R03, etc as required.
All revisions approved for issue or design will be issued at A01, with subsequent A02, A03, etc as required.
Documents approved for Construction will be issued at C01, C02, and C03 respectively.
Documents or drawings revised as As built will be issued as Z01, Z02 Z03 etc.
Narrative sections revised from previous approved issues are to be noted in the table below and/or highlighted in the RH
margin (using the appropriate revision status) thus: | A02
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas and by the use
of a triangle containing the revision status.

Revision History
REVISION NO.

R01

DATE OF
ISSUE

REASON FOR CHANGE

Issue for Internal Review

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METHD STATEMENT FOR INSTALLATION OF

COMPRESSOR AFTERCOOLER (E-2180)
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TABLE OF CONTENT

S. NO.
1.
2.
3.
4.
5.
6.
7.
8.

DESCRIPTION
INTRODUCTION
SCOPE
REFERENCES
RESPONSIBILITIES
MANPOWER, MACHINERY AND EQUIPMENT
HSE REQUISITES
PRE-REQUISITES
PROCEDURE

PAGE
4
4
4
5
6
6
7
8

1. INTRODUCTION
This method statement outlines the requirements, responsibilities and effective guidance for the
installation of Aftercooler Compressor, E-2180 for the SOKU NAG COMPRESSION FACILITY
INSTALLATION PROJECT.
Whilst there are inherent dangers associated with this work, consequently, this method statement is
developed to ensure that all activities to be carried out are in compliance with applicable COMPANY
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DEPs and Standard Construction Specification Section 19 (Mechanical Equipment).

2. SCOPE OF WORK
The scope establishes the requirements and responsibilities for the installation of the
Aftercooler, E-2180 in accordance with the contract. The CONTRACTOR shall be responsible
for the loading, unloading, safe handling, installation of the Compressor Aftercooler, E-2180 and
connection of the associated insulated pipe work including electrical and instrumentation
ancillaries required. Lifting and installation of the Compressor Aftercooler, E-2180 shall be in
stages and by approved cranes with the appropriate safe working loads (SWL). The new
Compressor Aftercooler, E-2180 shall be installed on the existing supports. The lifting and
installation of the Compressor Aftercooler, E-2180 shall be in accordance with relevant
COMPANY DEPs, Standard Construction Specification Section 19 (Mechanical Equipment)
Approved for Construction drawings.

3. REFERENCES:
Project Quality Plan

SOK-NG01011666-SOKG1-QA5798-00001

Non-Conformity Procedure

SOK-NG01011666-SOKG1-QA5880-00001

Material Control Procedure

SOK-NG01011666-SOKG1-VA6036-00001

Procedure for Equipment and

SOK-NG01011666-SOKG1-VA6180-00002

Material Preservation
Lifting, Erection and Installation Plan

SOK-NG01011666-SOKG1-BA5736-00002

AFC DRAWINGS
Project Quality Assurance

DEP 82.00.10.10-Gen

Preservation of New & Old Equipment

DEP 70.10.70.11

and Piping Standing Idle

Field Inspection Prior to Commissioning of

DEP 61.10.08.11

Mechanical Equipment
Human Factors Engineering Application

DEP 30.00.60.14-Gen

During Construction
Manufacturers Erection Manual

4. RESPONSIBILITIES
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METHD STATEMENT FOR INSTALLATION OF

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PROJECT MANAGER

The CONTRACTOR Project Manager shall primarily be responsible for the coordination and
execution

of all activities relating to the Soku NAG Compression project.

CONSTRUCTION MANAGER
The Construction Manager shall coordinate all construction activities whilst stand in as the
interim Project Manager during the absence of CONTRACTORs Project Manager.

He shall be present at construction sites at all times when construction is in progress and shall
be responsible for the installation of the Compressor Aftercooler, E-2180.
MECHANICAL SUPERINTENDENT
The CONTRACTORs Mechanical Superintendent shall coordinate and oversee the installation
of the Aftercooler, E-2180 and its ancillaries.
RIGGING SUPERVISOR
The Rigging Supervisor shall be responsible for the coordination, and monitoring the lifting and
moving of the Aftercooler, E-2180 and its components during the installation activity.
QA/QC MANAGER
The CONTRACTORs QA/QC Manager shall be responsible for quality assurance/quality
control actions associated to the installation of the Aftercooler, E-2180.
QA/QC INSPECTOR
The CONTRACTORs QA/QC inspectors shall be responsible for the monitoring of all QC
activities whilst ensuring work being executed is in conformance with the project specifications.

