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Sunday, 3 April 2016

METHOD STATEMENT FOR GROUTING IN MECHANICAL EQUIPMENTS

TABLE OF CONTENTS

1........... PURPOSE

2........... SCOPE

3........... REFERENCES

4........... RESPONSIBILITIES

5........... MANPOWER AND EQUIPMENTS

6........... SAFETY

7........... GROUTING MATERIALS

8........... APPLICATION AND LIMITATIONS

9........... INSTALLATION PROCEDURE (NON-SHRINK CEMENTITIOUS / EPOXY GROUT)

10......... FINAL INSPECTION & ACCEPTANCE

11......... ATTACHMENT

PURPOSE

The purpose of this method statement is to estabilish and control all activities involved for the installation of mechanical equipments in accordance with good working practice as per Client Standard Operation Instructor.

SCOPE

This method statement describes about the grouting work shall be carried out the under various contexts in accordance with the Saudi Aramco Requirements for the Luberef Yanbu Refinery Expansion Project.

The method and operations committed hereunder will be adhered to carrying out the works coming under its purview. This method statement covers grouting works using cement based non-shrink grout and non-shrink epoxy grout and dry pack grout.

REFERENCES

Saudi Aramco Specifications

1) SAES-Q-010 : Cement based, Non-Shrink Grout for Structural and

Equipment Grouting

2) SAES-Q-011 : Epoxy Grout for Machinery Support

3) SATIP-Q-010-01 : Cement-Based Non-Shrink Grouting

l SAIC-Q-1045 : Sampling, testing cement based non-shrink grout and

Review of Compressive Strength Test Report

l SAIC-Q-1046 : Material Components & Ingredients Receiving Inspection

l SAIC-Q-1048 : Cement Based Non-Shrink Grout Surface Preparation &

Formwork Inspection

l SAIC-Q-1049 : Mixing, Placement, Sampling, Testing, Curing & Final

Inspection

4) SATIP-Q-011-01 : Epoxy Grout for Machinery Support

l SAIC-Q-1051 : Sampling, Testing Epoxy Grout and Review of Compressive

Strength Test Report

l SAIC-Q-1052 : Grout Material Receiving and Storage Inspection

l SAIC-Q-1053 : Surface Preparation and Formwork Inspection

l SAIC-Q-1054 : Grout Mixing, Placement, Sampling & Testing Inspection

l SAIC-Q-1055 : Foundation and Grout Curing/Protection and Final Inspection

5) General Instructions (GI)

l 0002_710 : Mechanical Completion & Performance Acceptance of

Facilities

l 0002_100 : Work permit

l 0008_001 : Safety Requirement for Scaffold

6) SG2419-HSE-PLN-002 : Loss Prevention Program

7) SG2419-QUA-PLN-001 : Project QA/QC Plan

Abbreviations

· IFC : Issued for Construction

· Company : Saudi Arabian Oil Company(Saudi Aramco)

· Contractor : SAMSUNG Engineering Co Ltd (SECL)

· Sub-Contractor : Firms that has a contract to do part of job

· HSE : Health Safety Environment

· JSA : Job Safety Analysis

· SATIP : Saudi Aramco Typical Inspection Plan

· SAIC : Saudi Aramco Inspection Check List

· SATR : Saudi Aramco Test Report

· RFI : Request for Inspection

· QA/QC : Quality Assurance and Quality Control

· FMC : Field Material Control

RESPONSIBILITIES

Equipment Engineer / Mechanical Superintendent

· Shall report to Construction Manager

· Review the grouting procedure of rotating and static equipment, erection drawing and responsible for over-all direction, monitoring, coordination and control of all construction activities related to the equipment installation and grouting works.

· Prepare technical deviation, concession request, if required.

· Arrange as built drawings whenever required in accordance with site condition.

Equipment Supervisor

· Shall report to Equipment Engineer/Mechanical Superintendent.

· Coordinate with QA/QC inspector while performing inspection as per Saudi Aramco Specification.

· If any technical deviation or discrepancy is observed during the execution, he shall raise site technical query.

