ESR00550- Cold Field Bending-revB

Document No ESR00550-MS-01

METHOD STATEMENT FOR COLD FIELD BENDING PROCEDURE

Page 1 of 12 Rev. A

PROJECT: ENOC-EPCL PROJECT NO.: ESR00550 REFINERY EXPANSION PIPELINE WORKS

METHOD STATEMENT FOR COLD FIELD BENDING PROCEDURE DOCUMENT NO. ESR00550-MS-001

PREPARED BY: REG REGIONA IONAL L QHS QHSE MANA MANAGE GER R

___ ______ ______ _______ _____ ____ _______ ________ _____ ____ ___

APPROVED BY: PROJECT MANAGER

REV NO.

SUBJECT OF THE AMENDMENT

A

For Internal Review

______________________________

REVIEWED BY AND SIGNATURE

AUTHORIZED BY AND SIGNATURE

ESR0 ESR005 0550 500a 0ad9 d992 92d7 d796 9631 314e 4e9e 9ea5 a530 30d8 d8f2 f23b 3bda da67 6786 86.E .ESR SR00 0055 5500- Cold Cold Fiel Field d Bend Bendin ingg-re revB vB_1 _169 69E2 E2D6 D6

DATE

Date Date:: 12-F 12-Feb eb--



Page 2 of 12 Rev. A

CONTENTS

SECTION 1.0

PURPOSE

2.0

SCOPE

3.0

REFERENCE DOCUMENTS

4.0

DEFINITIONS & ABBREVIATIONS

5.0

HEALTH, SAFETY AND ENVIRONMENT

6.0

TRAINING OF PERSONNEL

7.0

ROLES & RESPONSIBILITIES

8.0

EQUIPMENT AND MATERIALS

9.0

PROCEDURE

10.0

DOCUMENTATION

ESR005500ad992d796314e9ea530d8f23bda6786.ESR00550- Cold Field Bending-revB_169E2D6

Date: 12-Feb-


1.0


Page 3 of 12 Rev. A

PURPOSE The Purpose of this Method Statement is to define the specific tasks to be performed by Overseas AST LLC during cold field bending operations on the Installation of 24Inch Pipeline ESR00550-Refinery Expansion Pipeline Works.

2.0

SCOPE This procedure is intended to provide a detailed description of shop cold bending operations of 24” pipes which is passing through DWC corridor under the EPCL Methos Statement is– to provide a detailed description of cold REFINERY EXPANSION PIPELINE WORKS (ESR00550 - NI/3367) project.

The scope of this field bending operations on the Installation of 24-Inch Pipeline ESR00550-Refinery Expansion Pipeline Works. and to ensure that the work is performed in a safe, professional and controlled manner by competent trained staff. . 3.0

REFERENCE DOCUMENTS

3.1

Contract Scope of Work

3.2

Project Specification

add PFI ES-24 - Pipe Bending Methods, Tolerances, Process and Material Requirements

ASME B31.3

3.3

ASME B31.8 – Gas Transmission and Distribution Piping System

3.4

Project Health, Safety and Environmental Plan and Procedures

3.5

EES-L-10-Fabrication Steel & and Tubing Assemblies

3.6

Project Quality Plan and Procedures

3.7

Pipeline Alignment Drawings

4.0

DEFINITIONS

4.1

COMPANY

ENOC -EPCL

4.2

ROW

Right of Way

4.3

PTW

Permit to Work

4.4

PPE

Personnel Protective Equipment

4.5

SWL

Safe working Load

4.6

IP

Intersection Point

Drawing Number


Date: 12-Feb-



5.0

HEALTH, SAFETY AND ENVIRONMENT

5.1

Induction

Page 4 of 12 Rev. A

Only minimum information required

Prior to commencing work all personnel shall have attended the Project HSE Induction Course conducted by the over Seas HSE Department.

5.2

PPE All personnel involved in cold field bending activities shall comply with the Project requirements for PPE. Where appropriate, training shall be given in the use of PPE. The PPE requirements on site during cold field bending activities shall be: • • • • •

Work Boots with toe protectors Safety Helmet Eye Protection with side shields Coveralls Labourer’s Gloves

Personnel shall sign for items of PPE issued to them and the Supervisor shall ensure daily that his crew is using the required PPE and that damaged or defective PPE is replaced or repaired. 5.3

Operating Plant and Equipment The Bending Supervisor shall inspect all equipment for damage and/or deficiencies prior to the commencement of work each day and surveillance shall be maintained on equipment to check if the equipment has sustained any damage during the course of the working day. Defective items, that affect the safe operation of the piece of equipment, shall be immediately taken out of service until repaired or replaced. Other deficiencies shall be rectified as soon as possible. Plant operators shall complete a Daily Plant & Equipment Checklist for the item of plant they operate and shall report all deficiencies to the Supervisor who will arrange the Plant Department to rectify the deficiencies. •

•

•

Only competent, licensed operators shall be permitted to drive and operate sidebooms and cranes. Competent, experienced riggers under supervision of the Supervisor will undertake any rigging work required when handling line pipe during cold field bending operations. Banksmen shall direct the movement of all equipment around the site and shall direct crane operator during lifting operations.