5. MANPOWER, MACHINERY & EQUIPMENT

5.1 MANPOWER:

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S. NO.

DESCRIPTION

1.

Lead Field Surveyor

2.

Surveyor Mate

3.

QA/QC Inspector

4.

HSE Officer

5.

Construction supervisors (Mechanical, Instrument, Electrical,

Civil)

6.

Rigging supervisor

7.

Mechanical Technicians

8.

E&I Technicians

9.

Crane operators

5.2 MACHINERY & EQUIPMENT:

S. NO.

DESCRIPTION

1.

Slings, shackles, chains & ropes

2.

Mechanical Tool Box (Torque wrenches, spanners, hammer etc.)

3.

Crane

4.

Man lift & Fork lift

5.

Spreader bar

6. HSE REQUIREMENTS:
Prior to commencing the works a detailed Job Hazard Analysis (JHA) shall be carried out. After all
known, suspected or potential hazards and risks have been identified, the work force shall be
informed of the hazard and control measures that must be put in place to eliminate or control the
hazard and potential risk.
All personnel involved in the survey activity shall receive safety training induction

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 All personnel to be engaged in this work shall be properly mobilized and inducted. This is to enable
them to appreciate the risk hazards involved in the operations.
All workers shall be medically fit to work.
The health, safety and environment of all personnel shall be safeguarded to avoid injuries and
illness.
There shall be a qualified first aider, fully equipped with first aid drugs required in the first aid
administration.
Dedicated site HSE officers shall man all work sites.
Warning signs and barriers shall be positioned around all work areas.
All personnel shall wear the appropriate PPE reference Job Specific JHA. All the work force shall
comply with the Contractors Health, Safety and Environment requirements as per the HSE plan.
Only authorized personnel shall be allowed into the work area. All necessary measures as per
Clients requirements or manufacturers recommendations shall be adhered to.
PTW and the JHA shall be signed off.
All personnel shall be swimming certified and only those required to use helicopter shall be HUET
certified.
Supervisor and safety officer to ensure lifting plan for the lift activity is prepared and understood.

7. PRE-REQUISITES:
All information related to the existing bench-mark shall be collected from the COMPANY and
transferred to the existing work site.

Calibration of Equipment shall be carried out.

Survey works shall be carried out with Interface with the Quality Control Department.
Site survey observations shall be recorded directly in the required forms.
Completed Forms shall be returned to the Lead Field Surveyor to form part of the quality record to
be retained and archived.

Verify the existence of sufficient controls to do the work.

Reference drawings shall be controlled documents.
Pre-mobilization and calibration certificates are made available.

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8. WORK PROCEDURE
S. NO.

8.1

8.2

8.3

8.4

TASK STEPS

STEP DESCRIPTION

Equipment

All related work equipment for survey works,

Certification shall be done

Calibration and

rigging and lifting, mechanical, electrical and

by a competent third party

Certification

instrumentation works shall be calibrated to

company.

Securing of work
area

SPDC required standard.

Caution tape will be used to barricade the work
area.
Safe path for personnel to be created.

Inspect & clear

Ensure that the work area is safe and the

Work area

environment is conducive for the operation.

Carry out gas

Continuous use of approved gas detector around

testing around the

the work site/area shall be done to ensure the

work area

area is safe for the installation activity.

existing steel

Verify the integrity of the foundation and existing

structure and

steel structure visually.

foundation
Carry out
8.6

Ensure adequate warning

signs.
Ensure good house
keeping.

