FOR CONSTRUCTION
Method Statement for Underground Underground Piping
s i t I n e . t s i r t o r s w n r e o c i r i l p t s ’ u I o H h t i M r w o e / d s n o a p , r C u p E y D n , a I r H o f M f t y o r n a o p i t d r a i h m t r o y f n n i a y o r t a d t e e i r s o p l o r c s p i n d i e a b t n t o c o n y n a a c m t d n n a e l m a i u t . c n t o e n d i d e s s f i n h n o o T c c
DISTRI.
20 Pages including Cover Sheet
CLIENT
4
MHI
N O I S I V E R
3
06.01.10
REVISED AS MARKED
2
03.12.09
REVISED AS MARKED
I.S.K.
C.G.J C.K.S
J.D.J.
1
17.10.09
FOR CONSTRUCTION CONSTRUCTION
I.S.K.
C.G.J C.K.S
J.D.J.
NO.
DATE
DESCRIPTION
ORDER NO. PROJECT TEAM APPROVED
DEC-
QA/QC
REFERENCE
APP’D SECTION
APP’D PROJECT TEAM
OWNER
AOFP J. D. Joh
PROJECT
SAFETY PROCURE CIVIL BILDING
El-Djaz El-Djazairia airia El-Omania El-Omania Li l Asmid Asm ida a Spa
MECHANIC PIPING
QA / QC SECTION APPROVED
C. K. Seo Piping Team C. G. Joung
ELECTRIC
PROJECT
INSTRU
Al A l g eri er i a Oman Om an Fert Fer t i l i zer Pro Pr o j ect ec t (A OFP)
PAINTING SUBCON
DWG. NO
DRAWN DRAWN DATE
D. J. Lee 27. Aug, 2009
.
6423DP420-00-00200 00 MHI-DEC Consortium
REV.
3 TOTAL
1
TABLE TAB LE OF CONTENTS CONTENTS
1.0
PURPOSE
2.0
SCOPE
3.0
REFERENCE
4.0
DEFINITIONS
5.0
ROLES AND RESPONSIBILITIES
6.0
GENERAL
7.0
PROCEDURE
8.0
TESTING
9.0
SAFETY
10.0 ATTACHMENT
1 / 19
1.0
PURPOSE This document is to define the methods and processes to be adopted in order to ensure that all underground piping system are installed in accordance with Algeria Oman Project (AOFP) specifications, applicable code and standard.
2.0
SCOPE This method statement covers the excavation, installation, jointing and backfilling of underground coated carbon steel piping. Pressure testing of all piping systems will be conducted in accordance with Hydrostatic Test Procedure (6423DP420-00-0130000).
3.0 3.1
REFERENCE Codes & Standards DPEM Circular No.2
Technical Control Regulation for Installation for the Treatment and Storage of Hydrocarbons and Electric Power Generating Stations
Decree 90-245
Statutory Regulations of Gas Pressure Equipment.
Decree 90-246
Statutory Regulations for steam / Vapor Pressure Equipment.
ASME B 31.3
Chapter V Fabrication, Assembly and Erection
ASME B 31.3
Chapter VI Examination, Inspection and Testing
ASME BPVC Sec. II Part C
Welding Rods, Electrodes and Filler Metals
ASME BPVC Sec. V
Nondestructive Examination
ASME BPVC Sec. IX
Welding and Blazing Qualifications
ANSI/AWWA C209
Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections and Fittings for Steel Water Pipelines
Steel Structures Painting
1.Steel Structures Painting Manual
Council (SSPC)
2. SP-3 Power Tool Cleaning 3.SP-10 Near White Blast Cleaning
NACE RP-02-74
Recommended Practice, High Voltage Electrical Inspection of Pipeline Coatings Prior to Installations
3.2
Technical Specifications / Documents The following technical specification / documents shall be used in conjunction with this document 6423MS231-00-00100 00
Specification for Piping Fabrication by Each Service Class
6423MS230-00-00200 00
Specification for Inspection of Piping Work
6423MS285-00-00100 00
Specification for Flushing & Cleaning of Piping
6423MS286-00-00100 00
Specification for Hydrostatic & Pneumatic Pressure Test
6423MP201-00-01200 00
Specification for Field Joint Rubber Lining
6423MP201-00-01100 00
General Specification for Rubber Lining (Seawater Piping)
6423MP201-00-01101 00
Rubber Lining Materials For Site Lining Work
6423MP342-00-91100 00
Wrapping Procedure For Underground Piping
6423MP202-00-00100 00
Piping Material Specification
6423DA060-00-00500 00
Qualification of Welding Procedure Specification
6423DA060-00-00700 00
Welder Qualification Procedure 2 / 19
6423DA060-00-00900 00
Welding Control Procedure
6423DA060-00-01200 00
Welding Material Control Procedure
6423DP420-00-00420 00
Method Statement of Painting
6423DS202-00-01300 00
Confined Space Procedure
6423DS202-00-01600 00
Excavation Work Safety Procedure
6423DC420-00-00700 00
Procedure for Earth Work
6423DP420-00-01300 00
Hydrostatic Test Procedure
Note : If there are any conflicting requirements between this specification and individual specification or drawings, the requirement shall be governed in accordance with the following order. (1) Drawing and individual specifications (2) This specification (3) Codes and standards
4.0
DEFINITIONS For the purposes of the document the following definitions shall hold.
