DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
MS-001
Rev.
02
DATE
12/23/2015
PAGE
1 of 10
METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
AT AT RAS LAFFAN LOADING & RECEIVING FACILITY (RALF)
CLIENT: WOQOD
Title Issued By: Reviewed by Approved By: Client approval
Signature
Date
DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
CONTENTS
1. PURPOSE 2. SCOPE 3. Resources 4. RESPONSIBILITIES 5. PROCEDURE 6. HEALTH & SAFETY 7. RECORDS 8. ATTACHMENT(S)
Rev.
MS-001 02
DATE
12/23/2015
PAGE
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DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
MS-001
Rev.
02
DATE
12/23/2015
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1. PurposeThis method statement describes the steps to be followed in repair of 14” GRE pipelines in a safe way to handle the job with qualified supervisors and Technicians with high experience in GRP/GRE works.
This Method Statement must be used and referenced in the pre-work “Tool Box talk” briefing. Any changes to the MS must be noted and addressed in the pre-work meeting. A copy of this MS must be kept either on site. All personnel must be familiar with this document prior to commencing any work. Any risks identified as part of this MS must have adequate control methods identified prior to commencement of work. This Safe Work Method Statement must be explained to all personnel involved in the work process, prior to commencing work.
2. Scope-
This method statement describes the steps to be followed pipes.
in excavation and
repair of 14” GRE pipelines
This Method Statement generalizes the different recipes prepared specifically for this project. The recipe specifies the minimum laminate thickness, the bonding and the number of layers will be calculated after physical inspection, the resin type will be isophtalic polyester resin (siropol 7440 ) according to specification. All parameters to be considered as per the joint diameter (14”) and the line pressure The laminators should make sure that they are carrying the right recipe related to the joint diameter & line pressure rating.
3. ResponsibilitiesProject Engineer Project Engineer is responsible for assisting Project Manager to control the project and a co-ordination between site and management.
Site Engineer Site Engineer is responsible for executing the job and manpower control according to plan schedule to work and client/customer standard.
QC Engineer: QC Engineer is responsible for maintaining the job according to Customer quality need.
Safety Officer Safety Officer is responsible to maintain the site in safe condition and keep monitoring the ongoing work according to Customer Safety Standards.
DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
Rev.
MS-001 02
DATE
12/23/2015
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Site Supervisor: Site supervisor is responsible to execute the job according to method statement. Review and approve lifting plan and operation submitted by contractor/crane supplier via the Executing Department as and when required. Constantly monitor the approved plan and identify improvement for future.
4.
Resources A. Man Power
Project Engineer Site Engineer Mechanical Supervisor Site Foremen Mechanical Fitter GRP/GRE Laminator Piping Fabricator Material controller Safety Officer Fire Watchman Riggers, Helper.
B. Tools & Equipment
4”, 6” & 9” diamond cutting disc. 4 ½” & 7 ½ “angle grinder, 220 V. Spirit Level 50 M long Electrical Cables with industrial plug Exhaust or blower fan for internal lamination, 220V Halogen Light / Torch Curve O mark Scissors Measuring tapes Wrap-Around Calibrated Barcol Impressor Right Angle 12” 100 ml Graduated Cylinder Catalyst Dispenser (for Vinyl ester lamination) Safety shield Portable Blower Ventilation fans Steel serrated roller Hard cotton gloves Ø2” x 7” Lamb wool Rollers (Refill) 4” & 6” Backing Pad 10 liters mixing buckets (graduated) Polyethylene Gloves 4” & 6” Emery Disc, grit 60 Dust Mask, 3m 8710 Marker Line string
DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
Rev.
MS-001 02
DATE
12/23/2015
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Paint Brush, 4” Tarpaulin sheet for shed, 10m x 10m Cleaning Rags Masking Tape Fire Retardant Paper Roll Ø2” x 7” Lamb wool Rollers handle Measuring Tools/ Precision Scale Nylon rope Misc. Tools & Tackles Lifting Tools & Tackles
C. Safety PPE
5.
