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199/00/00/CI/MS/NA/A50172
METHOD STATEMENT No.: UG PIPING
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Date:
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FOR GREEN & BROWN FIELD
UG PIPING COATING AND WRAPPING FOR GREEN & BROWN FIELD
Document Reference: KETTANEH
TCJV REVIEW
COMPANY REVIEW
199/00/00/CI/MS/NA/A50172
00
IFC
25/10/2011
FML
INR
B2
ICA
09/10/2011
FML
INR
B1
ICA
28/09/2011
FML
INR
Rev.
Doc. Isued for
Date
Prepared
Checked
Status
Initial
Date
Status
Initial
Review Legend: Code 1
– Rejected ;
Code 2 –
Approved as Noted Revise & Resubmit ;
Code 3 –
Approved as Submitted
Date
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TABLE OF CONTENTS
1
PURPOSE:
3
2
SCOPE
3
3
REFERENCES
3
3.1
PROJECT SPECIFICATION
3
3.2
CODES AND STANDARDS
3
4
ABBREVIATIONS
3
5
PERMIT TO WORK
4
6
RESPONSIBILITY
4
7
PROCEDURES
4
7.1
ACCESS AND BARRICADES OF TRENCHES
4
7.2
WEATHER CONDITIONS
5
7.3
SURFACE PREPARATION
5
7.3.1
CLEANING
5
7.3.2
ABRASIVE BLAST CLEANING
5
7.4
PAINTING APPLICATION
5
7.5
WRAPPING ACTIVITY
6
7.5.1
PRIMER APPLICATION
6
7.5.2
TAPE APPLICATION
6
8
INSPECTIONS AND TESTING
10
9
TOOLS AND EQUIPMENTS
10
9.1
EXECUTION
10
9.2
INSPECTION TOOLS
11
9.3
SAFETY
11
10
SAFETY and ENVIRONMENTAL INSTRUCTIONS
11
11
ATTACHMENTS
12
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PURPOSE: The purpose of this method statement is to describe the method, the sequence and the responsibilities of the painting and wrapping activities for piping field joints and fittings, performed at site by the construction team.
2
SCOPE The scope of this method statement covers the following activities. •
Surface preparation
•
Painting
•
Wrapping
3
REFERENCES
3.1
PROJECT SPECIFICATION
3.2
•
199/00/00/SP/TS/NA/000012
Design specification protective coating
•
199/00/00/SP/TS/NA/000122
Amendment to technical specification for color coding
•
199/00/00/CS/PC/NA/000840
TCJV PTW procedure
•
199/00/00/CS/PC/NA/000553
SHE instruction to subcontractor
•
199/00/00/CS/PC/NA/000803
SHE execution plan
•
199/00/00/CS/PC/NA/000839
Mobilization and demobilization of construction equipments procedure
•
01.15.02.10
QG permit to work procedure
CODES AND STANDARDS
4
•
ASTM D5162
Holiday testing
•
ISO 4624
Adhesion Test / Pull of Test
•
ISO 8502 6/9
Salt contamination of substrate
ABBREVIATIONS •
QG
Qatar Gas
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•
TCJV
Technip Chiyoda Joint Venture
•
KCQ
Kettaheh Construction Qatar
•
PPE
Personal Protective Equipments
•
U/G
Underground
PERMIT TO WORK Before starting the painting/wrapping activities, a permit to work should be prepared and submitted to TCJV with all required documents for approval. This U/G wrapping activities will be performed in confined space. If the work location requires QG PTW a confined space certificate will be provided along with the permit to work. All the remaining areas will follow TCJV PTW system. All equipments will be used to perform this job should be inspected and approved before moving to site.
6
RESPONSIBILITY It is the responsibility of the construction department to perform the work as per the requirements of Contract Documents, IFC Drawings, project specifications and Quality Plan. The responsibility of the QC Inspector is to perform all inspections as per the ITP to ensure compliance to the requirements of the IFC Drawings and project specifications and preparing the inspection reports. The QC supervisor will coordinate the inspection activities and verify the QC report for completion and sign the documents. The QC manager will verify the documents as required.
