CORPORATE CRITERIA
CRITERIA FOR MATERIAL STORAGE AT SITE AND PRESERVATION
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CORPORATE CRITERIA
CRITERIA FOR MATERIAL STORAGE AT SITE AND PRESERVATION
CR-COR-CONSTR-008-E
02/09/2013
01
First Issue
L.Ferrazzi COMET
M.Spongano CONFON
E. Magnani BL-ON
Date
Revision
Description of revision
Prepared
Checked
Approved
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Revision Summary
Date
Revision
Description of revision
Prepared
Checked
Approved
02/09/2013
01
First Issue
COMET L.Ferrazzi
CONFON M.Spongano
BL-ON E. Magnani
INDEX
CORPORATE CRITERIA
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1
2
3
SCOPE AND PURPOSE
REFERENCE DOCUMENTS
DEFINITIONS
GLOSSARY
4
ACTIVITIES DESCRIPTION
STORAGE AND PRESERVATION
CHECKING MATERIAL UPON ARRIVAL ON SITE ARRANGING MATERIAL IN THE WAREHOUSE
DOCUMENTATION MANAGEMENT WAREHOUSE AND LAYDOWN AREA SIZING AND LAYOUT
4.1 4.2 4.2.1 SIZING 4.2.1.1 MATERIAL LAYDOWN AREA 4.2.1.2 WAREHOUSE 4.2.1.3 PREFABRICATED PIPING SPOOLS LAYDOWN AREA 4.2.2 LAYOUT 4.2.3 EQUIPMENT AND VEHICLES 4.2.4 PERSONNEL 4.3 4.4 4.4.1 GENERAL CRITERIA 4.4.2 MATERIALS FOR STORAGE INSIDE THE WAREHOUSE 4.4.3 MATERIALS FOR STORAGE IN THE SHED 4.4.4 MATERIAL FOR STORAGE IN UNCOVERED AREAS 4.4.5 TRACEABILITY AND IDENTIFICATION OF MATERIALS 4.5 4.5.1 USE AND APPLICATION OF RUST-PROOFING PRODUCTS 4.5.2 PRESSURE EQUIPMENT 4.5.3 FURNACES, BOILERS AND FLUES 4.5.4 MACHINERY 4.5.5 PIPES/SPOOLS 4.5.5.1 ADDITIONAL REQUIREMENTS FOR COATED PIPES 4.5.6 FLANGES 4.5.7 FITTINGS 4.5.8 VALVES 4.5.9 GASKETS AND BOLTING 4.5.10 STAINLESS STEEL (INCLUDING AUSTENITIC) 4.5.11 STEEL STRUCTURES 4.5.12 ELECTRICAL MATERIAL AND INSTRUMENTS 4.5.13 BATTERIES 4.5.14 LOW VOLTAGE EQUIPMENT 4.5.15 TRANSFORMERS 4.5.16 SWITCHGEAR, STARTERS AND ELECTRICAL CONTROL EQUIPMENT 4.5.17 PROCESS CONTROL INSTRUMENTS AND EQUIPMENT 4.5.18 MOTORS AND GENERATORS 4.5.19 CABLES 4.5.20 PAINTING 4.5.21 INSULATION 4.5.22 CONSUMABLES 4.5.23 HAZARDOUS MATERIALS 4.5.24 MISCELLANEOUS 4.5.25 MATERIALS FOR PRE- COMMISSIONING AND COMMISSIONING OPERATIONS
5
ATTACHMENT
1 SCOPE AND PURPOSE
3
4
4
4
4
5 5 5 5 6 7 7 7 7 8 8 8 8 9 9 10 10 10 11 12 12 13 15 15 15 16 16 17 17 18 18 18 18 19 19 19 20 21 21 21 22 22 22
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This Criteria indicates the how to size the facilities and perform the material storage and preservation in construction projects. The purpose is to uniform the behaviours to be adopted in the various projects in order to optimize the solutions adopted. The roles and responsibilities of project organization for the management of materials and equipment at site are not dealt within this Corporate Criteria, since they are described in the Corporate Standard Procedure “Management of material and Equipment at site” (Doc. n. STD-COR-CONSTR-012-E). This Criteria defines the minimum requirements to be met by the Construction/ Warehouse Subcontractor and site personnel for adequate protection and preservation of equipment and materials at site during project period. Specifications, methods, and activities described in this Criteria are applicable for works performed by a Subcontractor or Direct Hiring.
