Piping Installation Works on Pipe Racks

Sadara Project

‫ﻣﺷﺭﻭﻉ ﺻﺩﺍﺭﺓ‬

Polyethylene Envelope Transmittal Sadara Unit(s)

455

460

470

Sadara Transmittal Sadara-L&T-T-1233 Issue Date 29 June 2013

Date Reply Needed N/A

From Majid Al Majid

To Mr. P. Sankaranarayanan Company L&T ATCO

SADARA Response to L&T-SADARA-T-882-13, Method Statement of Piping

Subject Installation Works on Pipe Racks (Rev.1) In respect of the above referenced transmittal;

Accepted with comments. SADARA request L&T to resubmit the Method Statement after incorporating the comments in the attached file for our records.

Subject

File Name

Date

Rev

Method Statement of Piping Installation Works on Pipe Racks (Rev.1)

SA-RTIP-PEAAA-LTAT-50-5001commented

N/A

N/A

Page: 1 of 1 Form Version: 23-Apr-2012

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS

PROJECT:

SADARA POLYETHYELENE LSPB -1

CONTRACT NO:

10001 / 6600028371

CLIENT:

SADARA

CONTRACTOR:

LARSEN & TOUBRO ATCO SAUDI

METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS

(SA-RTIP-PEAAA-LTAT-50-5001)

1

28-May-13

Issued for Review and Approval

KRK

DKU

CTK/PSN

0

21-Apr-13

Issued for Review & Comments

KRK

DKU

CTK/PSN

Prepared

Reviewed

Approved

Approved

L&T

L&T

L&T

SADARA

Rev

Date

Description

Date

Doc. No

Rev. No

Page

28-May-13

SA-RTIP-PEAAA-LTAT-50-5001

1

Page 1 of 12


REVISION RECORD SHEET

Rev. No.

Date

Reason for the revision

Revision details/ Locations

0

21-Apr-13


Superseded

28-May-13


1

All Sections has been modified

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 2 of 12


CONTENTS

1.

PURPOSE……………………………………………………………………............................... 4

2.

SCOPE……………………………………………………………………………………………… 4

3.

REFERENCES………………………………………………………………............................... 4

4.

RESPONSIBILITIES………………………………………………………………………………. 4

5.

DEFINITIONS………………………………………………………………................................. 6

6.

HSE REQUIREMENT……………………………………………………………………………....6

7.

EQUIPMENT AND TOOLS……………………………………………………………………….. 7

8.

MANPOWER……………………………………………………………………………………......7

9.

GENERAL PREPARATORY WORKS……………………………………………………………8

10.

WORK EXECUTION PROCEDURE………………………………………............................... 8

11.

ATTACHMENTS…………………………………………………………………………………...12

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 3 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS 1.

PURPOSE This method statement will serve as a guide line to carry out and complete the pipe installation works at pipe racks for Polyethylene SADARA Project.

2.

SCOPE This procedure will cover random pipes and pipe spools installation at pipe rack 640,565,500,440,305,350,400,235,200,220,150,700,750,775,825,850,905 for SADARA POLYETHYLENE LSPB PROJECT and to ensure that the entire recommendations are read and understood well prior to Start of erection works at site.

3.

REFERENCES x x x x x x x x x x

SADARA HSE Standard – A554-K-PRG-QM-GEN-PLN-004 L&T ATCO HSE Standard – SA-RTIP-PEAAA-LTAT-50-9001 Construction work detail procedure (Extra Length Management)- SA-RTIP-PEAAALTAT-50-3047 Construction work detail procedure (Welding Brazing) - SA-RTIP-PEAAA-LTAT-503004 Construction work detail procedure (spools cleaning) - SA-RTIP-PEAAA-LTAT-500057 Fabrication and Erection of On shore ITP for AG Piping - SA-RTIP-PEAAA-LTAT-31-5001 ASME B31.3 - Process piping Shop Drawings & Erection Drawings General welding requirements – RT85-6500-01

4.

