1. PURPOSE
1.1 This global engineering work instruction establishes the minimum requirements to verify the weights and dimensions of project equipment to be transported to the field for erection.
2. SCOPE
2.1 This work instruction is to be followed on all projects managed within Global Engineering.
3. DEFINITIONS
3.1 Equipment: Meant to include whole pieces shipped from vendors and to the site such as tanks, columns, compressors and/or components, cold boxes, skids, containers, etc.
3.2 Running Height: The distance above the ground to the top of the equipment when loaded and secured to the transporting equipment. Applies to all equipment being transported on the road. It will include the actual height of the equipment or component, the shipping or cribbing addition to that height, and the vehicle load bed height.
4. RESPONSIBILITIES
| Requirement | Proj Engr | Sr Proj Mgr | Const (2) | PDE Lead | Trans (2) |
| Overall coordination of this Work Instruction. | R | A | |||
| Develop “Definitive Estimate Equipment List” with weights, dimensions, and points of origin. | R | A | I | R | I |
| Indicate specific equipment and/or component parts to have weights and dimensions verified. | C | A | R(1) | I | R(1) |
| Document specific transportation route clearance and permitting issues, relevant to the transportation strategy and construction rigging issues relevant to the constructability plan. | C | A | R(1) | I | R(1) |
| Define transportation and construction rigging strategies for the “Definitive Estimate”. | C | A | R(1) | I | R(1) |
4. RESPONSIBILITIES (continued)
| Requirement | Proj Engr | Sr Proj Mgr | Const (2) | PDE Lead | Trans (2) |
| Develop “Definitive Estimate” transportation and construction estimates. | C | A | R(1) | R(1) | R(1) |
| Assure ‘mandatory’ equipment and/or components have weights and dimensions verified prior to shipment. | R | A | I | I | |
| Request required vendor/manufacturer documentation (via Vendor Document Record (VDR) when applicable) specific to weight/ dimension/location of the CG/transportation and lifting diagrams/packaging estimates and verification for transportation and construction execution during procurement. | R | A | I | I | |
| Distribute all changes to the “Definitive Estimate Equipment List” to the appropriate transportation and construction leads. | R | A | I | I | |
| Adjust transportation and construction strategies as required if changes to the “Definitive Estimate Equipment List” occur. | C | A | R(1) | I | R(1) |
| Obtain lifting plans from site contractors for lifts that exceed 16,000 Kg (17.5 short tons) and notify Project of specific needs to verify weights and dimensions. | C | A(1) | A (1), R |
I |
Responsibility (R), Accountability (A), Consulted (C), and copied for Information (I).
Notes: 1. If an A or an R is duplicated across a line item in the chart above, it means the accountability and/or responsibility is shared.
4.1 This RACI chart assumes Air Products Construction Engineering and Transportation Groups are part of the execution. If the contract is a sale of equipment (SOE) and Air Products is not responsible for transportation or construction, then alternative plans to cover the responsibilities and/or accountabilities for these disciplines must be made with the customer.
Note: The consequences of a failure to follow up on these requirements with the customer representatives throughout the project execution may result in costly back charges to Air Products.
5. General Transportation and Construction Requirements
5.1 Due to the extensive planning it takes to: schedule the transportation, get the required transportation routing and permits, develop Proforma invoices (for exporting), etc. and, locate, organize, and schedule the lifting equipment to receive and erect large equipment. ALL equipment that is expected to have a shipping weight in excess of 90,000 Kg or 100 US tons requires mandatory vendor or manufacturer verification of weight, actual shipping envelop dimensions, and Center of Gravity (CG) location PRIOR TO SHIPMENT. ALL transportation and/or lifting plans are initiated with ESTIMATED information. The primary objective of this mandatory requirement is to preclude any significant safety incident that can occur during transportation and/or erection caused by deviations from the estimated conditions. The secondary objective of this mandatory requirement is to preclude any significant changes to planned project costs and schedule. ACTUAL information is preferred (but understood not necessarily attainable) at least two weeks prior to shipping. The more time we have to react to any changes and correct plans, the less the negative impact on this objective.
