1. PURPOSE
1.1 This global specification defines the procedures to be used in joining column sections on site or other locations outside Air Products-owned manufacturing facilities, to protect the intellectual property within the column internals.
2. Scope
2.1 This specification applies to the site joining and erection of all shop-fabricated columns that need to be joined either at a final construction site or an intermediate location outside an Air Products-owned manufacturing facility.
2.2 It applies equally to whether the work is performed by Air Products manufacturing personnel on site, or a third-party fabricator under the supervision of Manufacturing.
2.3 This procedure (at revision 0) is only applicable to columns joined in the horizontal position. Columns must not be joined in the vertical position without a revision to this procedure.
2.4 No exceptions shall be permitted without the written approval of:
- The Global Manager of the CryoSystems ET (responsible for Manufacturing)
- The Process Technology Information Manager from the relevant ET (Cryogenic Systems, Generated Gases, Energy, HyCO, LNG, or Performance Materials)
- Regional Head of Construction
3. related documents
Note: The following documents by reference, form a part of this specification and refer to the latest edition and addenda in effect at date of manufacture of any item covered by this specification. Any conflicts among the referenced documents not resolved by this specification shall be brought to the immediate attention of Air Products.
3.1 Air Products Engineering Documents
4WCE-600500 Crane and Lifting Procedures
4WMA-007018 Site Plumbness Tolerances for Erected Distillation Columns and Cold Boxes Containing Distillation Columns
4WPI-EW44001 Pressure Testing of Process Piping and Equipment
- DEFINITIONS
4.1 Project Manager shall mean the senior project resource associated with a given project. This resource may represent any of the Engineering Teams within Air Products.
4.2 Contractor shall mean the company and its subcontractors awarded the work by Purchaser and named in the construction agreement.
4.3 Manufacturing personnel shall mean the Air Products personnel from one of Air Products manufacturing facilities.
- 5. SHIPPING TO SITE
5.1 All column sections must be shipped to site with fully sealed covers. These must be either metal sheeting or full pressure part dished heads dependant on the engineering decision. The type of sealing is likely to vary with the distance to be transported and the related environment (for example, ocean crossing, overland, or adverse weather).
5.2 The sealing of the equipment for transport must take place within the manufacturing facilities and must prevent access to the inside of the columns, physically and visually.
- RECEIPT OF EQUIPMENT AT SITE
6.1 Immediately upon receipt at site and before removal from the transport equipment, column sections shall be inspected externally for any signs of damage. Any such damage shall be reported to the Project Manager’s representative immediately.
6.2 For column sections shipped with dry, oil-free air purge, on receipt the indicated level of pressure shall be checked and verified against the shipping note and general arrangement drawing. If the purge pressure is less than that specified, the Project Manager’s representative shall be notified immediately.
6.3 Off-loaded columns shall be supported on their transport cradles/support feet at the locations specified on the Air Products shipping and handling drawing. Supports shall not be placed at any other location. They shall be located on a level, well compacted (for example, actual bearing capacity does not exceed allowable ground bearing capacity) and well drained area. Under no circumstances shall columns be laid directly on the ground.
6.4 On arrival the sections shall be positioned ready for joining BUT the metal shipping covers must not be removed.
- PROTECTING THE WORK AREA
7.1 The site contractor is required to set up to scaffolds near the ends of each section to be joined in accordance with Air Products supervisor’s instructions. The scaffold size must be bigger than the section size to create sufficient working space around the column section to allow taking off of the column end covers, alignment of sections, and joining all sections together.
7.2 The scaffolding shall be covered on the outside with temporary flexible material that shall be strong enough to prevent water and wind ingress into the work area around the column ends. This cover material shall be sealed to the form of the column around the sides and the area shall be rainproof.
7.3 The temporary flexible material cover material must be nontransparent so that the internal and external of column area is not visible from outside the work area.
7.4 The covers at the top of the column and scaffolds will need to be separate so that they can be removed to remove the metallic end covers from the work area (see Sections 9.2 and 9.3). Note the side covers shall be at least the height of the column, so that the internals cannot be seen from the site with the top covers removed.
- CONTROL OF PERSONNEL INTO THE WORK AREA
8.1 After the scaffolding and covers have been set up by the subcontractor, the area shall be designated a Restricted Area. Only approved personnel shall be allowed into this restricted area to perform necessary work. Approval to enter is on a need-to-visit basis and non-manufacturing personnel (including Air Products Visitors) shall generally be excluded.
8.2 Signs shall be placed at each side of the column identifying the restricted area with the following
RESTRICTED AREA
NO UNAUTHORISED PERSONNEL PERMITTED
Site management shall maintain a register of approved personnel and a log of entry and exit to the restricted area shall be maintained.
8.3 It is forbidden to bring or use cell phones, cameras or any photographic devices in this area. (Authorised Air Products inspectors can bring Air Products-owned cameras into the area for work need, but this shall be recorded in the entry log.)
- REMOVAL OF SHIPPING COVERS
9.1 Only manufacturing personnel or approved contractors under the supervision of manufacturing personnel shall remove the metal shipping covers which shall remain within the restricted area immediately after removal. The exposed ends of the column sections shall be covered with black polythene sheeting after removal of the shipping blanks.
9.2 The metal shipping covers shall be removed from the restricted area by overhead crane through the top covers of the shrouded area. Note: This activity should only be done when the weather conditions are such that manufacturing personnel are satisfied that no moisture or other loose debris can enter the column sections.
9.3 When full dished ends have to be removed from the column ends and an overhead crane is needed for this operation, it shall only be performed in suitable weather conditions, as above, since the top of the shroud will need to be removed for this operation.
- COMPLETION OF WORK
10.1 When the welding of the column circumferential closing seams has been completed the area will remain a Restricted Area, until any man ways or handholds that allow visual access to the inside of the columns have been welded and permanently sealed.
10.2 Access to large columns is generally available via a man way after joining, to remove any debris caused by backing ring scraping on the shell, or to check for correct positioning of some critical internal clearances. Access is often also required for NDT activities.
10.3 When the column joining is fully completed and internal access is no longer possible the area under the scaffolding shroud shall no longer be a Restricted Area, and the signs and access control may be removed.
10.4 The scaffolding and cover may be left in place at the option of the site contractor to aid subsequent activities such as air soapy water leak testing of the weld seam and inspection during pressure testing.