VESSEL FINAL BOX-UP

WORK PROCEDURE |
METHOD STATEMENT
1. PURPOSE
2. SCOPE
3. APPLICABLE DOCUMENTS
4. RESPONSIBILITIES
5. MANPOWER
6. TOOLS AND EQUIPMENT
7. METHODS / PROCEDURES
8. QUALITY CONTROL
9. SAFETY PRECAUTION
10. ATTACHMENTS

1. PURPOSE
This method statement shall provide minimum requirements
to implement final box-out works of related equipment during
pre-commissioning works at  plants and refinery projects to
ensure that the work is implemented safely and in accordance
with Project Specifications and Drawings.

2. SCOPE
2.1 This method statement shall apply to final box-up works
for all of static vessels which have manholes and/or hand
holes at plants and refinery projects.

3. APPLICABLE DOCUMENTS
3.1 Saudi ARAMCO Project Specifications and
Standard
3.1.1 SAEP-351  Bolted Flange Joint Assembly
3.1.2 G.I.2.710 Mechanical Completion and Performance
Acceptance of Facilities
3.1.3 CSM Saudi ARAMCO Construction Safety Manual
3.1.4  SAIC-L-2014 Inspection of Bolted Flange Joint
Assembly
3.1.5 SAIC-D-2012 Final Inspection of Pressure Vessels (Re-
Instatement)

3.2 Inspection and Testing Plan/ Method

Statement
3.2.1 SATIP-D-001-01 Pressure Vessel Installation
3.2.2 SATR-D-2003 Vessel Closure Inspection Certificate
3.2.3 All Other Applicable Contractor’s Inspection and Test
Plan

3.3 Contractor’s / Subcontractor’s Procedure and

Method Statement
Method Statement – Installation of Vessel Internal
(Contractor)
3.4 Contractor’s HSE Procedure
3.4.1 S-000-1650-001 Contractor Site Safety Program
3.4.2 S-000-1650-011 Isolation, Lockout & Tagout Procedure
3.4.3 S-000-1650-030 Confined Space Procedure

4. RESPONSIBILITIES
4.1 Pre-commissioning Manager
Ensure that all works are carried out according to this
procedure and secure that all work areas are in safe working
condition and monitor properly from time to time the
implementation of safe procedure, requirements.

4.2 Pre-commissioning Mechanical Manager

Make planning and Implementation including preparation of
box-up work schedule complying with the approved project
standards and safety requirements. Prepare material
requisition and assign competent supervisors to box-up work.

4.3 Pre-commissioning Mechanical Supervisor

Direct and control the box-up work schedules complying with
the approved standards and safe guidelines. Ensure that, prior
to enter to vessel, line-up of external pipes has been
completed with blind plates, if required. Supervise all related
activities on site and prepare the inspection request to QA/QC
section. Ensure competent workers are assigned to execute
the activities. Confirm all necessary work permits are in
proper places and the availability of all the materials, tools,
and equipment required to box-up work.
4.4 Quality Control Manager
Ensure full implementation of the required quality control
procedures and maintain the required documentation as per
applicable Saudi ARAMCO Inspection and Test Plan for the
final acceptance and handover of the systems. Guide and
inform QC inspectors to maintain the quality level of
inspection for the scheduled inspection activities.

4.5 Safety Supervisor

Ensure that relevant safety precautions/ procedures are in
operation and work permits have been obtained. Also, ensure
that safety barriers and warning signs are posted where
necessary. Verify all workers are using required Personal
Protective Equipment (PPE).

5. MANPOWER
– Contractor/ Subcontractor Manpower
– Licensor Representative (for Witness)
– Superintendent / Supervisor

– Foreman
– Mechanical Workers
– Pipe Fitter (for Manhole Closure)
– Crane Operator (if required)
– Rigger (if required)
– Helper

6. TOOLS AND EQUIPMENT

 6.1 Tools and equipment should be in good condition and
must be checked by supervisor and/or foreman prior to use at
site.
6.2 Torque wrenches shall have valid calibration certificates.
6.3 Tools and equipment must be color-coded.
6.4 Required tools and equipment are as follows but not
limited to:

6.4.1 Wrenches
6.4.2 Torque Wrenches
6.4.3 Cleaning Tools for Internal Vessel
6.4.4 Temporary Blowers and Lightings
6.4.5 Borescope (High Resolution Type with Minimum Reach
of 2m Length)
6.5 Personal Fall Arrest Systems.