2 REFERENCE DOCUMENTS
STD-COR-CONSTR-012-E Management of Material and Equipment at site STD-COR-CONSTR-010-E Field Back-Charge Procedure
3 DEFINITIONS
Contractor
Vendor Subcontractor
Warehouse Subcontractor
An Organization to which the Client awards performance for a project or a portion thereof. The party that supplies materials, equipment or packages An Organization appointed by the Contractor to perform activities that make up the scope of the active contract. Organization outside Warehouse activities.
the Group charged with carrying out
GLOSSARY
PVC RTRP HDPE FBE PE NPS HSE
Polyvinyl chloride Reinforced thermosetting-resin pipe High-density polyethylene Fusion Bonded Epoxy Polyethylene Nominal pipe size Health Safety and Environment
4 ACTIVITIES DESCRIPTION
Construction management shall prepare, supported by the Warehouse management and HSE, a project procedure at least 60 days prior to arrival of any material or equipment in the storage area. The procedure has to describe the requirements and specifications of the material management and preservation at site and
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has to be in accordance with this Corporate Criteria and the Doc. n. STD-COR-CONSTR-012-E.
The project procedure may contain also recommendations, requirements, technical specifications and indications of the Vendor;
Material storage activities have to be in accordance to the project procedure covering the material arrival in the warehouse , handling by Warehouse team and construction subcontractors during prefabrication and erection. Prefabrication and Construction Subcontractors have to include costs relating to conservation and protection of materials in the unit prices of the activities assigned to them.
The warehouse team has to apply additional measures, as specified in this document or as required by the Vendor, to protect equipment/materials from intense heat or cold, humidity, water and sand transported by the wind.
Materials and equipment sensitive to weather conditions (i.e. instruments, small tools, welding electrodes, delicate equipment and equipment for special uses) must be stored inside protective structures or in other types of weather-proof structure. These conditioned areas shall be evaluated case by case in accordance to the climate conditions and quantities of material to be stored.
All materials stored outdoors must be positioned so that they are raised at least 10 cm off the ground and not in contact with areas in which pools of water form; for this purpose wooden beams, pallets, concrete slabs or other appropriate means must be used.
Moreover, all the additional protective measures specified by the Vendor in its technical documents must be taken.
Packaged material shall be kept for as long as possible in its original packaging after opening of the parcel for inspection.
4.1 DOCUMENTATION MANAGEMENT
The Warehouse management shall ensure that the Warehouse staff implement and record all protection measures necessary/required for the preservation of materials and equipment. Recorded data must be kept by the Warehouse staff. Copies of these data must be provided upon request from the Warehouse management. Upon receipt of equipment, the relative operating and maintenance manuals and any other type of documentation accompanying the equipment must be immediately checked against the delivery note.
4.2 WAREHOUSE AND LAYDOWN AREA SIZING AND LAYOUT
4.2.1 Sizing
4.2.1.1 Material laydown area
The uncovered storage areas earmarked for material storage must be sized using the following parameters:
A) Fenced areas: 0,5 m2 per ton of mechanical material to be assembled, excluding tanks, spheres and
modules.
The fenced area must be:
− situated near to the site and the main offices, if possible; − provided with an office hut with services, covered shed and lean-to roofing; − adequately enlightened;
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−
flat and compacted to allow the circulation of vehicles such as fork-lift trucks.
B) Unfenced areas: 3 m2 per ton of mechanical material to be assembled, excluding tanks, spheres
and modules.
The unfenced area must be:
−
located as close as possible to the fenced area (for some materials areas with clear advantages can be identified and set apart: exploit pre-existing roads or tracks or place some materials near the assembly areas);
− equipped with wide enough roads to allow the circulation of trucks, even in the presence of a
crane in operating position.
If there is risk of theft of the material, the total area shall be fenced and considered 3 m2 per ton of mechanical material to be assembled, excluding tanks, spheres and modules.
4.2.1.2 Warehouse
The warehouse may be composed of one or more sections and will be provided with:
− electrical energy; − water; − drains (septic tanks); − ventilation (in tropical countries); −
fire-fighting system
- Covered section for mechanical material to be assembled.
−
- area of: 0.08 m2 per ton of mechanical material to be assembled , excluding tanks, spheres and modules.
It may be constructed using a traditional structure with walls made of corrugated metal, pre-fabricated modular wooden elements, brick, etc.
- Total surface of warehouse shelves
- 0,08 m2 per ton of material to be assembled
-
Covered separated section for painting to store a maximum 40% of material, considering rotation
due to the application:
- area of will be 1 m2 for every 3,000 m2 of surface to be painted.
For the storage of dangerous materials (toxic, corrosive, flammable etc) an isolated building with air conditioning must be provided, especially in tropical climates. In addition to the above, all the requirements included in the MSDS of the materials shall be followed during the design of the warehouse. Proper safety signs shall be applied at the entrance of the warehouse.
- Shed section for insulation material
- 1m2 of shed for every 150 m2 of surface to be insulated. The area may be used to store a maximum 40% of material, considering rotation due to assembly
- Marshalling yard
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- 0,8 m2 per ton of mechanical material to be assembled in order to consider the circulation roads
- Shed Section for materials which can be exposed to the weather, but in their packaging:
- 0.02 m2 of shed per ton of mechanical material to be assembled
4.2.1.3 Prefabricated piping spools laydown area
- 5 m2 per ton of prefabricated piping material considering rotation of the spools started on assembly
4.2.2 Layout
The typical layout of a warehouse of 5,000 tonnes is included in the attachment 1.
