| Reference Documents: | |
| 28-4WCE600510 | Specification for the Erection of Cold Boxes |
| 28-4WCE600500 | Crane and Lifting Procedures |
| 28-4WMA007018 | Site Plumbness Tolerances for Erected Distillation Columns and Cold Boxes Containing Distillation Columns |
| 28-4WPSVALV11 | Proper Handling and Weather Protection of Samson Cryogenic Globe Cold Box Valves with Bellows Seals |
| 28-4WPSVALV12 | Use of Samson Shipping Covers for Pressure Testing of Cold Box Process Piping and Valve Weather Protection |
1. Receiving and Off Loading
1.1 Thoroughly inspect boxes for shipping damage prior to acceptance from carrier, and transmit boxes to contractor prior to off-loading.
1.2 If box or column were shipped with acceleration and impact monitor secure record tapes.
1.3 Verify and document circuit pressures prior to off-loading. If purge has been lost, document on the transportation company’s “Bill of Lading”.
1.4 Lifting procedures for off loading cold boxes and column need to be submitted to and approved by Air Products home office Construction Engineering Department. Lift only at points shown on the transportation and erection drawings.
1.5 When transporting to site the cold box should only be supported at the cribbing points or saddles as shown on the transportation drawings.
1.6 If storing on the ground, use heavy timbers located at the cribbing points only.
1.7 Ensure areas for off-loading and cribbing have adequate bearing capacity. Mat as required distributing the dead load on supporting surface.
1.8 Remove all shipping supports and tie-downs from railroad cars and make sure all reusable and returnable materials are consolidated and returned to the sender if applicable.
1.9 Note the cold box and column purge pressures after every moving operation for future reference.
2. Transporting
2.1 Lowboys and dollies must have adequate capacity to handle loads. Home office approval of the transport is required.
2.2 Dolly controls shall not be directly lined to trailer without electrical isolation.
2.3 The contractor needs to obtain transport permits from the appropriate authorities.
2.4 The transport route shall be surveyed. Items to be noted are corner turning radius and obstructions, deep ditches, high humps in road can cause problems, overhead obstructions, etc.
2.5 Along the route, review height of overhead wires, especially high voltage electrical wires. OSHA specifies minimum clearance distances based on line voltages. Contact local telephone, cable television, and power companies to coordinate elevating or removal of cables or lines as needed along the route.
2.6 Make sure escorts are arranged for to accompany the loads, if necessary.
2.7 Boxes need to be securely tied down to all transport vehicles.
3. Erection
3.1 The assembly of the crane and boom shall be considered in the project schedule and layout.
3.2 A detailed procedure should be submitted to Air Products’ Construction Engineering Department home office for review and approval prior to lift. See 28-4WCE600500 for the full lift procedure.Lifting information required is defined in Appendix “A” Lift Plan Requirements of specification 28-4WCE600500. Some of the information required include:
3.3 Weight and center of gravity
3.4 Type and size of cranes being used.
3.5 Crane inspection and operator certifications.
3.6 Capacity chart and working radii to be used for each crane.
3.7 Certified capacities of the slings and shackles to be used.
3.8 Lifting/spreader bars need to have been tested and certified, or have a design drawing to verify capacity and safety factors.
3.9 Special custom design grabs, hooks, clamps, or other lifting accessories shall be marked to indicate the safe working loads and shall be proof tested prior to use to 125% of their rated load. Drawings/sketches required:
3.10 Plan: Drawings for crane layout in respect to foundations. Drawings should also show positioning of cold boxes or column while still in the horizontal, and swing stages.
3.11 Elevation: Drawings to also show load in vertical position so that optimum boom length is utilized to eliminate interferences between the boom and the cold box or column.
3.12 Main cranes shall have swivel hook to obtain proper box orientation.
3.13 Verify that all shipping supports are removed before or after erection as specified. The cold box designer or fabricator shall provide a list of these supports and other temporary shipping supports, along with notes on the drawings.
3.14 Review site underground drawings. Look for underground piping, drain lines, culverts, etc. that might cause ground to become unstable or collapse. This is particularly important where the outriggers will set.
4. Alignment
4.1 All distillation column, column boxes, argon column boxes or any other boxes with internal distillation columns require aligning to tolerance specified in 28-4WMA007018.
4.2 Use bulls-eye or edge of left front tube steel for aligning column.
4.3 Specification 28-4WMA007018 provides additional information, regarding alignment of vessels.
5. Anchor Bolts and Brackets
5.1 Check that the bracket welding conforms to sizes shown on drawings.
5.2 All anchor bolt brackets need to be welded prior to releasing main crane.
5.3 Dye penetrant check all welds on hold down brackets.
6. Lifting Lugs
6.1 Spreader beams must be used to eliminate excessive lateral loads on lifting lugs. For trunnions they may not be necessary. Side loading angles should be limited to ±5°. A minimum sling angle of 60° from horizontal is required on all lifting lugs.