7. VESSEL FINAL BOX-UP WORK

PROCEDURE | METHOD
STATEMENT
7 .1 Preparation
1. Prior to the start of final box-up, Licensor Representative will
conduct the detailed inspection of the equipment as per
Attachment-3 and this should be completed before issuance of
RFI (Request for Inspection) to Company that final box-up
has been made.
2. Confirm that all internals shown on design drawings have
been correctly installed and inspected. Typically this shall
include not only trays, but also all internal parts, such as 
 structure packing, baffles, dividers, vortex breakers, nozzles,
flow distributors, piping, demister pads and catalyst supports
and other mechanical parts of equipment.
3. Confirm that all external pipes connected to the vessels have
been hydro-tested and completed lay-up and reinstatement as
per marked-up P&IDs. Flange connection and bolt tightening
inspection shall be conducted appropriately.
4. Also confirm that the line-up of all connected pipes such as
blind plate installation, bolt torqueing and valve closing has
been completed as per marked-up P&ID to ensure there is no
chance of hazardous gas such as argon I nitrogen can intrude
into inside vessels during the final box-up works. If such
hazardous gas needs to be remained in a part of system,
ensure that vessels have been isolated by installing blind
plates with isolation tags. Manholes shall be kept open during
final box-up inspection and proper ventilation shall be
provided.
5. Confirm that all instruments have been installed in proper
locations.
6. Open all manholes and install ventilation fans and lightings
(low voltage types) as required inside the vessels.
7. Prepare and obtain confined space work permit for all vessels
appropriately.
8. Protect all surfaces of manhole flange to avoid any damages
during the final box-up works.
9. Confirm that mandatory access shall be remained inside of
vessels to inspect all points.
10. Confirm that all temporary covers and preservation
material such as VpCI shall be A removed from (shall not be
remained) inside vessels as much as possible. General
cleaning inside vessels shall be completed prior to the final
box-up works.

7.2 Final Box-up & Charging Activities

(Licensor Driven)
Guidance Note – Upon completion of Licensor driven
activities no further internal works such as manway closure or
charging will be required, the vessel shall therefore qualify for
both Sections A and B of SATR-D-2003 to be signed. This
certifies the vessel is complete and ready for start-up.

7.2.1 Contractor shall ensure all necessary components have

been installed per the drawings and SATR-D-2003, prior to
initiating request for Final Closure inspection, to the best of
their ability.
7.2.2 Contractor shall ensure the vessel is free of debris and
moisture per SATR-D-2003, prior to initiating request for
Final Closure inspection.
7.2.3 Licensor shall proceed to perform box-up activities
jointly with all Invested Parties (1).
7.2.4 Where a step-wise box-up is required, which involves the
installation of internal components and loading of
consumables, the Licensor shall guide the process. Such cases
include J 12-D-0201 A&B Adsorbent Towers.

7.2.5 The Licensor shall ensure Invested Parties remain

informed on progress of installations, and will be responsible
for ensuring Invested Parties are included in all necessary
inspections. Upon acceptance of each stage of
box-up/charging, the Proponent shall authorise the
Contractor/Licensor to proceed to the next stage.
7.2.6 At completion of all box-up/charging stages, the
Invested Parties shall perform the Final Box-up inspection.
The Proponent team shall inspect the external manways and
authorise closure of the vessel and witness insertion of the
permanent external manway gaskets and hot-bolting of the
manway cover. Proponent team shall then sign SATR-D-2003
Section A and B to verify the vessel is complete and charged,
and was released.
7.2.7 PID representatives shall ensure SATR-D-2003 Sections
B2 and B3 are completed, then sign SATR-D-2003 to verify
the action were complete.
Note (1): Invested Parties – The team required to perform the
sign-off of Box-up. Team shall include the Contractor/Third
Party members (Construction Representative, QC Inspector &
QC Supervisor) and Saudi Aramco members (PMT
Representative, JAPID Representative and Proponent)

