DOC NO: MS-834-164

REV. NO. 3
JUBAIL CHEVRON PHILLIPS PROJECT
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METHOD STATEMENT

MS-834-164

INSTALLATION OF COMPRESSOR & PRESERVATION

JUBAIL CHEVRON PHILLIPS COMPANY

JUBAIL CHEVRON PHILLIPS PROJECT

AL-JUBAIL KINGDOM OF SAUDI ARABIA

3 For Approval 12.07.2006

MB BS DH MS MZ
2 For Approval 22.06.2006 MB BS DH MS MZ
1 For Approval 05.06.2006 MB BS DH MS MZ
For Review &
0 25.05.2006
comments MB BS DH MS MZ
Site Manager Construction HSE QC Project
REV DESCRIPTION DATE JGC
Mechanical Manager Manager Manager Manager
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Index

1. Scope

2. Purpose

3. References

4. Definitions

5. Responsibilities

6. Procedure

7. Safety
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1.0 SCOPE

This method statement contains the general requirements for the site erection alignment and
preservation of compressor and steam turbine K 3106, K 3107 & K 3351.

2.0 PURPOSE
The purpose of this procedure is to provide a general guide line for the receiving and
installation of compressor and preservation activities.

3.0 REFERENCE

ITP 834 164 E : Compressor / Turbine Installation

V 2158 201 A 240 : Field Storage Procedure

V 2158 201 A 241 : Rotor Storage Procedure

V 2158 201 A 801 : Compressor Instruction Manual

V 2158 201 A 804 : Field Erection Manual

4.0 DEFINITION

COMPANY : Jubail Chevron Phillips (JCP)

CONTRACTOR : JGC Arabia Ltd. (JAL)

CCC : Consolidated Contractors Company WLL.

QCP : Quality Control Procedure

ITP : Inspection Test Plan

MHI : Mitsubishi Heavy Industries

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5.0 RESPONSIBILITIES
5.1 The following CCC site personnel shall be involved as responsible for the equipment
erection.

Section Engineer Equipment

Rigging Superintendant

Equipment Supervisor

QC Engineer

QC Equipment Inspector

Surveyor

5.2 Section Engineer is over all responsible for monitoring equipment erection operation
in accordance with the procedures, specification and construction drawing.

5.3 QC Inspectors in conjunction with the QC Engineer are responsible for the inspection
in accordance with specification and procedure of the equipment erection and the
compilation of equipment reports and records as per required ITP.

5.4 The equipment supervisor shall be responsible for the safe operation and quality of
work and shall ensure that the procedures are adhered to and that technical standard
are maintained.

5.5 The rigging superintendent is responsible for all rigging operation that includes off
loading, transporting, and erection and for the selection of proper crane capacity and
rigging gear.

5.6 The surveyor is responsible for checking elevations and verticality as per construction
drawing.

6.0 PROCEDURE

6.1 EQUIPMENT RECEIVING

6.1.1 All equipment received at site shall be inspected in accordance with vendors
instruction for site storage, installation and preservation.

6.1.2 Equipment shall be off loaded from trailer using the vendor recommended
lifting point and approved techniques.

6.1.3 All loose items that are not required for immediate installation shall be suitably
identified and retained in the stores.

6.1.4 Protective covers on all equipments shall be removed if they appear damage
and equipment inspected before replacing the cover, if any damage has
occurred, Discrepancy report shall be issued with photograph showing
damages as necessary and recorded.
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6.1.5 Preservation of compressors will be maintained as per field storage procedure

and as per vendor manual and logged.

6.1.6 Preservation of compressor accessories which ever required Nitrogen as per

vendor manual will be preserved and recorded on weekly bases Refill in case
of any leak and logged.

6.2 HANDLING OF EQUIPMENT

6.2.1 Equipment shall be unpacked in presence of JGC field Engineer and vendor
supervisor. All spare parts and tools shall be unpacked clearly marked with
equipment numbers and stored in the warehouse. Fragile parts such as level
oiler, capillary tubes, small piping shall be removed from the equipment after
match marked and stored. The parts shall be clearly identified by the tags with
equipment number.
6.2.2 All machined surfaces shall be checked and applied with rust-preventatives.
6.2.3 The equipment should not be placed directly on the earth, wooden blocks to
be used in horizontal position.