Notes: In locations where heavy lift cranes are not available and must be shipped to the site by loading on to cargo vessels, etc., cranes will not be released for shipment until the ACTUAL information has been received and reviewed by Construction Engineering. Rubber tire cranes are considered “rolling stock” and require additional review and approval prior to shipment. This needs to be understood and provided for in the construction scheduling.
5.2 The minimum acceptable approach to attaining and/or calculating the actual equipment weight will be by the use of calibrated load cells on the corners of the equipment. Other methods that providing +2% or better accuracy are acceptable. When providing verified weights, the vendors will provide equipment calibration verification and/or scale accuracy information.
5.3 All equipment weighing over 16,000 Kg (17.5 short tons) shall be weighed prior to shipment.
5.4 Transportation permits are required for transporting all loads (see paragraph 5.6) that typically exceed any of the following parameters: Continental US Width greater than 8 ft 6 in Length greater than 50 ft Height greater than 10 ft 6 in (a “running height” greater than 13 ft 6 in) Weight greater than 45,000 lbs Europe Width greater than 2.9 Meters Length greater than 18.3 Meters Height greater than 3.5 Meters Weight greater than 40,000 kgs (load and trailer wt greater than 80,000 kgs) Permits for loads whose parameters are close to the above are generally obtained within 2-3 days.
5.5 However, when loads approach any of the “super load” parameters, minor changes can significantly impact the planned transportation and costs (see paragraph 4.6). Continental US Width greater than 14 ft Length greater than 60 ft Height greater than 11 ft (a “running height” greater than 14 ft 6 in) Weight greater than 90,000 lbs. Europe Width greater than 6.1 Meters Length greater than 30 Meters Height greater than 4.0 Meters Weight greater than 80,000 Kg
5.6 Parameters for “permitted loads” and/or “super loads” can vary from state to state, country to country, OR continent to continent. Therefore each project team must fully investigate and understand the specific rules that apply along the routes from points of origin to site in order to effectively and accurately define the feasibility, proper strategy, and cost of transportation.
Note: Transportation limitations, strategy to deal with transportation, and/or cost may have major impact on project manufacturing, procurement, construction, and other execution strategies and, therefore, needs to be an integral part of the project development process.
6. PROJECT DEVELOPMENT AND EXECUTION ACTIVITIES/ DELIVERABLES
6.1 Firm Bid and Definitive Estimate Phases
6.1.1 During the Sales Estimate (SE) phase, a “Firm Bid” or “Stage II” estimate is developed for an opportunity. “Equipment Lists” may or may not be initiated by PDE during this phase. Transportation estimates may be developed as a percentage of the total equipment estimated costs. Transportation and erection strategies and associated estimates will only focus on known larger pieces or specific site issues.
6.1.2 During the ‘Firm Bid’ phase the focus by PDE, Construction Engineering, and the Transportation Group is on the cost. Any preliminary route surveys associated with over the road ‘permitted’ and/or ‘super size’ loads, break bulk versus containerized ocean shipping, and general crane sizes and feasibility orientations required for erection may only be addressed by exception and for the major items ONLY.
6.1.3 The ‘Definitive Estimate’ or ‘Stage III’ estimate is kicked off after the business is awarded or funded. During this estimate, PDE develops a detailed “Equipment List”. ALL of the significant shippable equipment items need to be accounted for and have a transportation and construction/ erection strategy.
6.1.4 The final “Definitive Estimate Equipment List” should include all equipment with the latest weight, dimensional, and point of origin information. The final execution strategies and estimates for handling equipment by the Transportation Group and Construction Engineering will become the basis for the project control budget (PCB).
Note: The P&ID equipment is not necessarily reflective of how equipment will ship. Items may be combined on skids, boxes, etc.
6.1.5 The “Definitive Estimate Equipment List” should clearly INDICATE which equipment will require MANDATORY checks (above) prior to shipment. The procurement team needs assure that this requirement is clearly stated in specification for the equipment, the purchase order, and identified on the Vendor Document Requirement (VDR) as a required vendor document prior to release for shipment.