4.1
Owner This shall mean EL-Djazaria El-Omania Lil Asmida Spa (A joint venture of SBGH & Sonatrach) who initiated the project and ultimately specifies the technical requirements. The Owner may also include an agent or consultant authorized to act for on be-half of Owner.
4.2
Contractor This shall mean MHI & DEC who carries out all or parts of the engineering, procurement, supply, construction and commissioning.
4.3
Media The technical document may be prepared, submitted and reproduced using any of the following media.
4.4
-
Hard copy
-
Reproducible (transparencies, tracings…). Photocopies and electronic copies
-
Photographs
-
Electronic media including compact diskettes / floppy diskettes.
Shall This shall mean mandatory requirement.
4.5
Should This shall mean desired requirement.
4.6
Document This shall include output in the form of hard copy, drawing, tracing, reproducible, floppy diskette, compact diskette and field inspection reports.
5.0
ROLES & RESPONSIBILITES
5.1
Project Manager Project Manager shall responsible for overall management and HSE of all Construction activities at site including installation and testing of underground piping.
5.2
Piping Manager Piping Manager shall be responsible for overall management of piping activities. He shall be responsible for implementation of this procedure and shall pass the instruction down the line to 3 / 19
maintain the required quality level. 5.3
Piping Engineer Piping Engineers shall be responsible for planning and executing installation activities of underground piping at site and implementation of quality and HSE plans during construction.
5.4
Piping Supervisor Piping Supervisors shall be responsible for requisitioning the materials required for installation, ensuring the installation as per approved drawings and implementation of good piping work and HSE work practices in their areas of operation.
5.5
Civil Manager Civil construction manager is responsible for the excavation and back filling of piping trenches, construction of concrete pits and all associated survey work.
5.6
QA/QC Manager QA/QC Manager shall be responsible for overall management of QA/QC activities. He shall be responsible for non conformance management quality audits both internal and external.
5.7
QC Engineer QC Engineers shall be responsible for QA/QC activities, material control and traceability, and review of test packages for hydro tests. He shall also be responsible for non conformance management and internal quality audits.
5.8
QC Inspector QC Inspectors shall be responsible for carrying out inspection activities and witnessing NDE during the installation processes and coordinating with the owner’s QA/QC personnel for inspection and certification, as per approved ITP.
5.9
Safety Officer Safety officer shall be responsible for coordination with HSE authorities of owner safety officer shall monitor all the works to ensure that they are carried out correctly and in safe manner and advise supervisors for corrective measure, if required. He shall ensure that toolbox talks are held which shall cover details of specific tasks to the personnel and specific job risks involved are explained to the work force involved.
6.0
GENERAL
6.1
When welder is welding, he shall wear the appropriate safety equipment and clothing to prevent him from getting an electric shock or burns.
6.2
A confined space entry permit is required before entry to confined space. When welding in confined space, an extractor must be installed to remove hazardous / toxic fumes and to ventilate the area, if necessary a mask shall be worn and an assistant will be posted at the entrance to the work area in case of emergency.
6.3
When welding, inflammable materials must be removed from work area to avoid causing a fire.
