PEARL QATAR Sea Water Reverse Osmosis Plant GP - 047
Method Statements for INTALLATION OF RO SKIDS, PRESSUE VESSELS AND CONNECTING PIPES
Method Statement No: 517008-500-104, Rev. 1 Issued by: Metito Rev. No.
Date 28-April-09 011 Mar-09
DescriptionPrepared Issued for Information M.W. Issued for Information M.W.
Checked
Approved Y.K. M.W.
M.H. M.H.
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TABLE OF CONTENTS 1. TITLE. 2. SCOPE OF WORK 2.1. General description 2.2. Plant and equipment 2.3. Material Handling & Storage 2.4. Site planning & preparation 2.4.1. Site management plan & Access route 2.4.2. Coordination with other contractor 2.4.3. Communication 2.5. Work methodology 2.5.1. Installation of skids 2.5.2. Installation of duplex & 316 L Stainless Steel lines 2.6. Organisation, Responsibilities & Supervision 2.7. Work Force
3. HEALTH & SAFETY 3.1. General 3.2. Protective & Safety Equipment 3.3. Information to personnel 3.4. Emergency Procedures 3.5. Permit Requirements
4. ENVIRONMENTAL ISSUES 4.1. Environmental Impact assessment.
5. QUALITY ASSURANCE 5.1. Contractual Requirements 5.2. Follow up & Evaluation
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1.
TITLE Installation of RO skids, pressure vessels and connecting pipes
2.
SCOPE OF WORK
2.1 General Description This Method Statement details the procedure to be carried out during the installation of RO Skids and the pressure vessels along with the connecting pipes (Duplex Stainless Steel, 316 L Stainless Steel and uPVC spools) for both the first and second pass. Note: Hydro testing is not applicable after completing the RO skids & pressure vessels pipes installations as there will be no way to separate the low pressure pipes side from the high pressure one.
2.2
Plant and Equipment S. No.
Item Description
Quantity
1
Mobile Crane
AS Required
2
Hand Pallet Trucks
As Required
3
Hand tools, drill machine, Spirit level, measuring tape, etc.
AS Required
Purpose Allocation of Materials (Spools, Skids & pressure vessels) inside the building Moving Materials inside the building For fixing / measurement and installation purpose
2.3. Material Handling and Storage
Skids Duplex Stainless Steel Spools 316 L Stainless Steel Spools uPVC product line Spools
-
5 Skids each pass 5 Lots 5 Lots 5 Lots
All Materials shall be transported by suitable vehicles and secured properly during transportation. Loading and unloading shall be done carefully to prevent damage due to impact, abrasion or lack of support. All Spools should not be dropped onto hard surfaces and should not be dragged along the ground. Loading and unloading of Spools should be carried out by crane & nylon slings rather than fork lift, only hand pallet trucks shall be used for moving the
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spools inside the building. No metallic slings, hooks or chains should be used in direct contact with the spools. Special care shall be taken for the Stainless Steel Spools. Spools should be stored on a flat surface free from sharp projections, stones or other objects likely to cause damage to the spools. Always Refer to manufacturer’s recommendations & instruction manual.
2.4. Site Planning & Preparation 2.4.1 Site Management Plan and Access route 1. The Site Engineer shall be responsible for the installation as well as for the co-ordination and interfacing with other trade activities during the installation works. 2. The equipment tools and consumable required shall be planned and arranged at the Site before commencing the Erection. 3. Site Safety and personal safety equipment shall be planned and arranged in advance. 5. Toolbox talks shall be conducted at every morning before start of any job. 6. The Site Engineer and the Supervisor shall supervise and control all the work at the Site.
2.4.2 Co-ordination with other Contractors The Site Engineer shall be responsible for the co-ordination and interfacing with other contractors during the installation works. If there is any interface with civil contractor, they shall be informed well in advance and necessary precautions shall be taken care of.
2.4.3 1. 2. 3. 4.
2.5
Communication Toolbox Talks Staff Meetings Supervisor Instructions Communication at Site shall be by cellular phones. shall be issued with a cellular phone.
Supervisory personnel
Work Methodology
2.5.1 Installation of the Skids 1. Check & verify that the civil work is completed in compliance with all requirements for installation as per approved drawings and handed over for mechanical works. 2. Before starting the installation drawing shall be studied carefully to check the requirements. 3. Skids delivered to site are prefabricated members that are dismantled only to facilitate the shipping.