RESPONSIBILITIES

4.1

CONSTRUCTION MANAGER x x x x

Schedule the project in logical steps and time required to meet deadlines. Determine labor requirements and dispatch workers to construction sites Inspect and review projects to monitor compliance with building and safety norms and other regulations Interpret and explain plans to staff and clients representing the L&T and SADARA

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 4 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x

4.2

ENGINEERING DEPARTMENT x

4.3

x x x

Piping Engineer is required to ensure that all the pipe installation works are carried out as per project specifications, approved drawings & HSE requirements. Conduct daily tool box talks, before the commencement of the scheduled work explain the hazards associated with the work and the mitigation measures. Strictly follow the project schedule and release of work front to other disciplines like E&I Responsible for taking and closure of required work permits from HSE.

QA/QC MANAGER x

x

x x 4.5

Provide Technical Support to construction site execution section by providing drawings, procedures, material specifications, standard and technical specifications.

THE PIPING ENGINEER x

4.4

Co-ordinate with all internal department and obtain necessary permit and licenses for smooth installation of structural activities

Assist and coordinate with the construction manager and all personnel assigned to the project in establishing an overall Project Quality Management Plan based on approved standards. Responsible for ensuring that Project Quality Management policy, plans and procedures are implemented effectively and are suitable for the purposes and use for which they are intended. Coordinate and communicate with Client on Project Quality implementation Coordination with QC-Inspectors(Piping and Welding)

THE PIPING QC INSPECTOR x

x

QC Inspector will ensure that all the line clearance activities that are required to be inspected have been inspected and approved as per the project requirements and QP. Accompany the company representative while carrying out inspections and release of hold points.

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 5 of 12


4.6

QC WELDING INSPECTOR x x x

4.7

x

x x x x

HSE Supervisor will orient all erection people and provide sticker for competent people for identification & authorize to work at height. HSE Supervisor will ensure that the steel structural erection work is covered with valid elevated work permits including cold and hot work permit wherever applicable, and all permit & safety requirements are strictly followed. HSE Supervisor will ensure that daily tool box talks are carried out before the commencement of work, at all work locations, as per HSE Plan. HSE Supervisor will ensure that work locations are safe to work in & with appropriate safety signs and Barriers. Any unsafe act or conditions will be immediately stopped and reported to the HSE Manager and Construction Supervisor HSE Supervisor will Review and the implementation of Job Safety Analysis (JSA) and Method Statement.

DEFINITIONS x x x x x x

6.

Ensures Daily weld visual inspections are done, and monitor welder’s performance. Ensures NDT offer are done as per specification requirements. Ensures test packages NDT are cleared.

THE HSE SUPERVISOR x

5.

Qc Inspector will ensure that all fit-up’s inspection done and are according to Isometric and all supports are installed.

Project - Sadara Polyethylene LSPB -1 Company - Sadara Chemical Company Contractor – L & T ATCO Construction Supervisor - Contractor’s Supervisor QC Inspector - Contractor’s Quality Control Inspector (Piping) HSE - Health, Safety & Environment

HSE REQUIREMENT x x

Safety goggles Safety face shields

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 6 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x x x x x x

Safety shoes Dust masks Safety helmet Full body harness Hand Gloves (Leather) Reflecting Jacket Ear Plugs

Client’s safety instruction & Project Safety regulations shall be strictly followed. 7.

EQUIPMENT AND TOOLS x x x x x x x x x x

8.

Mobile/ Crawler cranes Welding Machines Pulley Pulling cable Chain block 2T,3T, 5T. Man lift Lifting Accessories Trolley assembly Nylon/ Teflon pipe rollers Hand tools & fixtures as required

MANPOWER x x x x x x x x x x x x

Piping superintendent Piping supervisor Rigger Foreman Piping foreman Riggers Pipe fitters Permit receiver Fire watcher Scaffolders Crane operators Welders Mechanic technicians

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 7 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x 9.

Man lift operators Safety Supervisors

GENERAL PREPARATORY WORKS x

x

x x x x x x x

Pipe rack sections (640 ,565 ,500 ,440 ,305 ,350 ,400 ,235 ,200 ,220 ,150 ,700 ,750 ,775 ,825 ,850 ,905) should first be turned-over for pipe installation. Secure work transfer sheet from structural group. Scaffolding and access are ready for use. Major pipe rack will be provided with mat type scaffolds at elevations where most work will be done. Others will be provided with scaffold individually at work locations. Walkway outside the pipe rack shall be provided along with scaffolds. Manpower, equipment, tools and other logistics are ready and prepared for installation. Lifeline to be provided for full length of working platform. The delivered spools, random length and other materials for erection shall be verified and checked as follow Verify piping spools are as per required ISO drawing and check for any damages. All spools shall be painted prior to erection. All spools shall be internally cleaned prior to erection.