7.0
PROCEDURE
7.1
Sequence of work (1) Pipe transportation (2) Excavation (3) Wrapping (External) 4 / 19
(4) Pin hole test & Inspection (5) Fabrication for spool and double joint pipe (6) Internal cleaning and arrangement (7) Fit-up and welding (8) Hydrostatic test (for WF line) (9) Rubber Lining (Welded Joints) (10) Line leveling and supporting by sand bag (11) Wrapping (Welded Joints) (12) Pin hole test & Inspection (13) Backfilling (14) Service test (for WCM, WCR, WCS, WW, WSM, WSR & WSS line) 7.2
Material control (1)
Rubber coated carbon steel pipe shall be provided by the contractor (MHI). All delivery inspections and certifications are done by contractor (MHI/DEC). All pipes shall be inspected for conformity by QC inspector.
(2)
Welding consumables shall be controlled in accordance with Welding Material Control Procedure (6423DA060-00-012000 00).
7.3
Handling and Transportation (1) All coated pipes will be handled by means of wide sling bands or belts to avoid damaging the coating material. (2) Coated pipe shall be handled with wide nonabrasive canvas, leather belts and or other. (3) All equipment designed to prevent damage to the coating. (4) The use of tongs, bare pinch bars, chain slings, rope slings without canvas or composition belt slings with protruding rivets, pipe hooks without proper padding or any other handing equipment found to be damaging to the coating shall not be permitted. (5) All skid used to support coated pipe shall be padded. (6) Walking on the pipe shall not be permitted.
7.4
Excavation (1) Excavation by machine shall be carrying out if the working space is within the safe limit against the existing facilities. (2) Manual excavation shall be performed if the working area is to close to the existing underground facilities. (3) Shuttering or sheet piling (if required) should be done initially to ensure proper protection and stability of the existing facilities before commencing the excavation work.
7.5
Wrapping (1) Surface Preparation Surface Preparation shall be according to Steel Structure Painting Council Specification SSPC-SP-3 (or equivalent), Power Tool Cleaning. SSPC-SP-2 (or equivalent), Hand Tool Cleaning may be used for narrow sections. Bare pipe shall be free from mud, mill scale, mill lacquer, wax coal tar, asphalt, oil, grease, or any other foreign materials. All prepared surface shall be coated on the same day it was cleaned. No pipe shall be allowed to flash rust before coating. (2) Liquid Adhesive (Primer) Application 5 / 19
Prior to any liquid Adhesive application, the pipe shall be cleaned to remove any wetness or other contamination. Liquid Adhesive shall be thoroughly agitated in its container before application to the pipe. Liquid adhesive shall be either brush or spray applied to the cleaned pipe surface in a uniform thin film at a minimum coverage of approximately 7.4 square meter per liter or Liquid Adhesive. Prime coat shall be dry to tacky at the time the anti-corrosion tape is applied.
(3) Tape Installation All irregular shaped items with voids and field welded butt joints shall be pre-coated with filler tape (mastic) such that smooth, rounded shapes are formed prior to application of anti-corrosion tape. The seam of the welded area of pipe from vendor shall be pre-coated with anti-corrosion-layer tape along its length. The anti-corrosion tape shall be applied directly onto the primed pipe surface approved by the tape manufacturer in compliance with the applicable standard. The anti-corrosion tape shall be spirally applied with minimum overlap of 55% of the tape width being used. The application tension on the tape shall be approximately 1% of tape width in width drawdown (approximately 5 to 10 lbs per inch width of tape). Hand application is permitted only for tape width no wider than 6 inches. A tight, smooth, wrinkle-free coating should be observed throughout the application.
The end of each new roll of tape shall overlap the end of the preceding roll by a minimum of 6 inches. This end lap splice shall be hand applied for a wrinkle free splice to maintain the continuity of the anti-corrosion tape. The spiral angle of the new roll should parallel the previous roll’s spiral angle.
The outer-layer tape shall be applied over the anti-corrosion tape using the same method used to apply the anti-corrosion tape. The seam for the outer-layer tape shall overlap the exposed seam of the anti-corrosion tape by a distance of half the tape width so that they do not coincide. The overlap width shall be 1”. The application tension and the minimum end lap of two rolls shall be the same as the anti-corrosion tape. The total thickness shall be kept in accordance with Wrapping Procedure for Underground Piping (6423MP342-00-91100 00).