Ensure the equipment is in

good working condition.
By competent

Integrity of
8.5

REMARKS

alignment check
on existing steel

Carry out horizontal alignment checks on column

and record as part of reliability check on structure.

structure

CONTRACTOR &
COMPANY personnel,
correct PPE and adequate
supervision.
To be verified by
competent
CONTRACTOR

A lifting plan for installing the Aftercooler shall be

personnel.
Approved lifting plan shall

submitted to the COMPANY for approval prior to

be in place and certified fit

Crane and rigging

start of operation and all crane operations shall

for use by COMPANY.

equipment

conform to OEM safe working load.

8.7

setting-out
The weight of the equipment is XX tons based on
data from VENDOR manual, a crane with a SWL
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S. NO.

TASK STEPS

STEP DESCRIPTION
of XX tons shall be used for this operation as per

REMARKS

the lifting plan.

The crane shall be positioned centrally on the
west of the equipment foundation. On the areas
not accessible by crane/ man-lift adequate
scaffold arrangements shall be made.
The manlift shall be used to carry personnel to
assist in the dismantling process.
8.9

INSTALLATION SEQUENCE
Assemble and fit into place the plenum, air cooler

8.9.1

Assembling of air
cooler

fan rings and ancillaries.

Assembling shall be done as per VENDORs
instructions or VENDORs installation manual.
The tube bundle shall be lifted in accordance to

Use of competent
personnel, correct PPE,
equipment, tools and
adequate supervision.

the lifting plan.

The crane shall be positioned at the specified
Lifting and
8.9.2

positioning of
tube bundle

location according to the lifting plan and the tube

Use of competent

bundle lifted with the aid of sling ropes and

personnel, correct PPE,

spreader bar attached to the lifting lugs provided

equipment, tools and

on the equipment.

adequate supervision.

The equipment shall be aligned to the relevant

bolt pockets with respect to the steel structure,
8.9.3

Fan & Motor

bolted into place and torqued.

Install the fan blades, motor sittings, electric

Use of competent

installation

motor and pulley belt;

personnel, correct PPE,

equipment, tools and

Confirm angle alignment of the fan blades, motor-

adequate supervision.

pulley alignment of fan in accordance to the

VENDORs specification;
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S. NO.

TASK STEPS

STEP DESCRIPTION

REMARKS

Ensure the fan and shaft rotates in the specified

direction in accordance to the VENDORs
specification.

8.9.4

8.9.5

Isolation of

Metal flange covers and rubber gaskets shall be

process inlet/

used to isolate process inlet and outlet until tie-in

outlet points

to process lines have been established.

Use of competent
personnel, correct PPE,
equipment, tools and

All electrical power cables and Instrument cables

adequate supervision.
Use of competent

shall be verified and confirmed for proper

personnel, correct PPE,

Electrical &

connections. Inspection and testing to be carried

equipment, tools and

Instrument

out after the final installation.

adequate supervision.

Installation
Connect all earth bosses according to VENDORs
specification.
8.9.6

Structural
Installation

8.9.7

Verification

Confirm ladders, stairways, platforms and

walkways are correctly installed according to AFC
drawings.
A general check of the installation shall include:

Use of competent
personnel, correct PPE,
equipment, tools and
adequate supervision.
Use of competent

The sealing between cooler bundles;

personnel, correct PPE,

The correct sloping of the horizontal parts

equipment, tools and

of the air plenum and tube bundles if

adequate supervision.

applicable;
Alignment of belt pulleys;
Rigidity of fan and belt guards;
Proper tension of belt drives;
Guards protecting personnel from hot
surfaces;
Proper alignment of process piping
headers to ensure no excessive nozzle
loading;
Full priming of grease lines between
grease nipple and bearing house;
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S. NO.

TASK STEPS

STEP DESCRIPTION

REMARKS

Tightness of fan blade securing bolts.

All A check sheet to be signed by the
client as per proper complete installation.
8.10

CLEANLINESS
Use of competent

8.10.1

House-keeping

Clearing of residual debris from the installation

personnel, correct PPE,

area.

equipment, tools and

adequate supervision.

8.11

DOCUMENTATION
Documentation(s) relating to the installation work

8.11.1

Documentation

to be CLOSED-OUT by COMPANY and

Use of competent

Completion

CONTRACTOR representatives.

personnel

ATTACHMENTS:

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