10.

WORK EXECUTION PROCEDURE

10.1

PIPING INSTALLATION USING NYLON ROLLERS ON PIPE RACKS x x x

x x

Pipe will be loaded using cranes into the extended scaffoldings at designated/ end of pipe rack.(Attached typical lift plan for PipeRack-640) Loading of spools on scaffolds is not allowed. Install extended scaffolding at designated loading area at first level. Once the erection of pipes at this level was completed, additional extended scaffold will be installed for the next elevation. Additional hanging scaffold with access walkway will be installed for fit-up and full welding of pipe joints and supports not accessible by the hanging mat scaffold. Install, align and fix the roller assemblies at rack beams. Nylon rollers will be employed primarily to move random lengths along the racks. Install required pulleys to complete with Chain block. The pulley and cable will be used to pull the pipes from loading end, along the rollers and to its final position

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 8 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x x

x

x x

x

x x

x x x x x x x x

Cranes will pick-up the pipes either directly from trailers or from temporary lay down nearby the pipe rack. Pipes will be lifted by cranes using correct nylon slings and will be rigged to position at rollers in working platform. Once the pipe is initially positioned at rollers (on two spans), hook the pipe to a Chain block. Pipe should be tied in such a way so as not to damage bevel at pipe end. When the pipe is being pulled, a watcher will check the travel of pipe such that it will safely and correctly ride the succeeding rollers. A signaling system for safe execution and control of pulling will be employed. Once the length of pipes reaches its destination, it will be removed from rollers using chain blocks. Pipe spools such as expansion loops, branch take offs and others will be placed directly in position using cranes or chain blocks where required. Fit up and welding of spooled pieces will be done in place utilizing the mat type scaffold or localized scaffold. For pipeline without attachments, a double ended welding execution will be adopted i.e. the first two random length rigged to positioned will be fitted up and full welded together. The succeeding lengths will be installed in the same manner. The double ended lengths are then welded together until the entire run is completed. Random Pipes will also be placed from selected intermediate columns also and will be pulled to their places and Aligned. During the installation process, if the gap between Grids is less, for erection feasibility chain block pulley will be used for the balancing of the spool in one end and the other end belt will used. At interconnecting pipe racks the same roller system will be utilized where new steel works is installed and when there are no obstructions. Other areas will utilize cranes or manual rigging method (sticking-out method) to directly install the spools and straight lengths into positions. Prior to full welding works, check the fitted up spool/ pipe joint for the following: The surface is clean and free from paint, oil, dirt, scale, oxides and other foreign materials. The bevel angle, weld joint, root opening and alignment as per Isometric drawing approved WPS. Flange face is free from damage and scratches. Weld seam is staggered so that longitudinal joint and also joints shall not touch the bearing surfaces (structural steel) Re-in forcing pad is provided with 6mm vent hole as per specification.

Date

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Rev. No

Page

28-May-13


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Page 9 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x x x x x

x x x x x 10.2

Socket welding gap is in accordance with specification. Welding consumables should be in accordance with approved WPS. All fit-ups shall be inspected by contractor or sub-contractor Piping inspector. Submit request for inspection (RFI) of the fitted spool/ piping. When fit-up is accepted, proceed full welding. Welding process shall be as per approved WPS. Only qualified welders can do welding works. Documents such as welding procedures and specification (WPS) and welders performance qualification record (WPQR) should be made available at site. All welding electrodes shall be backed and in site shall be stored in portable oven and shall have continuous power supply. During welding process, in-process inspection will be done by welding inspector and will be verifying the following items Welding consumables are in accordance with the approved WPS. Required pre-heat/ inter-pass temperature requirements are done as per approved WPS. Purging requirement, as applicable, is being maintained as per approved WPS.