A proper ramp and door shall be considered for the access of voluminous boxes.
4.2.3 Equipment and vehicles
The warehouse must have sufficient equipment for storing crates and enough vehicles for unloading and transporting materials, both inside and outside.
The vehicles required for a 5,000 tonne warehouse are as follows:
− A 10 to 30 tonne truck cranes, with four-wheel drive, suitable for loose, sandy ground, and
preferably with a telescopic arm;
− A 30 to 50 tonne truck crane, with four-wheel drive; − A 3-ton electrical fork lift to be used inside the covered warehouse; − A 7-ton diesel fork lift to be used outside and inside the covered warehouse; − Manual trolleys 2,5 or 4 ton ( mandatory if the electrical forklift is not available); − Hydraulic jacks (with maximum travel of around 250 mm); − Tractor with trailer; − Smaller items of equipment, etc.
For major site a boom truck (20 ton) shall be required. For the material management system (MAGA or similar), a Personal Computer must be provided in a dedicated Warehouse office.
4.2.4 Personnel
Here below the personnel involved in the management of material in the warehouse and between the bracket the minimum amount of personnel required for a 5,000 tonne warehouse:
− Warehouse Superintendent (n.1) − Warehouse Supervisor (n.1) − MAGA/MARIAN Operator & Data Entry (n.2) − Material reception assistant (n.3)
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− Material collection assistant (n.3) − Vehicle operators (n.3) − Labourers for opening crates and the physical storage of the materials. (n.10)
The sizing of the personnel shall consider the holiday rotation and absences of the workers. The reception material and issue group shall be independent in order to avoid backlog especially if more subcontractors are present at site.
4.3 CHECKING MATERIAL UPON ARRIVAL ON SITE
All the material received at site shall be inspected and if arrived in shortage/surplus quantity or damaged shall be treaded in accordance to the STD-COR-CONSTR-010-E Field Back-Charge. Upon arrival on site, all equipment shipped with protective covers or plugs over opening, and with rust preventive coating applied on exterior machined and threaded surfaces, shall be threaded as follows at arrival to site: • •
if damaged, the protective covers, caps and coatings must be replaced; if water or dirt has penetrated the equipment through damaged or incorrectly fastened caps or covers, it must be cleaned and the covers and caps repositioned and coatings must be reapplied.
If steam phase corrosion inhibitors or desiccating agents have been used to protect internal parts of mechanical equipment, the seal gaskets must be examined upon arrival on site. Any damaged steam seal gaskets must be replaced, including restoration works; if necessary the inhibitor or desiccating agent must be restored. Steam seal gaskets must be protected until the equipment is ready for start-up. Any damage to the gaskets before such time shall be immediately repaired. All items arrived under nitrogen preservation shall be regularly monitored and recorded in order to guarantee their conservation.
4.4 ARRANGING MATERIAL IN THE WAREHOUSE
4.4.1 General Criteria
the event
that materials normally destined
Storage must be carried out with due consideration for the type of material and for the recommendations of suppliers contained on the packaging and on the documents verified with PEM/FEM staff. The order number must be given on packages and on material using indelible paint. An exception to this is piping material, which is handled according to the GEMAPI programme logic (or similar) and then stored and identified by mark code. In for storage under cover (electrical switchboards, instrumentation etc.) must, for a variety of reasons, be stored for a reasonably long period outdoors, on arrival on site it must be ascertained that their wrapping is appropriate and in suitable condition for outdoor storage. Specifically, hole covers must be fully intact and must not have been damaged or cut during customs inspections, etc. In the event that packaging is not suitable for outdoor storage, a covered storage area shelter will need to be found. If water infiltrates, the equipment must be unwrapped immediately and placed under cover from where it can be checked and undergo any interventions required.
4.4.2 Materials for storage inside the warehouse
The following materials must be arranged, differentiated and kept separate on the shelving inside the warehouse:
fittings, flanges and valves smaller than or equal to 2”;
• gaskets; • • bolts and tie rods; • dry transformers;
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switchboards, cabinets;
• • accumulator batteries and accessories; • • •
spare parts; lighting equipment; telephone equipment, clocks, telecommunications;
loudspeakers,
intercoms, electronic components,
i.e.
for
• mineral insulated heating cables; coils of cables and conductors; • • cable accessories (couplings, terminal ends, mixtures, tapes, crimps, etc.); • materials for cathodic protection; • equipment, machines, worktops and instruments for laboratories and electrical workshops; • all electrical installation materials such as boxes, sockets, manipulators, lighting fixture accessories,
• • •
fittings and all small sized materials; relays, instruments, etc.; circuit breakers, disconnect switches, fuses; control panels, analysers, local switchboards, flow devices, levels, accessories and instrument assembly equipment;
• particularly delicate materials for which storage in a closed area or even in an air-conditioned
environment is requested.