Safety Helmet Safety Harness Safety Shoes Safety Goggles/Glass Hand Gloves Face Shield Respirator (If required) Ear Plugs/Muffs (if required) Dust mask Toxic Clip Fire Blanket Fire Extinguisher Chemicals Apron
PROCEDURE
A. PREPARATIONS
All necessary work permits will be secured from WOQOD Operations prior to start of any activity. Ensure all the workers and staffs that will be involved in the work have undergone WOQOD Safety Awareness Induction given by the Authorized in WOQOD organization prior to work. Ensure all the needed materials, tools and equipment are available and that vehicle(s) to be used on site have been inspected and approved by WOQOD Safety. Install all needed safety barricades and signage. Check for pipes identification code/class etc., and ensure that they are as per approved isometrics.
DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
MS-001
Rev.
02
DATE
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B. WORK EXECUTION
Mobilization to WOQOD site and arrange laydown area. Site survey and taking dimensions, check the location for the joints, fittings and supports, barricade for excavation,
Excavation, inspection for leak.
Fabrication of GRP 14’’ pipes, fittings and flanges at GRE vendor’s workshop if applicable.
Start site lamination ,spool fabrication and fittings lamination
Reference drawings will be made available on site and planned activities will be discussed and made clear to the understanding of each worker that will be involved in the work. Check the alignment on the new supports, pipe rack and level of pipes. After curing of the laminated joints, carryout barcol test. Back fill of excavation
Pipe Cutting & Lamination Cutting
The old GRE pipeline will be cut by grinder of steel disc, the tip below will be cut in order to remove any likely of water in the pipe, after the water has been removed, the whole pipe fittings will be cut if applicable External Lamination Fit layer
a. Measure and mark the fit layer bond length of 50 mm from the end of each pipe. b. Grind by angle grinder with emery disc the above area to remove the topcoat & surface layer of the pipes until the pipe glass fiber are exposed. The maximum depth of grinding should be within 0.3-1.0mm depth from top layer. c. Clean this area by dry clean cloth or paintbrush and ensure that it is fully dry.Ensure that the gap between the two pipes to be laminated is within the allowable limit of 0-3 mm for diameters up to & including Ø1800 mm. d. Fill the gap, if any, between the two pipes with milled-glass fiber resin putty. Note: The milled-glass fiber resin putty is compatible with desalinated water/ seawater/ hypo chlorite solution. e. Impregnate by lamb wool roller the roughened area with the resin catalyst mixture mentioned in the recipe.
DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
MS-001
Rev.
02
DATE
12/23/2015
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f. Apply woven roving glass 270 using a 50% overlap between each two consecutive windings so that wrapping the full surface will end up with two layers of glass. g. Impregnate by lamb wool roller the above layers with the resin catalyst mixture. h. Use aluminum roller to remove entrapped air and blisters. i. Repeat the above two steps till the required number of layers is applied as specified in the recipe. j. Wait till the lamination is cured under ambient temperature. Once the fit laminate is tack free, it is ready for the main laminate preparations. Main Laminate
a. Measure and mark the bond length as specified in the recipe on each pipe from the middle of the fit layer. b. Grind by angle grinder with emery disc the cured fit laminate and the pipe as per the mark bonding length until the pipe glass fiber are exposed in order to roughen the pipe surface to have good bonding prior to the main laminate. The maximum depth of grinding should be within 0.3-1.0mm depth from top layer. c. Special Note: If ground area is left under dusty weather conditions (with sand) or left exposed for more than one day under any weather condition; it is mandatory to clean the grinded area with a dry clean cloth or paintbrush and ensure that it is fully clean & dry. d.
A proper mixture of resin and catalyst is prepared as per recipe.
e. Impregnate by lamb wool roller the roughened area of the above area with the resin catalyst mixture. f. Apply woven roving glass 270 using 50% overlap between each two consecutive windings so that wrapping the full surface will end up with two layers of glass. g. Impregnate by lamb wool rollers the above layers with the resin catalyst mixture. h. Repeat the above two steps till the required number of layers is applied as specified in the recipe. i. Apply woven roving glass 360 using 50% overlap between each two consecutive windings so that wrapping the full surface will end up with two layers of glass j. Impregnate by lamb wool rollers the above layers with the resin catalyst mixture. k. Repeat the above two steps till the required number of layers is applied as specified in the attached recipe at this stage as “initial winding”. l. Apply the specified number of layers of woven roving 580 and 360 alternatively. Each type of glass should be applied in four consecutive layers before changing to the other type. Every two layers should be impregnated before applying the second two layers of the same type
DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
Rev.