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4. Layout the skid and mark on the concrete foundation to make sure the
erection will be adjusted in the correct location. 5. Erection starts with the base panel that shall be placed as per the
markings on foundation. 6. Vertical members and panels are then attached and the bracing
members are installed in place. 7. For point 4 & 5 a chain block hanged from the concrete beam is used to
move and lift the skid steel members. 8. Anchoring the skid to foundation using the bolts supplied with the skid. 9. Pressure vessels are then allocated in place as per the approved
drawing and design. 10. The clamps supplied with the pressure vessels are used to fix each
pressure vessel to the skid frame as shown in the approved skid drawings. 11. Final adjustments for the clamps is done after assembling the feed header (Duplex or SS 316) 2.5.2 Installation Duplex & 316 L Stainless Steel Piping 1. All spools shall be visually inspected for any possible damage prior to installation. 2. Spools must be adequately supported, pipe supporting shall be as referred to manufacturer’s recommendations & instruction should be followed. 3. Layout the locations of the pipe supports and drill the holes of the required size of anchor bolts for fixing the pipe supports on the floor as per the requirements. 4. Install the pipe supports on the floor as & where required. 5. Start installation with the spools that is connected to the pressure vessels. 6. Continue installations succeeding spools and make any required adjustments for the support and go on with the line. 7. Final adjustment for the HPP location and turbo charger location should be done to match with the installed spools. 8. Fix the clamps to attach the spools to the pipe supports and secure it with correct bolts. 9. All gasket and flange surfaces should be cleaned from any dust or dirt. Gaskets should be placed properly in the centre to achieve a reliable joint. 10. Align the flanges. Spools not yet connected should be aligned within the alignment tolerances with the flanges already connected before the bolts are installed. Bringing the flanges into alignment should not leave any residual stresses in the piping system 11. Use a cross pattern bolt-tightening sequence. This pattern helps to achieve a uniform bolt load around the flange. Use at least three rounds of tightening around the flange, increasing the applied load in each round. This approach helps achieve uniform bolt load around the flange circumference. 12. All work procedure in handling, storage and installation of stainless steel spools shall follow the manufacturer’s installation instruction. 13. The sequence shall be assembling the feed line, then the reject line then the product line (uPVC pre-fabricated spools – please refer to uPVC method of statement)
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2.6
Organization, Responsibility & Supervision:
S. No.
Designation Sr. Site Engineer HSE Engineer QC Engineer Supervisor/ Foreman Technicians, Pipe Fitters & helpers
2.7
Responsibility Manage the installation works for the fabrication of Skids Health, Safety and Environmental issues. To control the quality as required Supervise the installation as per approved procedure and HES requirements Conduct the installation on site.
Work Force S. No.
Description
No.
Plumbers / Pipe Fitters Mechanical Technicians Helper / Labour
3. HEALTH & SAFETY 3.1.
General 3.1.1
Barriers and warning tape will be provided as appropriate. Tape will be used as a warning of danger.
3.1.2
Prior to commencement of work a toolbox talk will be conducted by the Supervisor.
3.1.3
All personnel shall be equipped with PPE
3.2. Protective & Safety Equipment All work force shall be issued with the following personal protective equipment (PPE): • • • • •
Working Gloves Safety Goggles Safety Shoes High visibility vests Safety Harness when required
Additional protective equipment will be issued when and as required.
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3.3. Information to Personnel Communication to personnel shall be made through: • Safety Induction • Toolbox Talk Programme • Supervisors Daily safety toolbox meeting will be conducted by the assigned supervisors and/or HSE Engineer prior to daily work activities. In addition to the basic HSE instructions, the following will be discussed: All pertinent requirements of this Method Statement will be discussed with the concerned personnel.
3.4. Emergency Procedures METITO shall provide first aid kits on site for light injuries. In the event of an emergency, all workers will be asked to evacuate and assemble at the designated assembly area and wait for further instruction from supervisors.
3.5. Permit Requirements Gate passes for the personnel and vehicle will be issued to enter the UDC pearl Island. Prior to commencement of the works, METITO will secure site identification badges for the personnel.
4.0 ENVIRONMENTAL ISSUES 4.1. Environmental Impact Assessment No environmental impact is expected from the installation of RO Skids, pressure vessels and the connecting pipes. However, complete environmental impact assessment shall be submitted to UDC and ministry of Environment for approval for the whole plant along with the intake and outfall piping.
5.0 QUALITY ASSURANCE 5.1 Contractual Requirements RO Skids and piping Spools shall be installed as per the approved design in accordance with the relevant specification standards and approved Fabrication and GA drawings & manufacturer’s recommendations.
5.2
Follow-up & Evaluation Daily Reports and bi-weekly Reports as well as Monthly reports will be issued to follow up on the progress of the work.
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