4.4.3 Materials for storage in the shed
Materials that can be exposed to the weather as long as they are protected by the original, undamaged wrapping can be stored in the shed. These include:
• • • •
complete rotating machines; transformers, high-voltage equipment, generating sets; lighting fixtures for outdoor installation; recorders, earthing equipment, dielectric liquid oils, different liquids in appropriate, labelled containers, and similar liquids;
• machinery, safety valves and control valves; • •
catalysts; refractory materials that do not need to be assembled immediately.
The materials must be stored off the ground and protected with tarpaulin or polyethylene sheets. Safety and control valves in particular must be stored in their own casing. These items are usually included in seaworthy packing with silica gel bags to absorbe humidity.
4.4.4 Material for storage in uncovered areas
The following material must be stored in open fenced areas:
flanges, fittings, valves, filters over 1” ½
• • pipes below or equal than 2”; • • • machinery; • metal sheets and various steel sections.
stainless steel pipes; internals for columns and reactors;
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The following material must be stored in open unfenced areas( always if the area is safe and secured otherwise in fenced area): • prefabricated supports; • pressurised containers, heat exchangers, air coolers; • pipes of diameter greater than or equal to 2”; • • grating; • prefabricated piping; • other material for which there is no risk of tampering or theft.
structural steel works;
As reported in para. 4.4.1.1, if in case of risk of theft of the material, the total area shall be fenced and all the material shall be stored inside that area.
4.4.5 Traceability and identification of materials
Particular attention must be paid to the following regulations which allow warehouse staff to locate the position of materials and to identify them without the risk of error:
• First of all, an accurate map of covered and uncovered storage areas must be drawn up indicating a coding system (4 letters and numbers) which facilitates identification of all areas (each coded unit = max 15 m) and each shelf.
• The location codes must be highlighted in the areas by means of signs and also written on the
shelves.
• All the piping material shall be segregate by type of material Grade, and arranged by size schedule and rating, in ascending way from the smallest to the biggest. This will allow to easy track the items in the yard and in the shelf areas, furthermore it will keep distance between similar material, same size schedule and rating but with different base material, avoiding to be by mistake confused one each other during marking and or wrongly pick it up during issuance.
• All steel pipes must be identified with bands of paint coloured according to specifications issued by the Layout and Piping department (TUB). Whenever the marking has not been done by the supplier, the warehouse staff must see to this on site. It is advisable to extend this system to the fittings too. • Non piping materials belonging to the same order must be arranged, when possible, in the same
area, and packages or materials marked with the number of the order and the package.
• The location code must be accurately transferred to computer at the moment the materials are
logged.
4.5 STORAGE AND PRESERVATION
A correct materials conservation programme is a significant component low plant running costs. It supplies the necessary guarantees of efficiency and functionality of items upon whose original characteristics atmospheric agents act negatively over time. Failure to restore certain conditions recommended by suppliers can result in the loss of contractual guarantees for the materials. In the next paragraphs are indicated the indications to store and preserve properly based on the type of material.
4.5.1
Use and application of rust-proofing products
If required, all internal and external surfaces must be cleaned and dried before applying rust-proofing products. Cleaning must be carried out with alcohol based minerals or other standard solvents. In particular cases and where specified by the Vendor or the Contractor, cleaning can be carried out by blast- cleaning, pickling or with other chemical products, while inert gases can be used to protect from rust. Kerosene and petrol must not be used as detergents. The Warehouse Superintendent must specify the rust-proofing products to be used for each application.
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4.5.2 Pressure equipment
The following requirements integrate those already described in the previous paragraph, and must be applied to all pressure equipment, including heat exchangers such as: plate, plate-fin, electric, double tube, etc.
The equipment shall be placed on supports using the same criteria used by the Vendor during transport. The following instructions have to be complied with to protect the equipment until start-up:
• • • •
cover manholes with gasket; close all other openings and clamp correctly as established in the Vendor’s technical document; apply the rust-proofing product to flanges and exposed parts of bolts if required; check the condition of external primer and touch up where required.
The flanges of equipment with permanent blanks or with covers must be provided with the gasket and tie- bolts indicated for the project. As minimum they shall have to be secured with at least four tie bolts equidistant from one another.
Replaced inhibitor fluid and hygroscopic products must be Chlorine-free, suitable for the purpose and must not cause intergranular corrosion.
Threaded connections must be protected with caps. The vent holes of reinforcing plates must be sealed with grease.
Where marking is carried out, products used must be free of lead, sulphur, zinc, cadmium, mercury, chlorides and other halogens.
Additional instructions for reactors, columns and vessels
• Where possible, equipment to be erected in vertical position has to be stored in the storage area in the same position. After erection on the foundation, the interior has to be completely cleaned, dried and inspected.
• Equipment partially prefabricated in the workshop or subject to deformation during transport and/or lifting and erection, or delivered in ferrules for erection on site has to be suitably bracketed. Interior parts already installed inside equipment (e.g. wire mesh pads, distributors, etc.) have to be inspected to check their conditions; temporary supports will be checked and restored where necessary.
•
• Plates, packing, distributors and special parts have to be stored inside the warehouse or under a
shelter.