Pipe size ≤ 50” : Manual, Turning roller or machine wrapping application is permitted. Pipe size > 50” : Turning roller or machine wrapping application.
(4) Inspection and Testing All coating shall be subject to 100% visual inspection and 100% inspection with an electrical holiday detector. The holiday detector shall be as per NACE RP-02-74 during the inspection of the anti-corrosion tape coating. Holiday detector shall not be permitted to remain stationary around coated pipeline with the operating voltage switched on. All defects shall be clearly marked.
(5) Repairs to Coating All the defects in coating should be fixed immediately after the detection.
In case of inner/outer tape damage/defects: 1.
Peel back and remove the outer-layer tape complete around from the damaged/defect area. 6 / 19
2.
Peel back and remove the anti-corrosion layers
with minimum 3 inch apart from the
damaged/defect edge 3.
The exposed area shall then be coated with liquid adhesive(primer).
4.
Apply the anti-corrosion tape in strips with minimum of 55% from the edges of the exposed area.
5.
Outer layer tape should then be wrapped over the anti-corrosion tape with wrap-around method.
6.
The repaired area shall be tested with a holiday detector after the repair is complete.
In case of outer layer tape damage/defects only: 1) Remove the outer layer tape complete around from the damage/defect area with minimum 6 inch apart from the damage/defect edge. 2) Holiday test shall be done over the anti-corrosion tape where the portion of the damaged/defect of the outer layer is detected to make sure it is not also damaged. 3) Wrap the outer layer tape with wrap-around method. 7.6
String out the pipes into trench (1) Prior pipe string out, civil work for trench shall be completed. (2) Before putting the pipes into the sand bags, the circumferential area of the pipe with the contact points to the sandbags shall be tested using brush type holiday detector. (3) Pipe joints will be laid individually in the trench on sand bags, suitable spaced to support the length of pipe being installed. (4) On long pipe lengths, sand bags will be spaced on five meter centers. (5) To avoid damage to coating and following accepted construction practices. (6) Pipe will be installed in the trenches using wide sling belts and / or hands. (7) Tolerance of pipe laying shall be as follows : The level of the pipe at any point along its length is to within ±15mm of the level stated on the drawings. The center line of the pipe at any point along its length is to be within ±50mm of the location stated on the drawings. (8) Pipe lowering into trench, pipe shall be inspected internally for dust / debris which, shall be cleaned (air blowing, brushing etc…)
7.7
Welding (1) Welding preparation, fit up, inspection and testing shall be carried out in accordance with Specification for Piping Fabrication by Each Service Class (6423MS231-00-00100 00). All surfaces to be welded shall be free from oxides, scale, oil or other foreign matter. Production joints shall be made using qualified welding procedures and welders. Visual inspection shall be done by welding inspector during and after welding. (2) The daily welding report shall be generated by construction team in accordance with Welding Control Procedure (6423DA060-00-00900 00).
7.8
NDE Required NDE shall be requested and carried out in accordance with method statement for NDE control. All NDE requests shall be transmitted to subcontractor by QA/QC manager. Contractor will transmit hard copies of NDE information to the owner. Matrix operator will input NDE date to the data base.
7.9
Repair of welding 7 / 19
Welding repair shall be carried out in accordance with method statement for Welding Control Procedure (6423DA060-00-00900 00). 7.10
Rubber lining (1) Inspection for steel substrate Size, appearance, welded parts and so on shall be checked and confirmed whether there are no defects, which may influence on lining work. If there are such defects, repair shall be performed. (2) Surface preparation Surface preparation shall be carried out by grinder on welding area, so that rust and scale on a steel surface are completely removed. In this process, welding areas shall be rechecked and if any defects, such as pinholes are found, repair shall be performed. (3) Bonding treatment After grinded, first primer shall be immediately applied. After dried, rubber cement shall be applied and dried sufficiently. (4) Application of rubber sheet Pre-cure rubber sheet (vulcanized rubber sheet : B-5S) shall be applied to steel substrate, so that no air bubbles are locked between rubber sheet and the surface of steel substrate. Please refer to “Rubber Lining Procedure” below.