AFTER WELDING WAS COMPLETED, VISUAL INSPECTION WILL BE DONE CHECKING THE FOLLOWING ITEMS, AS APPLICABLE x x x x x x x x x x x

Inside surface of orifice flanges welded joints is ground or machined smooth. Threaded joints must be checked for fit and roundness as per spec. no. Weld surface reinforcement in accordance with ASME B31.3 table 341.3.2 Dimensions of fillet weld in-accordance with ASME B31.3 fig.328.5.2B and 328.5.4D Root pass in accordance approved WPS. Arc strikes in areas not covered by the finished weld and grounds. Temporary materials used are already removed as per spec. Cleanliness of pipe shall be maintained as per spec. no. The weld spatter, slag, flux and other foreign materials are removed. Welders ID, Weld no., and line no & WPS. Shall be marked with permanent marker on the pipe next to the weld. Completed weld shall be subjected to require NDE as per line Class. PMI as required shall be conducted. And marking shall be done as per PMI procedure PWHT.

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 10 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x x x

x

x x x x x

10.3

Hardness test as required on some joints shall also be conducted as required by line class. As per approved weld repair procedure. Rejected weld will be repaired and will under-go visual inspection as per above mentioned and required NDE as per above For threaded line installation, refer specification, method statement of Deluge piping system specification no only gasket installation and inspection. Bolt Tightening shall be done by trained persons, in sequence to produce even compression and uniform bolt loads Torque wrench used shall be calibrated valves shall be set daily When using stud tensioner, the manufacturer’s procedure must be followed. The bolt used shall be checked for conformance with the ISO drawing. For pipelines with shoes, saddle, others, this attachment will be Tac weld to the pipe after being rigged to position. Shoes and saddle shall be positioned such that it will align and rest properly at beams or supports. Prior to full welding the alignment, support location and orientation must be checked and verified with latest approved drawings. The supports used should be in accordance with the latest approved IFC drawings. Pipe Supports to be Over Head welded by only trained welders and cleaning will by means mechanical cleaning. For supports directly weld to Alloy pipes, PMI (If Required) shall also be conducted Pipe stoppers and guides shall be full welded and painted. Prior to closure of piping section, full compliance with internal cleanliness inspection and documentation shall be ensured in. Piping installation at pipe rack areas 640,565,500,700,445,305,440,235,350,400,200,150,905,850,etc., will be done as applicable.

SAFETY PRECAUTIONS x x x x x

Obtain the approval of the work permit from the concerned PERMIT department before starting any work. Fire watcher with fire extinguisher shall be at work area whenever there is hot work. All electrical tools shall be checked and color-coded. Continuous monitoring and inspection shall be implemented to detect and correct unsafe practices while performing the work activities. Provide warning signs and sufficient barricade on working area and only assigned personnel will be allowed in the area.

Date

Doc. No

Rev. No

Page

28-May-13


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Page 11 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x

x x 11.

Welding location shall be enclosed with wind barrier and provided with nonasbestos fire blanket to prevent spread of any welding sparks. Safety officer shall monitor the work activities to help and to protect all assigned workers against exposure to safety hazards. He shall ensure that personnel protection equipment (PPE’S) are supplied and used and comply with L & T/SADARA applicable general instruction and standards. Safety harness with double lanyards shall be used all the time when working at elevated temporary platforms. Man-lift users shall be trained and certified to operate.

ATTACHMENTS x x

JSA for AG Piping Installation works Lifting plan of AG Piping

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 12 of 12

Transmittal Sadara Unit (s)

X

X

455

X

460

470

L&T Transmittal L&T-Sadara-T-882/13 Issue Date 29-May-13

Date Reply Needed 30-May-13 To Majid Al Majid

From P.Sankaranarayanan

Company Sadara C.T Kuriakose D.K Upadhay cc M.K Sankar

John Hufnagel Julian Archer cc Mark Williams Alshobber Khalid

Subject Method Statement of Piping Installation Works on Pipe Racks (Revision 1)

The Following

Are Transmitted X

This is

Drawings

Specification

Schedule

Data Sheets

Calculation

Material Requisition

TBE

Vendor Document

MOM

Review

Information

Quatation

Construction

Revision

Final

Acceptance/Approval

X

Record X

Original Drawings / File Name

Size

Rev. No.

No. of Copies

Description


A4

1

1

Method Statement of Piping Installation Works on Pipe Racks

*** Nothing Follows ***

Receipt Not Required Receipt Required (Please Acknowlegde the Receipt of the Duplicate and Return) The Above Documents Received By: Signature:

Name:

Date:


PROJECT:

SADARA POLYETHYELENE LSPB -1

CONTRACT NO:

10001 / 6600028371

CLIENT:

SADARA

CONTRACTOR:

LARSEN & TOUBRO ATCO SAUDI

METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS

(SA-RTIP-PEAAA-LTAT-50-5001)

1

28-May-13


KRK

DKU

CTK/PSN

0

21-Apr-13

Issued for Review & Comments

KRK

DKU

CTK/PSN

Prepared

Reviewed

Approved

Approved

L&T

L&T

L&T

SADARA

Rev

Date

Description

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 1 of 12


REVISION RECORD SHEET

Rev. No.