Where required, unless otherwise specified by the vendor, nitrogen will be maintained at a pressure of 0.5 barg.
Additional instructions for shell and tube bundle of heat exchangers.
• The main flanges of tube heat exchangers which are normally closed with service gaskets will not
be opened, unless specifically required.
• Where required, unless otherwise specified by the vendor, nitrogen has to be maintained at a
pressure of 0.5 barg.
Additional instructions for air coolers.
• All electrical and moving parts such as: fan blades, hubs, actuators, belts, pulleys, vibration switches,
etc. have to be stored under cover in a dry place with no humidity.
• All parts delivered packaged such as: dampers, protective mesh, conveyor blades, etc., have to be
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inspected upon arrival on site. Damaged parts have be repaired or replaced according to Field back- charge Procedure (Doc N° STD-COR-CONSTR-010-E) and then stored in the warehouse according to the vendor’s instructions.
Additional instructions for special pressure equipment
• Stainless steel plate heat exchangers have to be protected with a non-toxic and easily removable vapour phase corrosion inhibitor (recommended quantity 1kg per cubic meter). Openings must be closed suitably to avoid leakage of the inhibitor, to ensure it remains efficacious.
• The junction box of heating elements of heaters exchangers have to be inspected to check there is no water or condensate; should these be present, the box has to be completely dried, cleaned and inspected to check the condition of electrical connections between heating elements. The main switchboard has to be stored under cover.
4.5.3 Furnaces, boilers and flues
After installation of furnaces, comply with the following procedures until start-up:
• hinges of furnace and of access doors must be greased to allow immediate operation; • moving components of burners must be lubricated to facilitate threading and allow
regulation of mechanisms;
• a rust-proofing product must be applied, with a brush or by spraying, to unpainted outer
surfaces to ensure the metal is protected; • Refractories must be kept dry at all times.
Any further storage requirements indicated by the manufacturer in the receipt, storage and erection phases must be strictly complied with.
4.5.4
Machinery
After installation at their final service location, turbines, centrifugal fans, gear unit cases, agitators, centrifugal pumps and centrifugal compressors shall be protected as follows:
•
• •
coat internal bearings, housings and gearboxes with a protective agent. Rotate the shaft of machines with roller bearings once a week, following the indication of the direction of rotation; for machines with sliding bearings, comply with the Vendor’s instructions; venting and drainage connections must be closed using steel fittings (caps, base plates or blind flanges);
• blind elements must be equipped with gasket; • motor joints and unpainted machined surfaces must be cleaned and coated with a suitable protective
• •
•
agent; spacers must be stored in the warehouse and duly identified; suction and delivery ports of centrifugal compressors, centrifugal pumps and steam turbines must be closed with sealed metal casings; closing/opening casings must not be removed until completion of the hydrostatic and flow tests of connection pipes;
• all centrifugal pumps with mechanical seal installed must be completely filled with a suitable
protective agent, in conformity with the mechanical seal manufacturer’s instructions; spare parts for shafts must be stored indoors, in accordance with the manufacturer’s instructions.
•
After packing removal, reciprocating pumps, reciprocating compressors and internal combustion engines shall be checked and protected as follows:
•
•
rods, cams, exposed pistons and machined surfaces must be coated with a suitable protective agent; cylinders and relative valves must be sprayed with a suitable protective agent;
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•
the transmission mechanism of proportioning pumps must be filled with a suitable protective agent;
Internal combustion engines must be protected in conformity with the specifications of the previous paragraph and with the following instructions:
• where possible, electrical accessories such as magnets, which can be damaged by humidity, must be
stored in a warm and dry place, protected from humidity and condensate;
• a small quantity of protective agent must be sprayed inside each cylinder through the spark plug openings
or through the injectors;
• a further protective agent of suitable type must be sprayed inside the cylinders each time the crankshaft is
rotated, in compliance with the times indicated by the manufacturer.
Other not painted mechanical equipment shall be protected as follows:
• units must be filled with a suitable protective agent until all internal surfaces are coated; • all shafts, couplings and unpainted machined surfaces must be coated with a protective agent; • chain transmissions (if present) must be cleaned with solvent and treated with a suitable protective agent.
4.5.5 PIPES/SPOOLS
In the operation of loading, unloading and storage in stacks, pipes must always be handled in a manner that prevents damages (shearing, cracks, bending, crushing, etc.) to pipe walls, to chamfered ends and to the coating (including the internal coating, if present).
Figure 1 – Piping laydown
Pipes must not be placed directly on the ground and at least 10 cm above. Surfaces on which the pipes are placed or stored in stacks must be flat and have no protruding parts, to ensure even support along the whole length of the pipe; otherwise, evenly spaced supporting strips must be provided, to prevent bending or deformation of the pipe.
Pipes must not be drawn or rolled on the ground.
Separate stacks shall be prepared for the different pipe diameters, thickness and material grade of project, each stack shall not be higher than 2 meters.