Rubber Lining Procedure (Pipe Joint Welding Area) : Example (5) Inspection After lining application, following inspection shall be performed for whole rubber lined area. (a) Appearance inspection (b) Dimension inspection (c) Thickness inspection (d) Hardness inspection (e) Pinhole inspection (f) Adhesion inspection 7.11
Backfilling (1) Backfilling work shall be carried out in accordance with Procedure for Earth Work (to be prepared by Civil Department). (2) Before the pipes are subjected for backfill, holiday test using the ring type holiday detector shall be done onto the remaining pipe’s surfaces that is not yet holiday tested except for the branch & fittings which is to be tested using brush type holiday detector. (3) Pipe padding should go after pipe bedding by filling with suitable materials 300mm thick from top of pipe. (4) Subsequently after completing the pipe padding backfilling of suitable excavated earth material shall 8 / 19
be placed 300mm in layers and compacted in accordance with project specification requirements. 7.12
Hydro test line (for WF line) (1) Epoxy coating shall be done at site. (2) Pipe surface shall be prepared by mechanical power tool cleaning. (3) Fit up and welding shall be carried out as per WPS. (4) Hydro test shall be carried out after completion of all NDE (if required) and spool clearance activities. (5) After completion of hydro test and its acceptance by owner, the epoxy coating of welded joints shall be done. (6) If any repair, modification occurs in the site during installation to the fabricated spool then the same spool shall be recoated and re-hydro tested in the site with the above same procedures. (7) The epoxy coating application shall be done in accordance with manufacturer’s instructions. Coating inspection shall be made and recorded on attachment #1.
7.13
Service test line (for WCM, WCR, WCS, WW, WSM, WSR & WSS line) (1) Before fit up and welding coating shall be removed from pipe in the range of 10cm over and the cut back area surface should be cleaned properly. (2) Pipe surface shall be prepared by mechanical power tool cleaning. (3) Fit up and welding shall be carried out as per approved WPS. (4) After completion of all NDE activities(if required), spool clearance shall be carried out epoxy and rubber coating. (5) Epoxy coating shall be done to all fabricated spools joints in the work shop. (6) The epoxy coating application shall be done in accordance with manufacturer’s instructions. (7) Field welding joints shall be coated at site as per manufacturer’s instructions. Coating inspection shall be made and recorded on attachment #1. (8) After installation of all spools at site and mechanical clearance of above lines by owner, the service test shall be done.
7.14
Holiday Test The following voltages shall be impressed in electrical inspection, based upon the calculation instructed in the Section 3 of NACE Standard RP-02-74. 1.
Summary of recommendation Minimum 10,000V shall be impressed to all sizes of pipe surface wrapped with POLYKEN tapes.
2. Calculation 1) Straight pipe (50” or below) Total tape thickness: 20x2+20 = 60mil → 9,682V 9,682V
→ +20%
9,682V
→ -20%
=11,618V =7,746V
2) Straight pipe (50” or above) Total tape thickness: 20x2+20x2 = 80mil → 11,180V 11,180V
→ +20%
11,180V
→ -20%
=13,416V =8,944V
3) Fitting, flange (50” or below) Total tape thickness: 35x2+15 = 85mil → 11,524V 11,524V
→ +20%
11,524V
→ -20%
=13,829V =9,219V 9 / 19
4) Fitting, flange (50” or above) Total tape thickness: 35x2+15x2 = 100mil → 12500V 12,500V
→ +20%
12,500V
→ -20%
=15,000V =10,000V
Holiday detection checks shall be carried out and recorded on attachment #2. 7.15
Drawings As-built drawings must be drawn before leak test (As-built drawing shall be checked during punch check).
8.0
TESTING
8.1
Preparation for testing (1) A punch list(will be attached in the Hydrostatic test procedure) shall be prepared by construction team to verify that the piping system are installed to the extent necessary for testing.
(2) A test punch list shall be made through line check and punch list will be to verify that all piping components requiring post test actions are documented. (3) After all punch items are completed satisfactorily, both contractor and owner shall sign all necessary documents. (4) Pipe lines (FW line) shall be thoroughly blown out by air compressor. (5) Lines shall be free from all debris such as trash, welding rods, rags, tools, etc. 8.2
Test pack preparation and control (1) Preparation and control of test package shall be done in accordance with Hydrostatic Test Procedure (6423DP420-00-01300 00) (2) All test package shall be approved by owner prior to the start of pressure testing.