7.3 Final Box-up Activities — No

Charging Required (Without Licensor)
Guidance Note – Vessels which are found to be mechanically
complete, and require no further internal works such as
manway closure or charging, will qualify for both Sections A
and B of SATR-D-2003 to be signed. This certifies the vessel is
complete and ready for start-up.
7.3.1 Contractor shall ensure all necessary components have
been installed per the drawings and SATR-D-2003, prior to
initiating request for Final Closure inspection, to the best of
their ability.
7.3.2 Contractor shall ensure the vessel is free of debris and
moisture per SATR-D-2003, prior to initiating request for
Final Closure inspection.
7.3.3 Invested Parties shall perform inspections per Saudi
Aramco and International Standards.
7.3.4 At completion of the inspection activities, the Proponent
team shall inspect the external manways and authorise
closure of the vessel and witness insertion of the permanent
external manway gaskets and hot-bolting of the manway
cover. Proponent team shall then sign SATR-D-2003 Section
A and B to verify the vessel is complete and charged, and was
released.
7.3.5 PID representatives shall ensure SATR-D-2003 Sections
B2 and B3 are completed, then sign SATR-D-2003 to verify
the action were complete.

7.4 Final Box-up Activities — Delayed

Charging (Without Licensor)
Guidance Note – Vessels which are found to be mechanically
complete, but require further internal works such as manway
closure or chemical/catalyst charging, will qualify for sign off
on Section A of SATR-D-2003. This certifies the vessel is
mechanically complete but not ready for start-up. Only at the
completion of man way closure or chemical/catalyst charging
can the Invested Parties sign off on Section B of SATR-D-
2003, indicating the vessel is now complete and ready for
start-up.

7.4.1 Contractor shall ensure all necessary components have

been installed per the drawings and SATR-D-2003, prior to
initiating request for Final Closure inspection, to the best of
their ability.
7.4.2 Contractor shall ensure the vessel is free of debris and
moisture per SATR-D-2003, prior to initiating request for
Final Closure inspection.
7.4.3 Invested Parties shall perform inspections per required
Saudi Aramco and International Standards.
7.4.4 At completion of the inspection activities the Proponent
team shall inspect the external manways and authorise
closure of the internal manways where applicable. Invested
Parties shall then sign SATR-D-2003 Section A.
7.4.5 Proponent team will authorise the Contractor to close
the vessel using compressed fibre non-asbestos gasket
pending completion of charging, and subsequent installation
of the permanent gasket.
7.4.6 Vessel will be placed under preservation conditions,
pending charging at a later date. Preservation must be
performed within 14 days of signing SATR-D-2003 Section A.

7.5 Final Box-up Activities — Internal

Manway Closure (Without Licensor)
Guidance Note – Vessels which are found to be mechanically
complete and require only the internal manway closure, the
Invested Parties shall sign off on Section A of SATR-D-2003.
At the completion of manway closure the Invested Parties
shall then sign off on Section B of SATR-D-2003. This now
certifies the vessel is complete and ready for start-up.

7.5.1 Contractor shall ensure all necessary components have

been installed per the drawings and SATR-D-2003, prior to
initiating request for Final Closure inspection, to the best of
their ability.
7.5.2 Contractor shall ensure the vessel is free of debris and
moisture per SATR-O-2003, prior to initiating request for
Final Closure inspection.
7.5.3 Invested Parties shall perform inspections per required
Saudi Aramco and International Standards.
7.5.4 At completion of the inspection activities the Proponent
team shall inspect the external manways and authorise
closure of the internal manways. Invested Parties shall then
sign SATR-D-2003 Section A and B to verify the vessel is
released for manway closure. Internal manway closure shall
begin immediately.
7.5.5 Upon completion of internal manway closure,
Contractor shall inform Invested Parties that the vessel is
ready for Final Vessel Closure Inspection. Invested Parties
shall perform the required inspection.
7.5.6 Following satisfactory inspection, Proponent Inspection
shall witness the insertion of the permanent external manway
gaskets and hot-bolting of the manway covers.
Proponent team shall then sign SATR-D-2003 Section A and
B to verify the vessel is complete and charged, and was
released.
7.5.7 Company representatives shall ensure SATR-D-2003
Sections B2 and B3 are completed, then sign SATR-D-2003 to
verify the action were complete.