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Figure 2 – Piping stack preparation
PVC/RTRP/HDPE pipes must be suitably supported; supports must be spaced apart to prevent bending of the pipe, which would also damage the coating. Threaded ends must be protected with grease and with metal, wooden or plastic covers.
RTRP pipes and fittings must be protected from direct sunlight if not treated with protective resin by the vendor.
All openings on austenitic stainless steel pipes/spools with the internal coatings must also be sealed to prevent humidity from entering. All prefabricated spools to be stored in the dedicated area must be prepared as follows:
•
flanges shall be covered with a timber, metal or plastic cap fastened to the flange by bolting or wiring. The cap dimensions shall be such as to ensure protection of the whole flange face and bevels shall be protected by means of covers fastened to the pipe;
• ends of threaded couplings shall be protected by means of caps; • pipes of large bore (DN 30”) shall be protected internally by means of suitable removable spiders
•
or cross-pieces to prevent flattening or deformation during transport; if chemical cleaning is to be carried out, flanges must be protected on the whole of the gasket surface with a stiff metal or wooden sheet, which will be firmly fixed after application and/or re- application of the rust-proofing product on the coupling surface of flanges; rust-proofing products and greases must not be used on previously cleaned spools;
• • all prefabricated piping material must be stored so that it is not in contact with the ground.
Figure 3 – Spool Area
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4.5.5.1 ADDITIONAL REQUIREMENTS FOR COATED PIPES
Coated pipe must not be drawn or rolled on the ground. The pipes are to be placed at a height of at least 150 mm from the ground on a wooden spacer planks, or sand bags sufficiently large to prevent damaging the coating. Internal coated pipes must only be handled on the outside. Pipes and fittings coated internally and externally must be handled with the aid of large slings and fabric or rubber padding. Belts and slings made of cloth or hemp must be used, of dimensions suitable for the weight of the equipment to be lifted. During storage, FBE (Fusion Bonded Epoxy) coated pipes must never be stacked directly against one another. They must be separated by non-compressible bands padded with rubber or equivalent, at least 10 mm thick that cover the whole of the circumference of the pipe.
The FBE coated pipe shall have full encirclement separation pads, two shall be located 1 to 3m from each end of the pipe, others pads shall be placed to support the center section of the pipe so that distance from one pad to each other is approximately 5 meters. If required, additional protective padding will be used to prevent contact between FBE coated pipes.
Padding must be fastened fixed to the pipes to ensure they remain in position.
PE coated pipes can be stored in stacks in direct contact with one another, without using separating padding.
In the case of supplies of flanged spools, the Contractor shall take the necessary precautions to prevent flange interference between spools using wooden protection disks, rubber protections or sand bags.
4.5.6
FLANGES
Flanges must be stored in pyramid shaped stacks, around 1 m in height.
They shall be coupled in pairs, separated by discs made of soft material (cardboard, strips of soft wood, etc.) in order to protect the resting surfaces of the gaskets.
Moreover, they must be raised off the ground and rest on wooden platforms.
Flanges must be protected with grease or another suitable protective agent, on the whole surface of the gasket. O-ring grooves must be protected with lubricating grease.
4.5.7
FITTINGS
Figure 4 – Flanges
The fittings must be properly arranged in stacks in order to prevent them from sliding down. The height of the stack must be proportional to the diameter and in any case no higher than 1.5 m.
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They shall be placed on a floor of wooden boards and in such position place that rain water does not stagnate inside. They must be handled following the same indications provided for pipes. Suitable measures must be taken for material grades subject to corrosion in order to avoid it.
4.5.8 VALVES
All valves must be stored under cover, with the exception of the following:
Figure 5 – Fittings
• manually operated valves, NPS (Nominal Pipe Size) or larger in size, can be stored outdoors, on
wooden strips, with the stem in vertical position;
• automatic control valves, NPS or larger in size, can be stored outdoors, on dry paved areas or on pallets if a canopy, roof or tarpaulin (or equivalent) is required, or according to other instructions of the vendor. The valves shall be kept in the box.
• actuators on control valves and on motorized valves must be protected from mechanical damage.
All exposed mechanical parts that may be subject to corrosion must be protected with a suitable protective agent. Pressure relief and safety valves shall be stored in an up-right vertical position in weather protected areas. The flanged ends shall be properly plugged, sealed and covered to prevent entrance of sand, dirt and rain. All valves stored outdoors must be completely covered with plastic sheets. After being stored, all valves must be in closed position, with the exception of plug valves and ball valves. All other manually operated valves must be provided with protective sheathing.
4.5.9 GASKETS AND BOLTING
Figure 6 – Valves
The Warehouse Subcontractor has to store these under cover in dedicated areas for all types of gasket according to various diameters and all types of stud and nuts according to various diameters.
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4.5.10 STAINLESS STEEL (INCLUDING AUSTENITIC)
The stainless steel material, including austenitic, must not be exposed to salt water or other products containing salt and to the effects of the weather.