Date: 12-Feb-


5.4


Page 5 of 12 Rev. A

Risk Assessment Prior to the commencement of cold field bending activities, a risk assessment shall be conducted jointly by the Construction Department and the HSE Department to ensure that all hazards and risks are identified and the required mitigation measures are in place, and remain fully implemented during operations.

5.5

Toolbox Talks Prior to the commencement of cold field bending activities, the Supervisor with support from the AST HSE Advisor shall conduct a pre-start toolbox talk with all the crew present. The Supervisor shall explain the method of cold field bending, focusing on the hazards and risks involved in the activity and the mitigation measures that shall be taken as detailed in the Risk Assessment. Regular Toolbox talks shall be conducted in order to prevent complacency within the crew. Toolbox talks shall be documented and the records maintained by the HSE department. Should any new personnel join the bending crew during the duration of cold field bending activities the Supervisor conduct a Pre-start toolbox talk for the new person/s prior to the person/s starting work.

5.6

Environment Dust control measures shall be implemented on sections of the ROW where dust will be generated by the movement of trucks and equipment along the ROW. The bending crew shall collect up all rubbish generated by bending activities and dispose of rubbish in an approved waste disposal location.

6.0

TRAINING OF PERSONNEL

6.1

Safety Training

Please Keep it short

All personnel involved in cold field bending activities shall have received the appropriate training applicable to their job designation. Further training will be given as required and when the need additional training is identified during the risk assessment process. 6.2

Trade Training All personnel involved in cold field bending activities shall be assessed for competency and if they have the required trade skills and experience required by their job function.


Date: 12-Feb-



Page 6 of 12 Rev. A

Competency assessment shall be made by verbally testing the person, checking trade certificates (where applicable), and field evaluation (where applicable).

7.0

ROLES AND RESPONSIBILITIES

7.1

Construction Manager

Please Keep it short

Responsible to the Project Manager for: •

•

7.2

Ensuring that all lifting gear to be used is certified by an approved ThirdParty Authority. Ensuring that lifting gear and equipment is maintained and stored correctly.

Crew Supervisor Responsible to the Construction Manager for: •

• •

• • • •

7.3

Implementing this construction execution procedure and other procedures affecting pipe cold field bending. Participating in the risks assessment for cold field bending activities. Ensuring that adequate and competent or appropriately trained personnel are available to perform the work. Supervising all pipe bending crew personnel. Verifying their training and competency levels. Ensuring plant and equipment is inspected and maintained in good order. Ensuring all cold field bending activities are carried out safely and under the correct conditions.

QC Inspector Responsible to the Senior QA/QC Engineer for: Witnessing, inspecting and documenting bending procedure. The surveillance inspection of cold field bending activities in accordance with the Inspection and Test Plan. HSE Advisor • •

7.4

Responsible to the Senior HSE Advisor for: • •

7.5

Participating in the risk assessment for cold field bending activities. Ensuring that cold field bending activities are performed in a safe manner in accordance with Project HSE procedures.

Crew Responsible to the Supervisor for: Performing their work in a safe manner at all times. •


Date: 12-Feb-


•

•

8.0


Page 7 of 12 Rev. A

Following the requirements of the risk assessment and this construction execution procedure. Informing their Supervisor of any health, safety, environmental or quality concerns.

EQUIPMENT AND MATERIALS

Mention Equipment details, Capacity, Model No, General arrangement drawing etc.

All plant and equipment, required for lifting shall tested 3 rollersoperations, should be covered withbe rubber sheet and approved or other suitable materials by an independent third-party authority prior to use on the Project. The Plant Department shall maintain the load test certificates and a copy of the certificate retained on site by the plant or machine operator. The S.W.L. of all lifting equipment will be marked clearly on the equipment. All lifting equipment should be securely stored and clearly identified and tagged to show limitations of use and the date re-certification is required. Cranes and sidebooms shall be of suitable capacity to handle the pipes and shall be operated by approved personnel. All bending machines shall be equipped with the necessary bending shoes to match the external pipe diameter. Bending shoes shall be covered with suitable material to avoid damage to the pipe external 3LPE coating. Hydraulically controlled internal mandrels are to be used to prevent buckling of the pipe during bending operations. 9.0

PROCEDURE

9.1

General Changes of the vertical and horizontal alignment of the pipeline, made necessary by the actual condition and contour of the ground, shall be provided for, where possible, by cold field bends. Minimum cold field bend radius shall be equivalent to 18 times pipe diameters as specified in ANSI/ASME B31.4. use parameters based on ASME B31.3

Induction bends shall be provided where bends of smaller radius are required or where such bends are specifically shown in approved alignment drawings.


Date: 12-Feb-



Page 8 of 12 Rev. A

A bending procedure shall be performed to establish the minimum bend radius that can be achieved on the wall thickness pipe using the AST bending machine and equipment. The procedure qualification bends shall meet the following criteria: •

•

The minimum acceptable cold field bend radius shall be equivalent to 18 pipe diameters. This pipe is coated with 3.5mm thk 3LPE, please check UT gauge suitability. Provide thickness the gauge walldetails thickness checked, by ultrasonic,

Each pipe will have at predetermined points along the length of the pipe prior to bending. On completion of bending the wall thickness shall be rechecked at the same points to determine that any reduction in wall thickness does not exceed the maximum under thickness tolerance specified in the pipe data sheets.