· Shall ensure the installation (dimensions, leveling and alignment) are as per vendor’s drawing and specification.

Foreman

· Shall be responsible to arrange the required work permit prior to start any type of preparation works.

· Shall be responsible for the direct execution of work involved in the equipment installation works according to the plan and shall direct control and give instruction to the labor.

· Shall also ensure that work is performed with proper tools, equipment, PPE and good housekeeping around working area.

· Shall ensure the installation (dimensions, leveling and alignment) are as per vendor’s drawing and specification.

QC Manager

· Shall report to Site Manager.

· Shall have responsibilities for the quality control of the equipment installation at site.

· Shall be responsible to the inspection or monitoring for preservation conditions in accordance with “Specification for Preservation”.

QC Inspector

· Shall report to QC Manager.

· Shall inspect the incoming materials (receiving inspection) as per design general specification and PO requirement.

· Shall prepare the inspection tools and measuring equipment for installation works.

· Shall monitor and inspect QC activities against Saudi Aramco specification and drawings.

· Shall liaise with Company Inspector during inspection, prepare and maintain inspection documents.

· Shall ensure that materials are handled, inspected and certified by concern authority.

Safety Officer

· Shall report to Safety Manager.

· Shall review the work permit before start of the work.

· Shall ensure that all equipment, tools and tackles are periodically inspected and color coding procedure is followed.

· Shall ensure that the person involved in rigging are experienced and qualified as per Aramco requirements.

· Shall inspect whether safety requirements are implemented and tool box meeting are conducted every day.

· Shall verify that the personnel involving equipment installation and have undergone safety induction program.

· Shall verify that the equipments (including lifting equipments) are in good and safe Working condition.

· Ensure that safety requirements are implemented and adequate safety measure are undertaken to prevent may damage to the work group, public, environment as well as properties.

· Shall monitor the safe work plan, safety task assignment and job safety analysis conducted for the job.

MANPOWER AND EQUIPMENTS

Manpower

· Supervisor

· Helpers

· Carpenters

· Safety Crews

Tools and Equipment

· Mixing Paddler

· Electric Generator

· Water Basket (Calibration Cup)

· Mixing Bucket

· Survey and leveling equipment such as theodolite spirit level etc.

· Air compressor

· Safety equipments (PPE etc.)

SAFETY

· Contractor’s safety supervisor shall carry out the safety site inspections to ensure that the safety requirements laid out in the HSE work plan are followed throughout all installation work.

· Contractor’s manager/supervisor shall review job safety assessment and work permit prior to the start of work, JSA will be followed.

· Pre-job instruction, toolbox meeting, training for the labors for working at height, fall protection shall be conducted by supervisor/foreman prior to the start of works.

· Full body harness with double lanyard shall be worn and properly hooked by everyone working at height of 1.8m and more, and be hooked just above ones shoulder height.

· Where provision to hook full body harness does not exist, temporary lifelines shall be provided and harness shall be hooked onto it.

· Barricading of lifting area of equipment shall be checked prior to the commencement of work and sufficient sign boards shall be replaced.

· All the lifting tackles shall be inspected and color coded certified by HSE.

· The work area shall be barricaded and no one shall be allowed to work or move below the lifting activity or suspended load.

· PPE implementation shall be monitored, violation shall be recorded.

Working at height of 1.8m and more, and be hooked just above ones shoulder height.

· Scaffolds shall be thoroughly inspected before green tag and use.

· All equipment, tools safety accessories shall be inspected on regular basis and shall be color coded as per safety standard.

· Trained fire watchman shall depute for all hot work.

· Slag and burrs due to welding, grinding or cutting at heights shall be secured by enclosing the area with fire blankets.

· Sufficient numbers of fire extinguishers shall be provided near working places.

· During working at height, tools shall be secured with lanyard.

GROUTING MATERIALS

General

· The material data sheet for Non-shrink cementitious and epoxy grout shall be submitted to Company/Contractor for approval prior to start grouting works. The approved material only shall be used for steel structure and equipment grouting.