Equipment, components and materials in stainless steel (including austenitic) must be protected as follows:
• under cover (only for pipe fittings or other items of small dimensions); • avoiding contact with carbon and alloy steel material, to prevent contamination; •
stored not in direct contact with the ground or on supports made of porous material such as untreated wood.
4.5.11 STEEL STRUCTURES
Steel structure material must be placed at least 15 cm above the ground with the intersection of padding or plastic between the elements. For the handling, soft slings shall be used in order to prevent damages to the painting.
Gratings shall be stock properly to avoid bends and damages to the toe plates already fabricated together.
Figure 7 – Steel structure storage
Figure 8 - Gratings
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4.5.12 ELECTRICAL MATERIAL AND INSTRUMENTS
Additional actions that Subcontractor has to take for the protection and conservation of electrical material and instruments, the contractor will take the measures indicated in the Vendor’s instructions.
Figure 9 – Electrical Material
4.5.13 BATTERIES
All batteries must be stored under cover in accordance with the manufacturer’s instructions.
Battery caps must be checked upon arrival on site and replaced if damaged.
For batteries shipped already filled with acid, the electrolyte level must be checked upon arrival on site and, if low, restored to the correct level.
The storage periods from the date of shipping to the date of installation and initial charging must not exceed those indicated by the manufacturer.
4.5.14 LOW VOLTAGE EQUIPMENT
All low voltage equipment, such as lighting equipment, transformers, push buttons, pilot flames, relays, counters, etc., must be stored under cover, in a dry place where condensation of humidity cannot occur.
4.5.15 TRANSFORMERS
All transformers must be stored under cover, with the exception of transformers designed for outdoor use. These can be stored outdoors without any protective covering.
For transformers supplied with insulating liquid, liquid level and ambient temperature must be measured and recorded upon arrival of the unit on site, and subsequently every month.
If the level drops, any leaks must be repaired by who is in charge of preservation and insulating liquid added to maintain the level within the tolerance limits; subsequently, any responsibility of the Vendor must be ascertained.
Transformers shipped with its main tank filled with insulating liquid and immersed in pressurized gas, or filled with pressurized gas, gas pressure, liquid level and ambient temperature must be measured and recorded upon arrival of the unit on site, and subsequently every month. If the pressure drops below the minimum level indicated by the manufacturer, any leaks must be repaired and gas must be added to return the
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pressure within the tolerance limits.
4.5.16 SWITCHGEAR, STARTERS AND ELECTRICAL CONTROL EQUIPMENT
Equipment not provided with suitable protective packaging for transport by sea must be stored under cover, in a dry and warm place, where humidity and condensate cannot occur as follows:
• •
• •
the storage place must be well-ventilated; in the case of high relative humidity or sudden and significant changes in temperature, heaters must be used to maintain the temperature in the place of storage at around 6 °C above the minimum daytime temperature (alternatively may be set 4°C under the dew point calculated with the minimum daytime temperature and higher daytime relative humidity); the temperature must not exceed 40 °C ( verify temperature on the vendor recommendations); in damp places, it may be necessary to remove equipment from shipping crates to allow air to circulate and prevent mould from forming.
Parts of equipment to be installed in vertical position must be stored in the same position.
Circuit breakers and similar items must be stored under cover.
Switchgear buildings shall be air conditioned after installation of switchgear, starters and control equipment (if the permanent air conditioning system is not available, portable units must be used to maintain the temperature below 40 °C).
4.5.17 PROCESS CONTROL INSTRUMENTS AND EQUIPMENT
All instruments must be stored under cover and marked with the appropriate tag number. The temperature inside the warehouse must be controlled to prevent humidity caused by condensate. Prefabricated electrical panels must be left in their packaging until reaching their final installation position. Instruments for which the manufacturer has not indicated temperature requirements must be stored at a temperature of between 6° and 40 °C. Potentiometers must never be exposed to temperatures below 0° or above 50 °C. Instruments including control valves and motorized actuators installed outdoor, must be protected from mechanical damage and from weather conditions. Glass screens must be provided with wooden coverings and openings/orifices must be equipped with dust covers or caps. Control valves must be protected following the same indications provided for valves (paragraph 4.5.7).Particular care shall be dedicated to the actuators. Motorized actuators must be protected following the same indications provided for motors (paragraph 4.5.17). For instrumentation equipment, including microprocessors, control consoles, video consoles, process computers and relative accessories, packaging must be removed in an air-conditioned, dust-free environment, with maximum temperature of 30 °C. Instrumentation equipment in control rooms shall be installed when such rooms are air-conditioned (permanent or temporary). For analysers, control systems and all control tools located indoors, such as DCS panel, computers, information equipment, control devices, etc., the manufacturer’s requirements and recommendations must be followed. They are usually included in an air conditioned warehouse.
4.5.18 MOTORS AND GENERATORS
Indoor storage is required for all motors and generators except motors designed for outdoors use, which can be stored outdoors without protective covering. Motors of 75 KW and greater must be equipped with internal heaters. After arrival on site, heaters must be energized using an alternating current socket, complying with the indications on the motor rating plate.
