Method Statement fo Equipment Internal Trays Installation Work

This Method Statement highlights the OWNER work sequence for the assembly and installation of trays, which are to be installed on the [Project Title] Project in [Location]. This Method Statement is applicable to all equipment requiring loading of internals. 

The procedure is intended to provide general application guidance and establish controls during preparation and execution and to ensure that the loading of equipment internals referred to as trays is carried out safely, and in accordance with good working practice, as per OWNER Specifications and Vendors’ Instruction Manuals.

Pre-Installation Activities for Equipment Internal Trays

• Prior to commencement of the work, ensure that erection personnel have read and understand instructions, Method Statements, Job Specifications and are familiar with tray assembly drawings. 

• Ensure that the erection personnel have undergone training and are certified by OWNER for confined space entry work prior to execution of the work.

• Conduct site survey to properly assess the physical condition of the confined work place and appropriately address the necessary precautions and requirements, such as lighting and air ventilators inside the column, if manholes are open and if blinds for column piping are installed.

• Co-ordinates properly with OWNER Representative for confirmation that the column is in gas free condition prior to entry inside the column.

• Ensure to install low voltage lighting inside the equipment and provide sufficient number of ventilators (air blower / exhauster) on open manholes, to establish air flow inside the column. Air compressor will be used to run the air ventilator.       

• Ensure to double-check the equipment internals such as tray panels, fasteners, main beam, cover plates and support rings as per IFC Assembly and Installation drawings as provided by OWNER. Each tray part is marked with its reference number, any deviation against the issued drawings during checking / sorting shall be immediately reported to OWNER for their information and appropriate action.  

• Ensure to erect, where required, necessary scaffolding / access platform located at each exit and entry manway for mechanical fitters prior to tray installation. Erected scaffold shall be in accordance with SUBCON Working Instructions.

• Prior to tray assembly and installation, ensure to locate the reference point inside the column, and that the rust preventive on the tray materials has been removed and washed clean by suitable solvent such as Acetone. For stainless steel trays, the solvent should contain less than 50 ppm leachable chlorides. 

• Ensure that “Work Permit and Entry Permit” to enter Confined Space have been secured and the standby man at manhole entrance is posted prior to commencement of the work. 

Procedures:

• The assembly and installation of equipment internals (trays) shall be carried out in strict adherence with OWNER furnished approved for Construction drawings, specifications, and Vendors’ Instruction Manuals.

• Vessel internal visual check shall be carried out before start of internal work.

• A 250-ton crane with sufficient boom length to reach above manway shall be used for external handling of heavy trays, support rings and other column accessories. Small tray items will be raised or lowered at various manway levels using pulleys and continuous long ropes.

• For internal handling of heavy column trays / parts, an electric hoist or air tugger will be used. This will be positioned at each working platform inside the column.

• Cleaning of all materials should be carried out before installation, if dirty.

• Conduct pre-assembly of the tray / tray panel on the ground adjacent to the column. Do not fix them together, but put the tray panels loosely together. Clamps and/or bolts should be fastened by hand only, in order to be able to adjust position of the tray during actual installation.

• Wherever possible, assemble two trays in such a way that one tray or tray part is pre-assembled on the ground while the other part is being installed on the column, thus permitting sequential and gradual progression of the installation.

• As soon as one tray is assembled, installation sequence of equipment internals will start at the bottom of the column, working up towards the top. For detailed tray installation procedures, seal welding, level adjustment and tolerances, refer to attached Sulzer Chemtech AG Technology and Koch-Glitsch Italia, Vendors’ Instruction Manuals. 

• For C-2115 Wash Tower, initially two-(2) crews shall be assigned for the assembly and installation of internal. Additional manpower will be employed as required. Since two-(2) crews shall be working simultaneously per shift at different levels, a safety net shall be provided above each manway to protect craftsmen working below from falling objects.

• Installed tray internals on each completed level shall be inspected to ensure that:

• Orientation and measurements are correct.
• Check tightness of 10% of the bolted connection.
• Evenness of the tray decks should not deflect due to work during installation.
• Levelness of tray floors shall be checked using a manometer (refer to Fig.1 sheet 5 of 12 Koch-Glitsch Italia, Vendors’ Instruction Manuals.)
• All parts are fitted properly and no loose hardware is left which may have adverse effect on the tray performance.

• Inspection shall be conducted by SUBCON, OWNER and PMT inspectors during the progress of the work, from bottom to top, and in accordance with approved QCIP inspection requirements and specification. OWNER inspector shall also make the final check and inspection prior to final acceptance / closing of manway.

• All dirt, debris, grease, tools and equipment shall be completely removed after work is completed and prior to final visual inspection / acceptance.

• This same methodology shall be applied to all equipment that requires assembly and installation of trays until all the trays of equipment have been installed. 

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