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PREAPARATION FOR REACTOR SURROUNDING:

Scaffolding from the Client:

 Scaffolding will be provided upto 2nd platform


Level erection exactly 7.5 meter height.

 Scaffolding platform provided at 7.5 meter


Height is to protect the falling object and also
Will be used at the time of erection.

 Scaffolding erection start from bottom to top


And step by step as per Al-muzain/ Site condition.

PREPARATION FOR PLATFORM FABRICATION:

Prior to start fabrication:

 ASSURE WORK PERMIT PRIOR TO START THE WORK


 FOLLOW JSA AS PREPARED BY THE CONTRACTOR
 The instrument line surrounding the reactor should be checked by the client.
 PRE PARTS VERIFY WITH APPROVED DETAIL DRAWINGS
 WELDING ROD TO BE KEPT IN GOOD BAKING CONDITION
 STANDARD SIZE WRENCH TO BE USED FOR BOLT UP
 PRE-FABRICATED MEMBERS LIFTING TO THE FABRICATION SHELTER BY CRANE/TROLLY
 Fabrication and assembly shelter location will be allotted by the client

PLATFORM FABRICATION PART BY PART:

Step 1: Pre channel bolt up with fabricated angle


Step 2: Fabricated angle welding with toe plate, handrail flat bar and pipe
Step 3: Grating will be installed at the time of fabrication.
Step 4: Platform 1 (bottom) all around fabrication
Step 5: Platform 12 (top) all around fabrication
Step 6: Platform 2-11 65% platform and 35% spiral stair case.
Step 7: Fabrication starts from second platform

Step 8: After the completion of 12th platform, the first platform fabrication will start.

Step 9: Cutting and welding edges should be cleaned and smoothen and should be painted.

Step 10: Modification will be carried out as per site condition


PREPARATION FOR ERECTION:

Prior to start erection:

 Assure work permit prior to start the work


 Follow JSA prepared by the contractor

Crane usage:

 Upto 20 meter (5th platform) 50 ton crane will be used for erection.
 Above 20 meter 250 crane will be used for the erection

PLATFORM ERECTION

Prior to start the erection:

 SAFCO/IBB qualified person only involving the job


 Fabricated parts, welding, touch up paints, alignments inspection will be carried out by SAFCO or
contractor QC.
 Crane should be located near the urea reactor prior to start the job.
 Lifting hook, chain block and belt should be inspected and verified by the rigging supervisor.
 Prior to the erection the rigging group should be altered in both top and bottom basis.

ERECTION STEP:

Step 1: Assembly member lifting by the crane

Step 2: Platform bolt up with urea reactor cleats

Step 3: Angle bolt up in between reactor cleats and platform bottom side.

Step 4: Crane will be holding the platform during the erection.

Step 5: Same method will be followed for all the platform erection

Step 6: Erection starts from second platform

Step 7: After the completion of 12th platform, the first platform erection will start

Step 8: Inspections will be carried out after the completion of 12th platform and after the completion of
the inspection the scaffolding will be removed.

Step 9: After completion of erection housekeeping will be followed as per supervisor

Step 10: falling object will be controlled at the time of erection

Step 11: For the height work Mobile communicator will be provided from SAFCO/Contractor will provide
and verification will do by the client safety, Authorized persons only handling the communicator.
2nd level
platform
MONKEY LADDER INSTALLATION:

 Pre fabricated ladder lifting by crane and bolt up with reactor cleats.
 Safety precaution will follow as per JSA
 Field modification as per site condition and approved by the client
 Bolt up verify by the client/contractor QC
 For the emergency purpose can be use those ladder
3RD LEVEL PLATFORM ERECTION:

Step 1: Erection method as follow 2nd platform level erection

Step 2: Safety precaution as per JSA

Step 3: Same method follow for remaining platform erection


SPIRAL STAIR CASE FILED FABRICATION:

Step 1: Spiral plate degree marking done at field.

Step 2: The instrument line surrounding the reactor should be checked by the client.

Step 3: Toe plate will be spiral bend between the two platform (top and bottom)

Step 4: Chain block will be used for field fabrication

Step 5: Spiral checker plate welding start from bottom to top at the marked location

Step 6: Checkers steps welding with inner and outer stringer at the degree point, toe plate

Step 7: Welding details: toe plate, channel and angle.

Step 6: Fabrication, welding, NDT and alignment inspection done as per ITP

Step 7: Touch up paints will be done after field fabrication.