6.2.4 All couplings shall be uncoupled and coupling elements shall be clearly
marked with equipment numbers matching the shaft hub and stored in the
warehouse while applying corrosion inhibitor and densso tape.

6.2.5 After checking the equipment and confirming that there are no discrepancies,
equipment shall be stored or delivered to installation site as and when
required.

6.2.6 Bottom of the base plate shall be cleaned or wiped by suitable means of
desiccant to remove mud oil or grease before installation.

6.3 INSTALLATION OF COMPRESSOR

6.3.1 FOUNDATION BOLTS, HOLE CHECK: axial centers of the compressor, steam
turbine and nozzle position of the surface condenser shall be marked on
foundation the positions and dimensions of the foundation bolt holes shall
then be checked and it will be ascertained by a plumb bob so that these holes
are precisely vertical. If any undesirable foundation bolt holes are discovered
they shall be completely corrected before the equipment is placed on the
foundation.

6.3.2 Chipping of foundation will be carried out for setting of pad plates for the jack
screws as per the elevation given by M.H.I drawing and after setting to correct
elevation it will be grouted.

6.3.3 After the above activities are completed equipment will be set on foundation
and preliminary alignment will take place like leveling of the base plate using
a straight edge and precision level which will satisfied the following condition:

6.3.3.1 A axial direction level on the both sides of the bearing pedestals shall
be within tolerance of 0.2mm/m.
6.3.3.2 A axial direction level on the exhaust side journal shall be within a
tolerance of 0.2mm/m etc.
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6.3.4 When the leveling and centering of the base plate have been completed all
foundation bolts shall be precisely tightened other wise if tighten too strongly
the level and centering might be disturbed the above measuring points for the
leveling and centering should be retain for future reference then the
compressor should be released for grouting.

6.3.5 If an unallowable miss-alignment exceeding in cold alignment MAP limitation

is observed a correction is made by adding or removing the shims beneath
the compressor by supports.

6.3.6 During the alignment work the distance between shafts will be measured
often and checked within a tolerance of 0.5mm if it exceeds the limitation will
be made by moving the compressor.

6.3.7 While the shaft distance is measured each shaft should be moved towards
the active side thurst bearing in order to put it at the expecting operating
position.

6.3.8 Regular preservation will be carried out as per below mentioned sequence:
the shaft of compressor shall be rotated biweekly and recorded in the
equipment preservation and maintain log summary (attached) spare rotating
elements shall be stored indoors and per the manufactures recommendation.
After installation the above compressor will be protected as follows:

6.3.8.1 Manufactures recommended shall be followed activity #1 compressor

and / or steam turbine rotors shall be manually turned a quarter of a
revolution once a week, during installation (as per MHI manual).

6.3.8.2 Cover on the suction and discharge nozzle it shall be remain in place
until hydrostatic testing and flushing of connecting piping is
completed blinds are to have tabs, which clearly identify the blinds in
the line activity # 4.

6.3.8.3 Space heater connection will be applied to electrical motor which has
a space heater to prevent accumulation of moisture whether in
storage area or at final installation. The electrical motors shall be
checked for insulation resistance before operation.

6.4 FINAL CHECK FOR COMPRESSOR

6.4.1 For compressor after Hydrotest activity completed and reinstatement of all
piping spools. The parallelism of flanges discharge and suction shall be
checked with equipment nozzles.

6.4.2 Final alignment using dial indicators by reverse alignment method or face rim
method will be used. Coupling shall not be installed until after the no load test
for the drivers is completed.
6.4.3 Oiler cans and all lubrication system shall be checked to assure, no leak on all
tubing.

6.4.4 All coupling guards should be in place to prevent any accident with the
running parts.
6.4.5 All equipment shall be barricaded and provided with warning signs, when its
energized.
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7.0 SAFETY
7.1 Job safety analysis attached.

7.2 All workers shall receive orientation course.

7.3 Work at height full body harness shall be used with 100%Tie off.

7.4 Make sure access completely safe on scaffolding with green tag.

7.5 All warning signs shall be fixed in proper location to ensure personnel safety.

7.6 All workers should wear required PPE at all time.

7.7 Use of preservation material should be accompanied by proper safety

material data sheet.

7.8 MSD sheets for chemicals used will be available and persons performing work
will be conversant with hazards associated.

7.9 Lifting plan to be submitted for approval before installation.

7.10 Daily safe work plan (SWP) required.