7
PROCEDURES
7.1
ACCESS AND BARRICADES OF TRENCHES After finishing excavation to the required depth according to the relative method statement “199/00/00/CI/MS/NA/50110A: MS for excavation, backfilling and compaction”, barricades should be installed all around the excavation with appropriate
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scaffolding platform and access ramp according to “199/00/00/CI/MS/NA/50107A: MS for scaffold works. This access should be green tagged to be used by workers.
7.2
WEATHER CONDITIONS Blasting and painting activities shall never start in rainy or fogg y conditions. Blasting and painting activities shall only start if relative humidity is below 85% and temperature is minimum 3ºC above dew point. Blasted surfaces exposed to inappropriate atmospheric conditions (relative humidity above 85% and temperature below 3ºC above dew point) shall be re-blasted. Blasted surfaces shall be primed in maximum 4 hours after blasting.
7.3
SURFACE PREPARATION Prior to start, surface preparation must have release for coating do cument signed by QC.
7.3.1
CLEANING
Piping surfaces to be blasted shall be clean free form oil and grease. In case of oil or grease or other contaminant deposits, the surface shall be cleaned using appropriate solvent. Welds shall be clean, brushed, free from slag, po rosity and spatters or any weld defects. 7.3.2
ABRASIVE BLAST CLEANING
Blasted piping surfaces shall have a profile of SA 2 ½. Garnet shall be used as abrasive material. The garnet particle size shall be selected to achieve an angular surface profile of 25 to 50 µ m.
7.4
PAINTING APPLICATION Painting application will be done by qualified painters. Painting application shall only take place when the following conditions are satisfactory: When relative humidity is below 85% and the temperature is minimum 3 ºC above dew-point. If weather is not rainy or foggy (except under shelters). Blasted surfaces shall be primed before any visible rusting or 4 hours maximum after blasting.
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Primer may be applied by a brush to all angles, corners, welds, bolts and any areas with difficult access. Painting shall be applied in accordance to the manufacturer recommendations. Curing time will be also according to the manufacturer recommendations. WFT and DFT shall be in accordance with the manufacturer’s recommendations and shall also be recorded in the specific quality forms provided with the relative ITP.
7.5
WRAPPING ACTIVITY Fittings and weld joints shall be wrapped at site with Polyethylene band. The following will describe the steps of the wrapp ing application.
7.5.1
PRIMER APPLICATION
Blasted surface shall be free from oil and grease or any other type of contaminations. Before applying the primer, the surface should be clean and dry. Primer shall be applied maximum 4 hours after blasting activities. A uniform coat of primer should be applied to the surface and 100 mm on the adjacent mill coat. Application of the primer, curing time, WFT and DFT should be according to the manufacturer’s recommendations. 7.5.2
TAPE APPLICATION
The tape must be wrapped spirally around the pipe in even layers with an overlap of 55%. When applied correctly there will be at least 2 layers of tape, with some areas having 3 layers due to the 55% overlap. Correct overlapping can be measured to ensure only 45% of the tape width is visible. The width of the tape should be according to the manufacturer recommendations. When a new roll of tape is required, the new tape must overlap the old one by minimum 1 tape width. Application can continue as above. Wrapping of welds, flanges, elbows, tees, concentric and eccentric reducers should follow the manufacturer’s recommendations.
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7.5.2.1WRAPPING OF A BUTT WELDED JOINT: For pipes that are already wrapped and welded together, follow these instructions for wrapping the weld, after application of primer •
The first turn must be circumferential (parallel) to the existing wrapping.
•
After the first turn, apply tape with 55% overlap.
•
The final turn must also be circumferential to the existing tape with a minimum overlap of 55%.