· All grouts shall be non-corrosive, non-staining and resistant to efforts to moisture.

Compressive strength of grout shall meet or exceed the strength of foundation concrete.

Delivery, Storage & Handling

· Non-shrink cementitious grout shall be delivered to the site as dry mix in pre-measured waterproof bags. Only water is to be measured at the site in the amount indicated on the bag as per manufacture recommendation.

· Non-shrink epoxy shall be delivered to the site as a complete system in pre-measured packages to facilitate accurate field mixing and instruction shall be followed as per manufacture.

· Grout shall be stored in a dry & weather proof area within the temperature range recommended by manufacturer. It is preferred to store in a dry warehouse. If the grout material wants to keep outside, it shall be placed on pallets off the ground surface and completely covered with durable plastic sheeting.

· Any materials, which found becomes damp or defective shall be removed from the site. Time of storage for non-shrink grout shall not exceed manufacturer’s recommendation.

APPLICATION AND LIMITATIONS

General

· Non-shrink grout shall be used for all mechanical equipment as per specifications and standards.

· Grouting of equipments supports shall be in accordance with equipment manufacturer’s recommendations and Aramco Standards.

· The details for grouting & form work for equipment foundation shall be as per approved GA drawing.

Non-Shrink Cementitious Grout

· Non-shrink cementitious grout shall be used as per approved drawings, specifications and standards.

· This type of grout shall also be used for grouting of structural column base plates having shear keys seated in companion keys formed in foundation piers and for sleeved anchor bolts designed to resist high shear forces.

· Non-shrink Cementitious grout shall be Grade C combination Volume-Adjusting in accordance with ASTM C1107.

· Plastic volume change: Grout shall show no shrinkage(0.0%) and a maximum of four (4) percent expansion at any time before initial set when tested in accordance with ASTM C827.

· Hardened volume change: Grout shall show no shrinkage(0.0%) and a maximum 0.2 percent expansion in the hardened state when tested in accordance with ASTM C1107.

· Compressive strength: Grout shall have a minimum compressive strength at 28 days of 350kg/㎠ when tested in accordance with ASTM C109.

· Initial set time: Grout shall achieve initial set in not less than 45minutes when tested in accordance with ASTM C191.

· Soundness: Grout shall contain no staining substances, no aluminum powder, no more than 0.1 percent chloride ions by weight of cement, or other materials known to increase drying shrinkage and/or compromise durability.

· The non-shrink or expanding grout shall be cementitious. Metallic fillers shall not be acceptable as non-shrink or expansion additive. Grout containing calcium chloride additive is not acceptable.

Epoxy Grout

· Epoxy grout shall be used as per approved drawings, specifications and standards.

· The epoxy grout shall be nonmetallic one hundred percent solids system and formulated with thermosetting resins and inert fillers. The cured grout shall be unaffected by oils, synthetic lubricants, water, or chemicals.

· The mixed consistency shall be pour able and self-leveling to ensure simple, accurate placement. The manufacturer shall determine volume change during curing by laboratory tests in accordance with ASTM C827.

· Volume change: Epoxy grout shall exhibit no shrinkage (0.0%) and a maximum of two (2) percent expansion when testes in accordance with ASTM C579, modified to use an indicator ball with a specific gravity between 0.9 and 1.1

· Compressive strength: Epoxy grout shall have a minimum compressive strength at 7 days of 845 kg/cm² or 12,000 psi (SAIC-Q-1054 Item A4) when tested in accordance with ASTM C579.

· Heat Development: The peak exothermic of a 50mm diameter by 100mm high cylinder of grout shall not exceed 35℃ when tested at 24℃ material and laboratory temperature.

· The peak exothermic temperature rise from ambient at maximum recommended pour depth shall not exceed 49℃. The direct-contact temperatures limit of grout to be used shall exceed the calculated temperatures of machinery by at least 10 percent.