6.1.6 Route clearance limitations are a concern during the estimate phase when large equipment weights and dimensions are not verified. Additional inches to equipment widths and heights at the execution phase can add significant cost and schedule delays to a project. The Transportation Project Lead will review the, ‘Definitive Estimate Equipment List,’ understand the basis and quality of the information from the PDE Lead, and document any risk and concern with route clearances or permitting because of the equipment list. The PDE Lead, Project Engineer, and Transportation Lead must decide how to address the risk/concerns in the bid by considering budget contingencies, obtaining better information from the Suppliers, increasing the freight estimate, or pursuing other options.
6.1.7 The Construction representative will review the, ‘Definitive Estimate Equipment List,’ to understand the basis and quality of the major equipment weights and dimensions as defined by the PDE Lead, and document any risk and concern to the plant constructability plan because of questionable equipment list information. The PDE Lead, Project Engineer, and Construction representative must decide how to address the risk/concerns in the bid by considering budget contingencies, obtaining better information from the Suppliers, increasing the freight estimate, or pursuing other options.
6.2 Execution Phase
6.2.1 Transportation and Construction Engineering are responsible to assure that the equipment on the ‘Definitive Estimate Equipment List’ indicated to be checked is correct for the estimate and updated throughout the project execution period. Project Engineering is responsible to assure these checks are performed and that the documentation is given to Transportation and Construction Engineering.
6.2.2 The controlling documentation for equipment weights and dimensions, used for the initial planning by transportation and construction, are typically the vendor’s equipment outline drawings. In addition to the outline drawing, a separate shipping weight and dimension verification document will be added to the VDR prior to release for shipping. SEE the transportation form titled “Required Information for Safe and Effective Transport” as an example.
6.2.3 Purchasing has developed standard clauses for weight and dimensional verification to include on any purchase order. Project Engineering must call out this requirement for on the appropriate requisition. EVERY purchase order for equipment should include an option cost to exercise the verification. Once the Construction Engineering or Transportation Group indicates the need for verification on the ‘Definitive Estimate’ equipment list (as revised through execution) the option can be exercised prior to shipment.
Note: There may be instances specific to certain projects that will have larger cranes continually available making verification and its cost unnecessary.
6.2.4 The timing for the verification shall be two weeks (or sooner) of the ship date so permits can be ordered, routes verified, and lifting plans finalized. Any requested exceptions to this timing shall be jointly reviewed and agreed between Project Engineering, Construction Engineering and Transportation Group.
6.2.5 In order to achieve the best possible opportunity for corrective action on the transportation and construction execution planned for major equipment items, the vendors/manufacturers will be required to reaffirm OR re-estimate the weight indicated on the equipment outline drawings AND provide a final ESTIMATED shipping information, at 50–75% of completion. The vendor/ manufacturer will be required to revise the outline drawing and provide a shipping drawing as necessary for this purpose and be instructed to do so by the VDR. Project will assure that any changes to original information is passed on to Transportation and Construction Engineering Groups so that plans can be updated as necessary.
6.2.6 “As-shipped” dimensions and weights may vary from the outline drawings based on packaging, orientation, assembly, etc. Project must assure that the VDR for the mandatory equipment provides for: a complete packing list shipping and handling drawings actual weight, dimension, and CG verification and are received prior to release for shipment AND immediately distributed to the Transportation and Construction Engineering Groups.
6.2.7 Smaller equipment items may be consolidated and shipped (ocean/barge) via container. These items need to be clearly highlighted by the Transportation Group (with Project Engineering assistance) on the Equipment List. Container shipments are typically consolidated by an ocean port vendor prior to ocean transport. Project must assure that each vendor/ manufacturer provides packing lists, weights and dimensions, etc. (above) per the VDR so that the freight forwarder can develop the overall packing list and weight for each container. Project will then be able to establish the Proforma invoice or similar documentation required for importation by the receiving country.
7. RELATED PROCEDURES /SPECIFICATIONS/CHECKLISTS
7.1 EP-4.1 Project Execution Strategy EP-3.2 Estimate Approval Documentation Global Engineering Specification 4WCE-600500 “Crane and Lifting Procedures”