PRESSURE VESSELS AND HEAT EXCHANGERS | SCOPE

OF WORK

8. QUALITY CONTROL
8.1 Ensure that all required inspections for vessel installation
work had been completed and accepted in accordance with
SATIP-D-001-01 and applicable Contractor’s Inspection and
Test Plan prior to the final box-up inspection.
8.2 Ensure that all open Work Sheet, NCR and LBE had been
closed prior to the final box-up inspection.
8.3 The inspection of final box-up shall be conducted in
accordance with SATR-O-2003.
8.4 Contractor shall prepare a document folder of “final box-
up inspection package” for each equipment item. The
document folder will contain as minimum:

a) P&ID
b) Equipment Data Sheet
c) General Arrangement Drawings
d) Marked-up P&ID showing Location of Package Limit
/LOTO’s Blinds / Vent & Drain Points for Purging and/or
Preservation
e) Blind List
f) SATR-O-2003
g) Preservation Method

All documents shall be verified as being correct with all piping

and equipment correctly identified. Red-line drawings will be
acceptable, but must be properly incorporated in the
document folder prior to final box-up inspection.

A Contractor shall ensure the line-up of LOTO’s blind

positions as per marked-up P&ID prior to the final box-up
inspection, and if any LOTO’s blinds had been changed
(removed or added) after the box-up inspection due to the
preparation/line-up of adjoining systems, or
extension/combination of LOTO’s boundaries, Contractor
shall update the marked-up P&ID as per the actual condition.
The updated marked-up P&ID shall be incorporated in the
final box-up inspection package without removing the
previous marked-up P&ID, so that history of LOTO’s
boundaries can be monitored appropriately.
8.5 Company Project Inspection Division, Company
Representative, Proponents, Licensor (if required),
Contractor’s and Subcontractors’ QC inspectors shall attend
all inspection of the final box-up works on site to ensure that
all applicable requirements, codes and standards are complied
with. RFI should be submitted 3-4 working days in advance.

8.6 Preservation of vessels after the final box-up shall be

conducted as a part of the system lay-up together with related
piping which are connected to the vessels. System
preservation shall be reinstated within 14 days following the
box-up per SATR-D-2003 Section A and B has been accepted.
Preservation status shall be monitored and tracked weekly
and documented. The record shall be available for Company
upon request.

9. SAFETY PRECAUTION
9.1 Ensure that no hazardous gas is remained in related piping
system or those parts have been isolated by blind plates with
isolation tags.
9.2 Ensure that confined space entry permit of each vessel
shall be obtained prior to the final box up works and that all
persons involved in confined space entry work have attended.
Contractor’s confined space entry training including standby
men. Required gas test inside vessels shall be conducted
properly and frequently as per the safety requirement.
9.3 Assign designated standby men who are always present at
manholes to control the related persons’ entry and exit of the
vessels. The duties of standby men shall be as follows:
► Keep recording the entrants list for confined space entry/
exit
► Maintain the contract with entrants at all time
► In case of emergency, make direct contact to emergency
response team
► In case of emergency, make evacuation alert to entrants
using whistles, radios or other method
9.4 Prepare and install sufficient blowers and lights (LV types)
to maintain good conditions inside vessels.
9.5 Ensure that barricades and warning signs are properly
installed.
9.6 Conduct Safety Tool Box and TSTI every morning prior to
the box-up works.
9.7 Ensure that JSA and rescue plan are prepared and
approved for all confined space entry works.
9.8 Ensure that heat stress is taken into consideration during
confined space entry works and appropriate rotation of
personnel in/out of the confined space is implemented.

10. ATTACHMENTS
ATTACHMENT-1 Job Safety Analysis for Vessel Box-up
Works.
ATTACHMENT-2 SATR-D-2003 – Vessel Closure Inspection
Certificate.
ATTACHMENT-3 Equipment List for Final Box-up.