8.3
Main pressure testing (1) Every part that has to be tested should be vented until free of air. (2) Be aware that there is always a possibility of the presence of entrapped air in a system. (3) A hydrostatic pressure has to be built up gradually and, in doing so, no fast closing valves and booster pumps should be used.
8.4
All final inspection and documentation after pressure testing shall be done in accordance with method statement for pressure test of piping.
8.5
Service test line (Seawater, CCW and etc) shall be back filled after lapping & testing.
8.6
Records of pressure test and leak test shall include the following items. (1) Date of test (2) Identification of piping tested(line number and service) (3) Test fluid (4) Test pressure (5) Certification by examiner (6) Design pressure (7) Photograph of pressure gauges and indication board showing the test sequence (time and pressure, etc.)
8.7
Repairing of defects (1) When the defective material found during construction, a repairing method and extent shall be prepared. 10 / 19
(2) Imperfections in welds exceeding specified limitations shall be considered as defects, removed and repaired in accordance with the followings. (a) Defects shall be removed completely under the careful examination. (b) Repair welding shall be also done in accordance with welding procedure specification(WPS) (3) Repaired welds shall be examined and inspected in accordance with Specification for Piping Fabrication by Each Service Class(6423MS231-00-00100 00) 8.8
Inspection and testing (1) All the work shall be inspected or examined as per approved ITP and inspection records shall be prepared as per ITP (6423DA424-00-00200 00). (2) Before starting the job the drawings shall be checked for the latest revision. (3) All piping material & welding consumables shall be checked for conformity to specifications, construction drawings and approved WPS.
(4) All measuring instruments shall be checked for valid calibration. (5) Area to be welded shall be checked for the cleanliness, free of paint, grease, dirt etc. (6) Each piping installation, including it’s components and workmanship, shall be examined to ensure compliance with applicable examination requirement. 9.0
SAFETY
9.1
The unsafe work practices and conditions in the work place shall be immediately identified and eliminated through the use of analytical techniques such as risk assessment.
9.2
Build a team safety mentality where each worker contributes to the effort and each superintendent is fully aware of the capabilities and limitations of their team.
9.3
All tools and equipments shall be used in accordance with the manufacturer’s recommendations, required tool guards in place, and maintained in good working order.
9.4
Where appropriate shall require employees to wear eye, ear, head and face, foot protection outfit.
9.5
Special care shall be taken for the erection of scaffolding and ladders at height.
10.0
ATTACHEMENT 1)
Attachment #1 : 6423DP420-002-01 Inspection and Testing Coat of Joint & Repairs (Inner-layer tape application)
2)
Attachment #2 : 6423DP420-002-02 Inspection and Testing Coat of Joint & Repairs (Outer-layer tape application)
3)
Attachment #3 : 6423DP420-002-03 Holiday Detector Test Report (HTR)
4)
Attachment #4 : 6423DP420-002-04 Rubber Lining Inspection Records
5)
Attachment #5 : 6423DA060-009-01 Daily Welding and Inspection Record (DWIR)
6)
Attachment #6 :
Job Safety Analysis (JSA)
Attachment #1
Inspection and Testing Coat of Joint & Repair Report ( Inner-layer tape application) 11 / 19
Al geria Oman Fertil izer Report No. :
Date :
PCWBS
Sheet No.
Drawing No.
Component Descrip tion
Rev. No.
Pipe No.
Spool No.
Construct ion
QC
Weld No.
Remarks
Owner
Preparation of substrate Time duration between surface preparation and coating of primer Application of filler tape (mastic) (for irregular shape only) Application of primer Application of tape wrap Wrap overlap
Prepared by : (Construction)
Name
Signature
Date
Inspected by: (QC Inspector)
Name
Signature
Date
Inspected by: (Owner)
Name
Signature
Date
6423DP420-002-01(3)
Attachment #2
Inspection and Testing Coat of Joint & Repair Report (Outer-layer tape application) 12 / 19
Al geria Oman Fertil izer Report No. :
PCWBS
Date :
Drawing No.
Sheet No.
Component Descrip tion
Rev. No.
Pipe No.
Spool No.
Weld No.