· Thermal expansion:

Maximum coefficient of thermal expansion (ASTM C531): 54 x 10^-6 mm/mm/℃

· Linear Shrinkage: Maximum linear shrinkage (ASTM C 531): 0.080 percent.

· Irritants: The use of epoxy grout that gives off noxious fumes or volatile shall be prohibited.

· Creep resistance: The compressive creep shall be within 3.0±0.5 x 10^-3mm/mmwhen tested in accordance with ASTMC1181 under a 28kg/cm² constant pressure at 60℃.

· Effective bearing area shall be a minimum of 95%.

Installation of Equipment

8.4.1 After the final grouting, once the compressive strength is achieved according to the requirements, the equipment shall be released for further activity.

8.4.2 The drivers and driven equipment shall be released for installation after the grout has cured for a minimum of 24 hours.

INSTALLATION PROCEDURE (NON-SHRINK CEMENTITIOUS / EPOXY GROUT)

General

Grouting steps shall be based on manufacturer’s procedure, approved drawings & Specifications, and this Method Statement.

Surface Preparation

9.2.1 Concrete on which grout bear has reached the curing period up until the compressive strength has reached 70% of the specified strength, but not less than 7 days after placement. (SAIC-M-2006: Inspection of Support Foundation Prior to Structural or Equipment Installation)

9.2.2 Concrete shall be sound and surfaces to be in contact with grout shall be free of oil, grease, paint, laitance and other coatings. Surface shall be roughened by chipping, abrasive blasting or other mechanical means in order to expose coarse aggregate and to create irregular surface to which the grout will bond. Prepared surface shall be cleaned of all dust and loose particles. Raking and brooming of neither the concrete before hardening to achieve rough surface is not suitable nor a substitute for chipping or abrasive blasting.

9.2.3 After cleaning, foundation surface shall be tightly covered to keep it free of dust and oil.

9.2.4 Before grouting, equipment bases and base plates shall be leveled and aligned in accordance with design drawings and equipment manufacturer’s recommendations. Vent holes may be necessary in the base plate to eliminate air pockets.

9.2.5 Unless otherwise specified or shown on drawings, the entire foundation surface under the base plate shall be grouted. Areas not to be grouted, such as oil pans or air circulation spaces, must be sealed off before the equipment is lowered into place.

This may be accomplished with oakum or hemp rope, expendable fabric hose (such as canvas fire hose), rigid polyurethane foam, Styrofoam or other soft compressible material.

9.2.6 When using a canvas fire hose, the hose shall be pressurized to a maximum of approximately 0.34 kg/cm²to avoid moving the equipment and affecting its alignment. Also for epoxy grout the fire hose shall be wrapped with polyurethane tape and coated with a heavy paste wax for ease or removal.

9.2.7 When using rigid polyurethane foam or Styrofoam (do not use Styrofoam for epoxy grout), allow 6mm per 25mm of height for crush. The foam shall be installed prior to setting the equipment to ensure a leak-proof joint, apply a bead of caulking compound on the mating surfaces of the concrete to the foam, and of the rigid foam to the bed plate.

9.2.8 Expansion joint in epoxy grout shall be spaced at a maximum of 1.4 meters or 48 inches unless otherwise specified in the approved drawing. Joint filler shall be compatible material and sealed with silicon sealant.

(Note: As per Saudi ARAMCO Engineering Standards, only Cement-Based Non-Shrink and Epoxy Grout are acceptable for Structural and Equipment base)

9.2.9 When using non-shrink cementitious grout, the roughened concrete surface shall be presoaked with clear, portable water in accordance with manufacturer’s recommendation.

9.2.10 When non-shrink epoxy grout is used, all surfaces must be kept completely dry before grouting, unless otherwise specified by grout manufacturer.

Forms, Equipment and Tools

9.3.1 When forms are required they shall be designed for rapid, continuous and complete filling of the space to be grouted, Forms shall be of adequate strength to withstand the forces produced during placement of the grout.

9.3.2 Forms shall be caulked or sealed with tape to provide watertight seal.

9.3.3 For non-shrink cementitious grouting, the foam shall be made according to the grouting height with chamber to avoid grinding in the foundation corners after grouting.

