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Preparatory works for installing any process equipment are carried out in a certain sequence and must meet safety requirements. All information on the order of carrying out the installation works, the application of technological solutions and the instructions for complying with safety rules is entered into the work execution plan (PPR), developed and approved before the start of the assignment.
Before starting the assembly, all specialists involved in the installation, together with the manager, study the PPR and the diagrams attached to it. In accordance with the document, responsibilities are distributed and the measures necessary to fulfil the PPR are agreed, and the availability of the equipment and tooling needed for installation is determined. Only workers who have received clear explanations of their duties and have been familiarised with the safety rules will be allowed to proceed with further work. If any changes need to be made to the approved design, permission must be obtained from the organisation that developed it.
The equipment installation works begin with preparing and marking out the site where the installation will be carried out. The places for the future equipment and for storing the materials and units needed for the process must be clearly defined. The vehicle access points are marked out, taking into account the impossibility of through traffic across the installation site, and the paths for people’s movement are determined. In addition to the marking, which is clearly visible in any lighting, dangerous zones must be surrounded with tape or fencing. After dark, all workplaces, including driveways and stairs, in the installation area must be lit.Equipment installation cannot begin until a number of preparatory works have been completed:
- The openings needed for installing the equipment have been made in the walls, partitions and floors;
- Areas have been prepared for organising a store of materials and components before they are brought into the installation zone;
- For routing pipelines and installing embedded parts to fasten equipment elements and engineering networks in the building's load-bearing structures and columns, holes are made into which sleeves are inserted;
- If large-unit assembly is required, an area is prepared for it.
An organisation with the relevant experience, able to mobilise qualified engineering-technical workers and labourers for the works and, if necessary, to arrange training, is engaged for the equipment assembly. By the start of installation, the necessary lifting mechanisms, tooling, assembly and welding equipment must already have been delivered to the site. By this point, the foundation acceptance reports must be signed, as-built diagrams drawn up, and the PPR and sets of drawings for metal structures and pipelines obtained from the design organisation.
At the preparatory stage, the installation organisation’s specialists must determine the need for and order the required materials, rolled metal and pipe products, as well as conclude contracts for the manufacture of metal structures.
During the preparation period, the installation organisation must ensure:
- full mobilisation of equipment and personnel;
- the issuing of assignments to a specialised design organisation for the development of the PPR and working drawings of metal structures (KMD) and pipelines (KTD);
- determining the need for rolled metal, pipes and materials, and preparing requests to obtain them;
- placing orders at factories for the manufacture of metal structures and pipeline units;
- the necessary lifting-transport and welding equipment, fitter's and measuring-and-control tools;
- obtaining from the contractor the reports on the handover of the foundations, with a set of as-built diagrams;
- the necessary labourers and engineering-technical specialists and the organisation of their training.
Recommended composition of preparatory works:
- Obtaining the initial data on the installation site
- Inspection of the building structures and engineering systems of the installation site
- Development of the Work Execution Plan (PPR)
- Setting up the welfare camp
- Connection to the in-shop engineering systems
- Preparation of installation equipment, mechanisms and tools
- Preparation of the logs
- Preparation of the geodetic base
- Preparation of an area for storage and large-unit assembly
- Installation of guides for gantry hoists
The acceptance of foundations, buildings and structures for equipment installation must be carried out in accordance with the requirements of SNiP 3.05.05-84 “Process equipment and process pipelines”.
The main requirements for occupational health and safety when carrying out works are set out in SNiP 12-03-2001 and SNiP 12-04-2002 “Occupational safety in construction”
Completed foundations must be accepted from the construction organisation according to as-built diagrams that indicate the actual and design plan and elevation dimensions.