Construct ion
Remarks
QC
Preparation of substrate Time duration between surface preparation and coating of primer Application of filler tape (mastic) (for irregular shape only) Application of primer Application of tape wrap Wrap overlap
Prepared by : (Construction)
Name
Signature
Date
Inspected by (QC Inspector)
Name
Signature
Date
6423DP420-002-02(3)
Attachment #3
Holiday Detector Test Report (HTR) Al geria Oman Fert il izer Projec t 13 / 19
Report No. :
Date :
Drawing Number
:
Line Number
:
Test Pack Number
:
Type of coating
:
Test Equipment used
:
Test setting value
:
Test carried out by
:
Repairs required
:
Repairs complete
:
The testing of the above coating has been satisfactorily completed in accordance with the drawings and specifications.
Prepared by : (Construct ion)
Name
Signature
Date
Inspected by : (QC Inspec tor )
Name
Signat ure
Date
Inspected by : (Owner)
Name
Signat ure
Date
All underground pipe coating shall be checked for pinholes and holidays by contractor. Testing shall be performed using a contractor approved holiday detector Piping is to be backfilled immediately after being checked for holidays. This form shall be retained with the appropriate piping field test report (underground piping).
6423DP420-002-03(3)
14 / 19
a
c
Date
OHJI RUB ER
OWNER
6423DP4 0-002-04(3)
15 / 19
Attachment #5
Daily Welding and Inspection Report (DWIR) Report No. :
Date :
Algeria Oman Fert ilizer Proj ect
Page :
Area
Sys tem
Isom etri c Draw ing No.
Sheet No.
Rev. No.
Spool No.
Weld No.
Material
Piping Class
Prepared by :
Inspected by :
Name :
Name :
Date :
Welder No. Size
Sch.
WPS No. Root
Date : (Construction)
(QC Inspector)
6423DA060-009-01(0) 16 / 19
Cap
PWHT Req’d
NDE
Inspected Result Remarks
Req’d
%
Fit-up / Root
Final
Attachment #6
JOB SAFETY ANAL YSIS Date of Issue
JSA No.
Work Group Preparing JSA
Piping
Prepared by
Job Description
Underground Piping
Approved by
Sequence of Task
Potential Hazards
Recommendations / Contro l Measures ► All
Mark out exact location of proposed excavation site, plus erection of barricades and safety signs.
Minor works only, no major hazards associated with this task.
works to be fully supervised at all times. ►If the supervisor has to leave the area, for any reason, then the job will be temporarily suspended until such time he returns to site. ►The excavation areas are to be identified on attached plot plan, highlighting the areas which can be excavated using machinery and the critical areas which must only be excavated by hand dig only.
Obtain excavation certificate including a hot work permit
For information only.
►Hot
work permit to be issued by AOFP safety department.
►Physical
Contact with moving machinery. Carry out excavation work using 360° mechanical excavator and hand digging operations as per attached plan.
Heat source from diesel powered equipment is a potential for explosion in the event of gas escape from live plant Earth sliding, cave-ins and collapse.
Pipe laying in the trench and fit-up
Tear of slings / belts Fall of materials
Equipment Failure Bursting, Leakage of test medium Pressure testing Damage to ear drum Heat stress and dehydration
barricades shall be erected to prevent access by unauthorized personnel. ►Warning signs to be erected also to advise personnel of ongoing excavation work. ►Take all necessary precaution as required in confined space procedure when working in excavation or trench 1.5m or above. ► All excavated area should be barricaded by safety barrier and alerted by warning light at night. ►Proper slope should be maintained in all trench excavations (45deg slope is required or as per actual soil condition). ►Ladders, steps, ramps or other suitable means of access and aggress shall be provided as per procedure. ►Excavator operator and other related personals should be properly trained. ► All rigging area should be properly barricaded by suitable means. ► All riggers should be trained. ►Know the weight and C.G of the material to be lifted and use proper tools and equipments. ► All rigging tools and tackles should be checked before using. ►No one should stand beneath the load. ►Do not allow unauthorized p ersons in rigging premises. ►Ensure well maintained and periodic inspection of equipment & tools’ ►Only trained personnel is required to handle the pressure testing equipment / tools. ►Ensure equipment is pre-mobbed and certified for use ►Prior to testing, ensure proper check on hose connections, blind points, bolting and on-line piping components and certified for test ►Ensure barriers / warning signs are in place around test areas and specify distance. ►Ear muffs must be worn at test area all time ►Ensure weather condition is conducive for work. ►Ensure availability of potable drinking water at work site and short break for workers.