7.5.2.2WRAPPING OF A FLANGE JOINT: When a flange is to wrapped after bolting, follow these instructions after application of primer. •
• •
Use a filler paste, to create a smooth profile as shown, ensuring all cavities and gaps are filled. There should be no gaps or voids. Push the filler into all gaps to ensure all air is remo ved. Apply wrapping either continuously from the pipe or apply as per butt weld areas if joining pipes are already wrapped
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7.5.2.3WRAPPING AN ELBOW The follow instructions apply for 90° or 45° elbo ws, or where the pipe has a bend. • •
Continue to wrap the tape around the elbow as per general application. Ensure the outside radius of the elbow is overlapped by 55% which is the same for straight section. The inner radius will be overlapped by more than 55% as a result.
7.5.2.4WRAPPING A TEE Cut lengths of tape long enough to completely wrap around the tee as shown in figure 1a •
Wrap the tape around the inside radius of the tee as shown in figure 1b. Ensure there is no exposed material and that a minimum 55% overlap has been maintained.
•
•
If the pipe is already wrapped up to the weld, start wrapping as for butt weld sections, ensuring the first turn is circumferential. Start wrapping the tape at the branch of the tee piece making the first turn circumferential and making sure to cover all exposed surfaces from the first and second operations of wrapping the tee.
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7.5.2.5WRAPPING A CONCENTRIC AND ECCENTRIC REDUCER Cut lengths of tape and place on the reducer from the butt weld area on one edge to the butt weld on the other. •
•
Place the strips all around the circumference starting at the larger diameter, working to the smaller diameter. Ensure there is no exposed material and that a minimum 55% overlap has been maintained at the larger end. The smaller diameter will have more that 55% overlap; this is acceptable. After completion, the pipe can be wrapped as normal from each end ensuring the first turn is wrapped circumferentially.
NOTE: The correct width tape is to be used for the larger and small diameter pipes.
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7.6
COATING REPAIR The repair of the damaged existing coating will be done by wrapping reference to the supplier recommendations.
8
INSPECTIONS AND TESTING Inspection and testing activities will be held b y certified inspector, Holiday testing will be used following the requirements of the relative ITP.
9
TOOLS AND EQUIPMENTS
9.1
EXECUTION •
Hand tools
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9.2
9.3
•
Power brush
•
Grinders
•
Air compressor with air dryer
•
Air filter
•
Blasting machine
•
Blasting gun
INSPECTION TOOLS •
WFT Gauge
•
DFT Gauge and calibration shims
•
Pressure gauge
•
Temperature Gauge
•
Salt tester
•
Dew Point Calculator
•
Whirling Hygrometer
•
Holiday detector
SAFETY •
10
Nomex coverall
•
Safety helmet
•
Safety goggles
•
Blasting helmet with air supply
•
Safety shoes
•
Working gloves
•
Gloves appropriate as per task
•
H2S toxic clip
•
Dust mask
•
Safety Harness (If required)
•
Fire extinguisher
SAFETY AND ENVIRONMENTAL INSTRUCTIONS •
All work permits shall be prepared and approved prior to start any activity.
•
Work permits shall be present at site in work area.
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•
•
•
•
• •
• •
•
•
A safe working practice and procedure pertaining to the coating works shall be ensured. Correct Lifting and Rigging practices will be used, in accordance with QG Lifting Procedure. sign Board will be display " KEEP AWAY BLASTING IS PROGRESS"/KEEP AWAY PAINTING IS PROGRESS" All personnel will use the necessary PPE. Workers will be made aware of the safety requirements of this activity through daily specific Task Instruction, MS / JSA. Housekeeping shall be maintained at all times. All waste shall be properly collected, segregated and disposed in accordance with the project requirements. The ground is not to be contaminated by spent abrasive and/or primer paint materials and will be protected by tarpaulins. Any spillages shall be cleaned up immediately as per project procedure. It will be ensured that directions and guidelines of the supreme council for the environment regulation are followed.
•
When working at height, fall protection measures shall be taken.
•
Remove all tools and materials from work site after completion of job.
•
All ICE Equipment shall have QG Blue sticker p rior to entering the plant area.
•
11
Tool box talk form is to be filled prior to start of any task by sub contractor supervisor
Task supervisor shall pass QG PTW Receiver training and present at work location at all times.
ATTACHMENTS JSA