9.3.4 For non-shrink epoxy grouting, on the open side ( Just opposite to pouring side), the form shall extend a minimum of 25mm above the bottom of the base plate being grouted and shall be placed no closer than 45mm~65mm from the edge of the base plate.

9.3.5 On the pouring side, the form shall extend at least 75mm above the bottom of the base plate and shall be place 45mm~65mm from the edge of the base plate or manufacturer’s recommendation.

9.3.6 Form for cementitious grout (normal or non-shrink) shall be coated with approved release agent to prevent grout adherence and absorption.

9.3.7 All chamfered edges required in grouts shall be incorporated into the forms.

9.3.8 The following tools and equipment shall be used for grouting works,

l Hand Wire Brush

l Rotary Wire Brush or Sander

l Air Compressor

l HILTI Machine

l Mixer

l Ladder

l Grinding Machine

l Scaffolding

l Shuttering Material

Mixing and Placing of Grouting Material

9.4.1 Manufacturer’s instructions shall be strictly followed for non-shrink grout preparation, proportions, mixing, forming and depth of pour, pouring, curing and protection.

9.4.2 Grouting shall be preferably be accomplished when ambient and mix temperature are between 5℃ and 32℃ for cementitious grouts and between 12℃ and 31℃ for epoxy grouts. For non-shrink cementitious and epoxy grouts, manufacturer’s recommendation shall be followed.

9.4.3 Sufficient manpower and equipments shall be available for rapid and continuous mixing and placing of grout. Grout shall be mixed in quantities no greater than can be placed in the manufacturer’s specified working time for the temperature at which the grout is being placed. Working time specified shall be considered a maximum value and any grout remaining after the specified working time has elapsed shall be discarded. Do not remix or re-temper stiffening grout.

9.4.4 Any grout that shows evidence of initial set or entrapped air shall be discarded.

Once grout is mixed, it shall be placed continuously and rapidly, preferably from one side only, to avoid cold joints and minimize the change of air entrapment.

9.4.5 The grout level shall not drop below the equipment base. The grout fill location shall be removed only after the grout has filled past the new fill location. Expansion joint dividers shall be used to section off the maximum areas to be poured and worked at one time. Expansion joints shall be installed in accordance with the manufacturer’s instructions for epoxy grout placements of long length or large area.

9.4.6 For flat base plates, grout shall be placed across the small dimension of the equipment base from one long edge to the other, in one direction only. The use of a head box with an inclined plane to direct the grout across the compartment is recommended.

9.4.7 For inverted “U” shaped base plates, such as pump base plates, the base shall contain a sufficient number of relief holes (one 3mm minimum diameter hole per corner) or grout shall be poured from a 100mm hole in the center of each compartment.

9.4.8 Use of a vibrator is not permitted. Also grout shall not be placed when vibrations are being transmitted by the operation of other equipment. Such equipment must be shutdown while grouting and kept idle until grout has set sufficiently.

9.4.9 Cementitious grout may be tampered or rotted to eliminate voids. Care shall be exercise however, so that air is not introduced into the grout.

9.4.10 In making deep pours, epoxy grout shall generally be poured in thickness of 50mm to 100mm per layer. Minimum depth of pour is 50mm or manufacturer recommendation.

9.4.11 Depth of pour is dependent on the product selected and on ambient temperatures.

Deeper or shallower pours may be made if permitted by the manufacturer’s standards.

9.4.12 The final layer, which is to the adhere to the machine base shall be limited to between 25mm and 50mm in thickness, measured from bottom of the machine base or manufacturers recommendation. Epoxy grout shall not be rotted.

Surface Finishing

9.5.1 Exposed surface of grout shall slope away from base plates.

9.5.2 Cementitious grouts shall be trimmed back to the lower edge of the base plate and tapered to the existing concrete once the grout has reached an initial set. Protruding edges shall also be cut back.

9.5.3 Epoxy grout cannot be trimmed after initial set. Top surfaces shall be finished to proper slope before initial set.