Date

Reason for the revision

Revision details/ Locations

0

21-Apr-13


Superseded

28-May-13


1

All Sections has been modified

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 2 of 12


CONTENTS

1.

PURPOSE……………………………………………………………………............................... 4

2.

SCOPE……………………………………………………………………………………………… 4

3.

REFERENCES………………………………………………………………............................... 4

4.

RESPONSIBILITIES………………………………………………………………………………. 4

5.

DEFINITIONS………………………………………………………………................................. 6

6.

HSE REQUIREMENT……………………………………………………………………………....6

7.

EQUIPMENT AND TOOLS……………………………………………………………………….. 7

8.

MANPOWER……………………………………………………………………………………......7

9.

GENERAL PREPARATORY WORKS……………………………………………………………8

10.

WORK EXECUTION PROCEDURE………………………………………............................... 8

11.

ATTACHMENTS…………………………………………………………………………………...12

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 3 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS 1.

PURPOSE This method statement will serve as a guide line to carry out and complete the pipe installation works at pipe racks for Polyethylene SADARA Project.

2.

SCOPE This procedure will cover random pipes and pipe spools installation at pipe rack 640,565,500,440,305,350,400,235,200,220,150,700,750,775,825,850,905 for SADARA POLYETHYLENE LSPB PROJECT and to ensure that the entire recommendations are read and understood well prior to Start of erection works at site.

3.

REFERENCES x x x x x x x x x x

SADARA HSE Standard – A554-K-PRG-QM-GEN-PLN-004 L&T ATCO HSE Standard – SA-RTIP-PEAAA-LTAT-50-9001 Construction work detail procedure (Extra Length Management)- SA-RTIP-PEAAALTAT-50-3047 Construction work detail procedure (Welding Brazing) - SA-RTIP-PEAAA-LTAT-503004 Construction work detail procedure (spools cleaning) - SA-RTIP-PEAAA-LTAT-500057 Fabrication and Erection of On shore ITP for AG Piping - SA-RTIP-PEAAA-LTAT-31-5001 ASME B31.3 - Process piping Shop Drawings & Erection Drawings General welding requirements – RT85-6500-01

4.

RESPONSIBILITIES

4.1

CONSTRUCTION MANAGER x x x x

Schedule the project in logical steps and time required to meet deadlines. Determine labor requirements and dispatch workers to construction sites Inspect and review projects to monitor compliance with building and safety norms and other regulations Interpret and explain plans to staff and clients representing the L&T and SADARA

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 4 of 12


4.2

ENGINEERING DEPARTMENT x

4.3

x x x

Piping Engineer is required to ensure that all the pipe installation works are carried out as per project specifications, approved drawings & HSE requirements. Conduct daily tool box talks, before the commencement of the scheduled work explain the hazards associated with the work and the mitigation measures. Strictly follow the project schedule and release of work front to other disciplines like E&I Responsible for taking and closure of required work permits from HSE.

QA/QC MANAGER x

x

x x 4.5

Provide Technical Support to construction site execution section by providing drawings, procedures, material specifications, standard and technical specifications.

THE PIPING ENGINEER x

4.4

Co-ordinate with all internal department and obtain necessary permit and licenses for smooth installation of structural activities

Assist and coordinate with the construction manager and all personnel assigned to the project in establishing an overall Project Quality Management Plan based on approved standards. Responsible for ensuring that Project Quality Management policy, plans and procedures are implemented effectively and are suitable for the purposes and use for which they are intended. Coordinate and communicate with Client on Project Quality implementation Coordination with QC-Inspectors(Piping and Welding)

THE PIPING QC INSPECTOR x

x

QC Inspector will ensure that all the line clearance activities that are required to be inspected have been inspected and approved as per the project requirements and QP. Accompany the company representative while carrying out inspections and release of hold points.