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Upon arrival of motors and generators, the insulation resistance of the windings must be tested and recorded. For motors and motorized valves stored outdoors and without protection, the following measures must be observed:
• all inlets that are closed during operation of equipment, such as the cable and duct entry in
terminal boards, must be closed with watertight caps;
• all valve actuators must be in their normal service position during storage, i.e. vertical motors will
be positioned vertically with the shaft facing downward.
After installation, motors with oil lubricated bearings, motors and generators must be protected according to the Vendor’s indications.
Every three months, the insulation resistance of each coil with a value greater than or equal to 2300 Volts must be measured and recorded; weather conditions and temperature must also be recorded during this operation; if the resistance value is low, the Subcontractor must inform the Contractor immediately to decide which corrective actions must be taken.
If units lubricated with grease have remained out of service for more than a year, the condition of the grease of the bearings must be checked before use; if there is visible deterioration in the lubricating properties of the grease, it must be replaced and the bearings subsequently re-filled according to the manufacturer’s instructions.
Motor shafts with a power greater than or equal to 75 KW must be rotated once a month or more frequently, complying with the manufacturer’s indications, to prevent the shaft from becoming permanently deformed during storage.
4.5.19 CABLES
Cables arranged on reels without covering must be protected from direct sunlight. The ends of cables must be protected with tape to prevent humidity from damaging the insulation (if not already provided by the Vendor). Reels must be arranged in parallel double rows, spaced from one another to allow the passage of vehicles for handling; storage in stacks is not permitted. Moreover, reels must be stored in a manner that prevents them from rolling or slipping. To facilitate location, reels must be arranged in sections and numbered accordingly. The fiber optic cables and for the electrical heat tracing is mandatory a covered dry storage. For cold climate, it’s preferable to store the cable under sheltered area to avoid ice creation.
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Figure 10 - Cable drums
4.5.20 PAINTING
The material shall be stored in well ventilated places, far away by fire ignition sources and with fabrication/expiration date well indicated. Special precautions shall be adopted in accordance with vendor and safety recommendation.
4.5.21 INSULATION
The storage should be in a covered and dry area and the materials should be left in original packing. An air gap should be provided between the products and the floor and stacking should be limited to 2 heights (2.40 m maxi).The storage shall be done in accordance to vendor and safety instructions.
4.5.22 CONSUMABLES
This material is usually provided by Subcontractors. Subcontractors are required to provide the procedure for receipt, handling and storage of consumables supplied by them. The electrodes, especially the covered one and rods, shall be stored in a conditioned, dry and water tight area to avoid moisture pick-up and contamination. Vendor recommendations shall be followed As per general indication here below some data about the temperature and humidity level to be maintained:
• 5-15 °C • 15-25 °C • >25 °C
max 60% RH max 50% RH max 40% RH
If the electrodes are included in vacuum pack can stay al higher temperature that shall be verified inside vendor datasheets. Low hydrogen covered basic electrodes should be re-dried before use whenever there are application requirements relating to weld metal hydrogen content and/or radiographic soundness (not needed for vacuum packed). Acid rutile stainless electrodes and all types of basic electrodes may produce pores in the weld metal if they have not been stored in sufficiently dry conditions. Re-drying the electrodes will restore their usability. Mild steel rutile and acid electrodes normally need no re-drying. Cellulose electrodes must not be re-dried. The electrodes that are seriously damaged by moisture, cannot be restored to their original condition by baking and should be scrapped. The electrodes shall not be stacked more than four layers of electrodes in the redrying oven and it’s
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recommended not to redry covered electrodes more than three times. The maximum storage time for all the electrodes is 3 years. After this time the product should be thoroughly checked before use.
4.5.23 HAZARDOUS MATERIALS
Storage of hazardous materials must be carried out in a reserved area following the precautionary measures indicated in the Vendor’s data sheets and according to the project HSE requirements.
4.5.24 MISCELLANEOUS
The storage and handling of all catalyst material are to be carried out strictly in accordance with Licensor and Vendors’ Instructions. Any containers damaged during transport must be repaired and stored separately, following the Contractor’s recommendations.
Drums of lubricating oil must be stored outside the warehouse and be positioned with the oil pouring spout facing upward and in any case in a manner that prevents spillage of oil. Soft wood must be used to prevent direct contact of drums with the ground.
4.5.25 MATERIALS FOR PRE- COMMISSIONING AND COMMISSIONING OPERATIONS
Storage of operating materials must be carried out in a reserved area following the precautionary measures indicated in the Vendor’s data sheets and/or the instructions of the Commissioning Manager. The chemical and lubricants shall be stored following the precautionary measures indicated in the Vendor’s data sheets and in case that are hazardous in accordance to HSE requirements
5 Attachment 1 : Typical warehouse layout for 5,000 tonnes
ATTACHMENT
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Project: Q-32705 - Saipem COMP3 Folder: RFQ Files