MS-001 02
DATE
12/23/2015
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m. Apply two “sealing layers” of woven roving glass 360
n.
Impregnate by lamb wool roller the above layers with the resin catalyst mixture
o.
Wind 2 layers of top tape glass around the laminate to extract the excess quantity of resin and to provide smooth surface.
p.
The lamination will harden under ambient temperature .Make sure that the joint is undisturbed for a MINIMUM of 12 hours.
q.
Once the curing of the lamination is completed, inspection and the required test of the lamination joint can be carried out as per the Inspection & Test Plan; the laminated joint shall be considered accepted only after passing the hydrostatic test. However, as per document Inspection & Test Plan, FPI Qatar supervisor shall certify at site each joint prior to the hydrostatic test.
Operations will have to pressurize the line after the connection is made complete and quality inspections are done and comments satisfied. Re-check laminated connection after 24 hours the line is put in service.
DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
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MS-001 02
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HEALTH AND SAFETY MANAGEMENT AND CONTROL MEASURES General Safety Requirements
All personnel involved shall use necessary PPE as required and supervisors shall ensure regular inspection of workers PPE. Ensure that all staff and workmen assigned to carry-out the task have undergone the required WOQOD trainings. The workers shall be made aware of safety requirements related to this activity through daily, weekly and monthly toolbox and safety talks. The JSA shall be used to the site supervisor as the basis of conducting his daily Tool Box Talks. All equipment, plant, machineries and tools that shall be utilized in the job shall be kept in good working condition having relevant and valid documents and should pass WOQOD inspection requirements and certifications. Access and good housekeeping should be maintained in all erection areas. Waste Management Procedure shall be strictly followed to keep the job site neat and clean. The required Process / Mechanical, Electrical and Instrumentation LOTO shall be obtained and attached with the PTW. Working area shall be barricaded with Warning Tape. Safety watch shall be present from start up to the completion of the installation/erection work. All lifting equipment required valid third party certificate and to be maintained at site. Proper fire protection to be employed at site while hot and open flame activity. Personal protective equipment: All workers will be wearing appropriate PPE. (Rubber safety boots whilst working with concrete or in the mud area, dust mask, chemical mask, safety helmet, high visibility vest, gloves and overall a. The lamination bond area should be provided with adequate cover to protect the joint from desert conditions. (Sand, dust, humidity etc.). Aluminum frame or similar improvised mobile scaffolding should be arranged to straddle the pipe with interconnecting pipes and planks/platforms at suitable height to aid lamination effort of workmen. b. Proper provision of a safe means of access to the work area c. All workers will be informed (via a site induction / toolbox talk) of and expected to comply with the client site rules. d. The prepared bond surface area should be free from grease, oil, dust, moisture, water etc. Clean the surface using a clean and dry cloth or a dust brush. e. Do not distu rb the joint before the lamin ate is cured.
DOC. REF. NO.
PETROL& GAS CONSTRUCTION CO. METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GRE FIRE LINE
LIST OF CONSUMABLES CONSUMABLES
7-
a.
Resin
b.
Hardener
c.
Cobalt
d.
Fiber Mat
e.
Combination Fiber
f.
C Glass
g.
Hard cotton gloves
h.
Ø2” & 7” Lamb wool rollers handle
i.
Ø2” x 7” Lamb wool rollers (Refill)
j.
4” Backing Pad
k.
10 liters mixing buckets (graduated)
l.
Polyethylene Gloves
m.
4” Emery Disc, grit 24
n.
Dust Mask, 3m 8710
o.
Marker
p.
Tarpaulin sheet for shed
q.
Cleaning Rags
Records-
a. As Built Drawing b. Barcol Hardness Test Report c. Hydro Static Test Report 8-
ATTACHMENTS-
MSDS of chemicals
Rev.
MS-001 02
DATE
12/23/2015
PAGE
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