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 5 of 12


4.6

QC WELDING INSPECTOR x x x

4.7

x

x x x x

HSE Supervisor will orient all erection people and provide sticker for competent people for identification & authorize to work at height. HSE Supervisor will ensure that the steel structural erection work is covered with valid elevated work permits including cold and hot work permit wherever applicable, and all permit & safety requirements are strictly followed. HSE Supervisor will ensure that daily tool box talks are carried out before the commencement of work, at all work locations, as per HSE Plan. HSE Supervisor will ensure that work locations are safe to work in & with appropriate safety signs and Barriers. Any unsafe act or conditions will be immediately stopped and reported to the HSE Manager and Construction Supervisor HSE Supervisor will Review and the implementation of Job Safety Analysis (JSA) and Method Statement.

DEFINITIONS x x x x x x

6.

Ensures Daily weld visual inspections are done, and monitor welder’s performance. Ensures NDT offer are done as per specification requirements. Ensures test packages NDT are cleared.

THE HSE SUPERVISOR x

5.

Qc Inspector will ensure that all fit-up’s inspection done and are according to Isometric and all supports are installed.

Project - Sadara Polyethylene LSPB -1 Company - Sadara Chemical Company Contractor – L & T ATCO Construction Supervisor - Contractor’s Supervisor QC Inspector - Contractor’s Quality Control Inspector (Piping) HSE - Health, Safety & Environment

HSE REQUIREMENT x x

Safety goggles Safety face shields

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 6 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x x x x x x

Safety shoes Dust masks Safety helmet Full body harness Hand Gloves (Leather) Reflecting Jacket Ear Plugs

Client’s safety instruction & Project Safety regulations shall be strictly followed. 7.

EQUIPMENT AND TOOLS x x x x x x x x x x

8.

Mobile/ Crawler cranes Welding Machines Pulley Pulling cable Chain block 2T,3T, 5T. Man lift Lifting Accessories Trolley assembly Nylon/ Teflon pipe rollers Hand tools & fixtures as required

MANPOWER x x x x x x x x x x x x

Piping superintendent Piping supervisor Rigger Foreman Piping foreman Riggers Pipe fitters Permit receiver Fire watcher Scaffolders Crane operators Welders Mechanic technicians

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 7 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x 9.

Man lift operators Safety Supervisors

GENERAL PREPARATORY WORKS x

x

x x x x x x x

Pipe rack sections (640 ,565 ,500 ,440 ,305 ,350 ,400 ,235 ,200 ,220 ,150 ,700 ,750 ,775 ,825 ,850 ,905) should first be turned-over for pipe installation. Secure work transfer sheet from structural group. Scaffolding and access are ready for use. Major pipe rack will be provided with mat type scaffolds at elevations where most work will be done. Others will be provided with scaffold individually at work locations. Walkway outside the pipe rack shall be provided along with scaffolds. Manpower, equipment, tools and other logistics are ready and prepared for installation. Lifeline to be provided for full length of working platform. The delivered spools, random length and other materials for erection shall be verified and checked as follow Verify piping spools are as per required ISO drawing and check for any damages. All spools shall be painted prior to erection. All spools shall be internally cleaned prior to erection.

10.

WORK EXECUTION PROCEDURE

10.1

PIPING INSTALLATION USING NYLON ROLLERS ON PIPE RACKS x x x

x x

Pipe will be loaded using cranes into the extended scaffoldings at designated/ end of pipe rack.(Attached typical lift plan for PipeRack-640) Loading of spools on scaffolds is not allowed. Install extended scaffolding at designated loading area at first level. Once the erection of pipes at this level was completed, additional extended scaffold will be installed for the next elevation. Additional hanging scaffold with access walkway will be installed for fit-up and full welding of pipe joints and supports not accessible by the hanging mat scaffold. Install, align and fix the roller assemblies at rack beams. Nylon rollers will be employed primarily to move random lengths along the racks. Install required pulleys to complete with Chain block. The pulley and cable will be used to pull the pipes from loading end, along the rollers and to its final position