6.2 Inspect welding and perform a dye penetration inspection on all lifting lugs unless dye penetration test results have been received from cold box or column fabricator.
6.3 Verify that lugs and trunnions are the thickness specified in the structural drawings.
7. Grouting
7.1 Please refer to Audit #16 for more information and Quality Assurance and Quality Control concerns.
7.2 Verify the proper grout is being used. In most cases, non-shrink grout is required. Grout requirements are typically defined in the grout specification.
7.3 Verify drawings and with designer whether internal base members need to be grouted.
7.4 The foundation shall be roughed to expose aggregate for grout areas prior to setting the cold boxes or columns.
7.5 Shims shall be level, recessed, and grouted with a 1″ minimum coverage. Verify that the shims are of an adequate number and size so that the loading on the concrete does not exceed the foundation compressive design strength, typically 3000psi.
7.8 All grout must be properly sealed after curing.
7.9 After the grout cures, apply the torque levels to the anchor bolts as specified in the contract documents for proper bolt pre-tensioning. If none are specified contact the cold box engineer..
8. Valve Installation
8.1 On packed boxes, remove all rockwool from valve area and protect openings against elements.
8.2 Verify that new gaskets were sent for the valve or actuator installation.
8.3 Remove spacers and use new gaskets for butterfly valve installation.
8.4 Inspect piping and valves for cleanliness. If necessary, clean before installation.
8.5 Ensure valves are installed in the proper orientation. If flow directions are not shown on the drawings nor the P&ID’s, consult Design Engineering. The installed valve flow direction may be opposite the actual flow direction. Typical butterfly valves used have the following orientations:
8.5.1 Posi-Seal valves – stem always upstream.
8.5.2 DeZurik valves – flat side always upstream.
8.6 Use only stainless steel for all bolting inside the box.
8.7 After butterfly valves are installed, attach the gear-box or bonnet so that the engraved letter on the stem aligns with the engraved letter on the bonnet when the valve is in the closed position.
8.8 On all globe valves, inspect the seats and plugs (Teflon rings) and clean/replace, as necessary. Slight scratches or marks will cause leaks.
8.9 Sampson valves have their own special installation requirements and a written procedure. Please review this with the contractor prior to installing Samson valves, otherwise leaks may occur, and the valve will not operate correctly. Refer to procedure 28-4WPSVALV11.
8.10 All instrument penetrations must be valved in for pressure testing.
9. Pressure Testing Shop Fabricated or Field Erected Boxes
9.1 Please refer to Audit #7 – Piping and Pressure Testing for more information and quality control requirements..
9.2 Project Engineering must provide pressure test procedures, and Process and Instrument Diagrams (P&ID’s) before starting.
9.3 Unpacked boxes should be pressure tested to discover any shipping damage prior to insulating. Proper confined space safety requirements must be followed for entry into cold boxes.
9.4 Check location and orientation of all orifice and in-line elements.
9.5 Check for any temporary carbon steel hardware, such as studs, U-bolts, angle iron, that is inside cold box and must be removed.
9.6 Cold box and column piping may be tested separately from the yard system. In some cases it may be advantageous to test as one unit even though this may cross-contractual boundaries.
9.7 Ensure all in-line valves are closed after overall circuit test and the downstream side is bled down to check in-line valve holding capacity. Hard seated valves, such as gates and globes, may leak through. List all valves suspected or known to leak through. Identify circuit and drop in pressure for a 10 minute period. Check with Design Engineering for acceptance criteria and correct all valves that have unacceptable leak by. Provide list to PDO of final leak rates for all valves.
9.8 Ensure all instrument taps are bled down after pressure test to ensure that lines are not plugged.
9.9 Bleed down pressure between check valves, block valves and blinds to release trapped gas.
9.10 At a minimum all mechanical joints in unpacked boxes need to be leak tested. If the source of pressure drop cannot be located, branch connections and welds may need to be checked. For packed boxes, only valve bonnets can be leak tested.
10. QC DOCUMENTATION
10.1 Approved transport, offloading and rigging procedures.
10.2 Temporary pipe support log and/or drawing signed to indicate removed supports.
10.3 Temporary heat exchanger plug removal log.
10.4 Vertical alignment records
10.5 Torque values used for anchor bolts
10.6 Dye penetration records for hold down brackets
10.7 Pressure test records
10.8 Pressure test gauge certification sheets
10.9 Rockwool test results and packing records, if a packed box was received
10.10Perlite test records, if a filled box was received