Flattening of a bend, the difference between The maximum and minimum diameters shall be checked at predetermined • maximum and minimum diameters at any cross locations section, shall not exceed 8% of nominal outside along the length of the pipe prior to bending. On completion of diameter for internal pressure and 3% for external bending the diameters shall be rechecked at the same points. The pressure. between the maximum and minimum diameters of the completed Removal of metal shall not be useddifference to achieve these requirements. bend shall not exceed 2.5% of the nominal diameter. •

•

•

•

The completed bend shall be visually inspected and shall have a gauging plate of 95% of the nominal internal diameter pulled through the pipe, to ensure the pipe inside diameter is within the specification. The completed bend shall have a smooth contour and be free of mechanical damage, cracks, wrinkles or buckles. No damage to external pipe coating (minor scuffing is acceptable) or damage to the pipe bevel ends. The completed bend shall be holiday tested at the specified voltage to check for external coating damage.

The bend data for each procedure bend shall be documented and shall form the criteria for all the cold field bending to be performed on the Project. 9.2 Why 1.5m ?

Production Bend Requirements All the pipe cold bends shall be according to the following requirements: The minimum tangent length at each end of the bend shall be 1.5 m. The radius of the cold bend shall be not less than 18 times the nominal pipe diameter. The longitudinal axis of the pipe shall not be deflected more that 1.5 degrees, in a length along the pipe axis, equal to the pipe diameter.


Date: 12-Feb-



Page 9 of 12 Rev. A

All completed bends shall be tested for ovality with a gauging plate consisting of two aluminium discs rigidly connected at a distance of 750mm apart and having a diameter not less than 95 % of the pipeline nominal internal diameter. There shall be no significant coating damage (minor scuffing is acceptable) or bevel damage evident on the completed bend. The pipe end caps shall be reinstalled after the bending is completed. The bend type (Sag bend, over bend, side bend or combination bend) and the bend angle shall be clearly written on the outside of the pipe, using indelible marker.

9.3

Bending Methodology The bending operation shall be performed in accordance with the following methodology: The Bending Foreman shall systematically measure the length of each pipe and mark the centreline of the pipe for subsequent slinging, transfer the pipe data (pipe number, heat number and pipe length) to the end of the pipe, if not already done. The degree of bends required shall be determined in the field by the Surveyor from stripped ground levels, special crossing/ pipeline profile drawings. The Surveyor will record the length, pipe number, heat number and angle required of each strung pipe to be bent on the bending schedule.

Coating damage should be referred to AST

Pipes shall be visually inspected for coating and pipe damage/defects prior to bending. Bending machine elements (shoes and dies) shall be checked to ensure they are clean and free from any material that could damage the pipe, external coating and internal lining. The pipe shall be lifted, using a specialised belt and positioned on the stiff back end of bending machine. Hydraulically controlled mandrels are fitted internally at the bend location and are used to prevent buckling of the pipe during bending procedure. One end of pipe is lowered on to the roller and the pipe is moved halfway into the machine then the mandrel will be loaded and set to the desired bend position. The cable hook is then attached to the stiffback end of the pipe.


Date: 12-Feb-



Page 10 of 12 Rev. A

The winch cable is slowly tensioned until the pipe is properly located for the first bending operation and the stiffback is then raised. The pin-up shoe is raised until the pipe touches the lowest point of the curvature of the die. The distance from the front of the die to the top of the pipe and the distance from the rear of the die to the top of the pipe should be equal. The bending gauge is marked at this setting as the reference starting point for each increment of the bend for the size of pipe. The pipe is marked with its centre point (length) and the pipe is lowered on to the roller using the sideboom & lifting belt and the winch cable is unwound for "freewheeling". The stiffback is then raised up to reference mark on the bending gauge scale. Then the pipe shoe is raised to the bending limit of the pipe or until the hydraulic pressure gauge reads maximum at pressure. The bending cycle is then repeated until the required degree of bend is achieved. The step length shall be marked on the pipe and the required pull per step length shall be made and measured by bending machine’s measuring rod. After pipe is bent, but while still in the machine, the total amount of bend is measured by using a clinometer or electronic true bend device. Cold bending of ferritic materials shall be done at a temperature below the transformation range.

If lubrication or cooling liquids used, it must be compactable to use over 3LPE coating. Attach Data Sheet & MSDS for the same


Date: 12-Feb-




10.0 Bending Procedure


Date: 12-Feb-




Include section for inspection & Testing

11.0

DOCUMENTATION The Bending Foreman shall complete a Bending Report for all cold field bends and the report shall be submitted to the AST QC Department at the end of each day’s work. The AST QC Inspector shall verify the recorded data.

Coating damage should be referred to AST Attach related formats, Calibration register


Date: 12-Feb-

ESR00550- Cold Field Bending-revB

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