9.5.4 Forms shall remain in place for 24hrs or manufacturer’s recommendation.

9.5.5 The final layer, which is to the adhere to the machine base shall be limited to between 25mm and 50mm in thickness, measured from bottom of the machine base or manufacturers recommendation. Epoxy grout shall not be rotted.

Curing & Protection of Grout

9.6.1 Non-Shrink Grout shall be cured in accordance with the manufacturer’s recommendations or when reached up to 70% of the specified strength but not less than 7 days whichever is more stringent.

9.6.2 The temperature of the base plate, supporting concrete foundation and grout shall be maintained during curing as per manufacturer’s recommendations.

9.6.3 After placement, cementitious grout shall be protected from premature drying, excessively hot or cold temperatures and mechanical injury. Curing of non-shrink cementitious grout shall be in accordance with manufacturer’s instructions.

9.6.4 Since water interferes with proper curing of epoxy grouts, moist curing shall not be used.

9.6.5 Curing for epoxy grout shall be in accordance with manufacturer’s instructions.

9.6.6 Unless stated otherwise by the manufacturer, epoxy grouts shall be protected from sudden temperature change for 48hrs.

Fixing and Removed of Shim, Wedge & Pad Plate

9.7.1 Padding shall be done at four sides as minimum or more if required, by using non-shrink cementitious grout for maintain the level of base frame prior to anchor box grouting for pump foundation.

9.7.2 If leveling screws are used to level equipment, the screws shall be coated and backed off after the grout has hardened (after 48hrs) so that machine loads are transmitted only through the grout.

9.7.3 After removing the jack bolt the jack bolt holes shall be filled with epoxy material.

While removing the jack screws, dial indicator shall be placed on the base frame / plate and coupling to indicate any movement is occurred.

9.7.4 Leveling shall be ensured within 0.2mm/m by jack bolt. If required, shims shall be used as minimum.

9.7.5 Metallic shims for all equipment and structural steel shall be blocked off and removed once the grout has hardened, unless specifically requested otherwise by the rotating equipment manufacturers. The space left by the removal of the shims shall be epoxy grouted if required.

9.7.6 Where ever jack bolt is not available in the base frame, the new jack bolt will be welded with base frame for alignment.

9.7.7 For other static equipment the sufficient pads shall be given between the anchor bolts to maintain the base level prior to grouting.

9.7.8 The thickness of the pad plate shall be minimum 10mm

Anchor Bolt / Box & Pipe Sleeves (Pump Foundation)

9.8.1 Except where the use of epoxy grout is identified on drawing, all anchor bolt sleeves shall be filled with the non-shrink cementitious grout after the equipment is in place. (Refer to IFC Drawings)

9.8.2 Once the grouting is completed in the anchor box, the epoxy grouting shall be done to the bottom of pump base frame. (Refer to IFC Drawings)

9.8.3 After that, inside the base frame will be filled with non-shrink cementitious grout. (Refer to IFC Drawings)

9.8.4 All surfaces shall be free of oil, grease and foreign substances.

9.8.5 Where epoxy grout is used, anchor bolts shall be protected from the grout by means of PVC pipe, rubber hose or polyurethane wrapped in several layers around the bolt threaded portion. Annular space within anchor bolt sleeves shall be plugged with a sleeve seal to prevent epoxy grout entering the sleeved space.

FINAL INSPECTION & ACCEPTANCE

The following work shall be subjected to the surveilance of the Company / Contractor inspector at any times as follows,

l Compliance of material with requirements specified herein.

l Preparation of existing surfaces to receive grout.

l Inspection of grouts

l Surveillance performed by Company/Contractor inspection shall not relieve either the Contractor performing the work or a supplier of material of any responsibilities connected with Quality of materials or satisfactory installation of materials.

l During grouting, the field grouting inspection report shall be recorded and it will be submitted for Company/Contractor review.

l After grouting, once the curing and surface preparation is completed the field inspection shall be offered for Company/Contractor QC and it shall be released for further activity.