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Sequence of Task
Potential Hazards
Recommendations / Contro l Measures ►Wearing
Welding and Cutting works
Fire, explosion, damage to lives and properties
Injuries by grinding machine Grinding work Fire burn and eye injuries
NDE
Exposure to X-ray
Housekeeping and area cleaning
Slip, Trip, Fall
of PPE shall be mandatory in all aspects of welding and cutting works. ►This shall include face shield and welding goggles. ►Hot work permit shall be secured prior to start of any welding and cutting works. ►Fire extinguishers shall be available near the work site at an y time. ►Proper use of fire extinguishers shall be disseminated to all personnel involve in the job. ► All welding, grinding and cutting equipment shall be inspected prior to start. ►This shall also include inspection of electrical sources and cables. ►Damage cables shall be immediately replaced. ►Only properly trained personnel shall be permitted to do welding and cutting works. ►Work area shall be properly barricaded. STAART required prior to start of task. ► Always check areas around and below prior to commencing welding or cutting operations. ► Ali combustible materials under or near welding or burning operations must be moved to a safe distance away or covered with a fire retardant material. ►Welding leads and gas hoses shall not be placed where they will present tripping hazards. ►Proper spark containment method such as fire blanket shall be used when doing welding and cutting. ►The welding machine shall be properly grounded and as close to the work as possible. ►Never leave a welding rod in the electric holder when not in use. ►Never use a torch as hammer to remove slag or scale. Use the proper tool. ►Never use lighters, matches or cigarettes to light a torch. Use only approved spark lighter. ►Welding machine shall be turned off at the end of the shift. ►Fire Blanket shall be used for welding habitat. ► All galvanized pipe shall be cleaned in areas to be welded prior to welding. ►Only skilled worker can carry out the job. ► Avoid water contact and keep grinding machine always dry. ►Continuous training and remained hazard of grinding ►Damage of electric wire to be checked continuously. ►Grinding machine and grinding wheel should be checked before use ►Wear adequate PPE ►Working area should protected by installing warning tape and x-ray hazard symbol. ►Only skilled worker can carry out the job ►Wear radioactive absorption batch when working to neutralized radioactive emission. ►Proper housekeeping to be maintained at all times ►Material should never obstruct walkways / staircase / ladders and access to emergency equipments. ► Area to be cleaned and barricades and warning tapes to be removed
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Sequence of Task
Potential Hazards
Recommendations / Contro l Measures ►Hose
Handling of pressurize tanks (Oxygen, Acetylene, Argon)
Fire explosion damage lives and properties
All risks to be happened during working General Expected risks during night shift
and fittings of gas cylinders shall be checked for leak by soapy water. ►Oxygen and fuel gas cylinders in storage shall be separated by a minimum of 6 meters. ►Gas cylinders shall be handled carefully. Avoid bumping or dropping them. ► Always secure in an upright position and properly supported. ►Valve protection caps shall be on cylinders when not in use and when being transported. ►Be sure protective caps are adequately screwed down. ►Use a holding cage when lifting cylinders with a crane. ►Choking around cylinder shall not be allowed. ►Smoking is not allowed on the project site except in properly designated areas. ►Discard butts approved containers, not on the floor/ground or in trash cans. ►Every day before start of work tool box meeting to be between supervisor and worker. ►Supervisor should give information regarding hazards indulged to daily work activities. ► Always keep clean working area. ►Close supervision shall be done during late night hours. ►Supervisor should give information regarding hazards indulged to daily night work activities. ► Adequate drinking water facilities should be provided. ►Every night before start of work tool box meeting to be between supervisor and worker
Comments 1. JSA should be used in conducting Tool Box Talks(TBT) with all concerned workers 2. Provide that all the necessary PPE are used, relevant PTW requirements are followed and all the control measures stated above are adhered to, the activity can proceed. PPE & Safety Equipment Required to Perform Task (Tick as Appropriate) Safety Helmet
Face Shield
Goggle
Barricade
Harness
Hand Gloves
Safety Shoes
Ear Plug
Coverall
Safety Glasses
Work Permit
Fire Extinguisher
Dust Mask
Others
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