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 8 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x x

x

x x

x

x x

x x x x x x x x

Cranes will pick-up the pipes either directly from trailers or from temporary lay down nearby the pipe rack. Pipes will be lifted by cranes using correct nylon slings and will be rigged to position at rollers in working platform. Once the pipe is initially positioned at rollers (on two spans), hook the pipe to a Chain block. Pipe should be tied in such a way so as not to damage bevel at pipe end. When the pipe is being pulled, a watcher will check the travel of pipe such that it will safely and correctly ride the succeeding rollers. A signaling system for safe execution and control of pulling will be employed. Once the length of pipes reaches its destination, it will be removed from rollers using chain blocks. Pipe spools such as expansion loops, branch take offs and others will be placed directly in position using cranes or chain blocks where required. Fit up and welding of spooled pieces will be done in place utilizing the mat type scaffold or localized scaffold. For pipeline without attachments, a double ended welding execution will be adopted i.e. the first two random length rigged to positioned will be fitted up and full welded together. The succeeding lengths will be installed in the same manner. The double ended lengths are then welded together until the entire run is completed. Random Pipes will also be placed from selected intermediate columns also and will be pulled to their places and Aligned. During the installation process, if the gap between Grids is less, for erection feasibility chain block pulley will be used for the balancing of the spool in one end and the other end belt will used. At interconnecting pipe racks the same roller system will be utilized where new steel works is installed and when there are no obstructions. Other areas will utilize cranes or manual rigging method (sticking-out method) to directly install the spools and straight lengths into positions. Prior to full welding works, check the fitted up spool/ pipe joint for the following: The surface is clean and free from paint, oil, dirt, scale, oxides and other foreign materials. The bevel angle, weld joint, root opening and alignment as per Isometric drawing approved WPS. Flange face is free from damage and scratches. Weld seam is staggered so that longitudinal joint and also joints shall not touch the bearing surfaces (structural steel) Re-in forcing pad is provided with 6mm vent hole as per specification.

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 9 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x x x x x

x x x x x 10.2

Socket welding gap is in accordance with specification. Welding consumables should be in accordance with approved WPS. All fit-ups shall be inspected by contractor or sub-contractor Piping inspector. Submit request for inspection (RFI) of the fitted spool/ piping. When fit-up is accepted, proceed full welding. Welding process shall be as per approved WPS. Only qualified welders can do welding works. Documents such as welding procedures and specification (WPS) and welders performance qualification record (WPQR) should be made available at site. All welding electrodes shall be backed and in site shall be stored in portable oven and shall have continuous power supply. During welding process, in-process inspection will be done by welding inspector and will be verifying the following items Welding consumables are in accordance with the approved WPS. Required pre-heat/ inter-pass temperature requirements are done as per approved WPS. Purging requirement, as applicable, is being maintained as per approved WPS.

AFTER WELDING WAS COMPLETED, VISUAL INSPECTION WILL BE DONE CHECKING THE FOLLOWING ITEMS, AS APPLICABLE x x x x x x x x x x x

Inside surface of orifice flanges welded joints is ground or machined smooth. Threaded joints must be checked for fit and roundness as per spec. no. Weld surface reinforcement in accordance with ASME B31.3 table 341.3.2 Dimensions of fillet weld in-accordance with ASME B31.3 fig.328.5.2B and 328.5.4D Root pass in accordance approved WPS. Arc strikes in areas not covered by the finished weld and grounds. Temporary materials used are already removed as per spec. Cleanliness of pipe shall be maintained as per spec. no. The weld spatter, slag, flux and other foreign materials are removed. Welders ID, Weld no., and line no & WPS. Shall be marked with permanent marker on the pipe next to the weld. Completed weld shall be subjected to require NDE as per line Class. PMI as required shall be conducted. And marking shall be done as per PMI procedure PWHT.

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 10 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x x x

x

x x x x x

10.3

Hardness test as required on some joints shall also be conducted as required by line class. As per approved weld repair procedure. Rejected weld will be repaired and will under-go visual inspection as per above mentioned and required NDE as per above For threaded line installation, refer specification, method statement of Deluge piping system specification no only gasket installation and inspection. Bolt Tightening shall be done by trained persons, in sequence to produce even compression and uniform bolt loads Torque wrench used shall be calibrated valves shall be set daily When using stud tensioner, the manufacturer’s procedure must be followed. The bolt used shall be checked for conformance with the ISO drawing. For pipelines with shoes, saddle, others, this attachment will be Tac weld to the pipe after being rigged to position. Shoes and saddle shall be positioned such that it will align and rest properly at beams or supports. Prior to full welding the alignment, support location and orientation must be checked and verified with latest approved drawings. The supports used should be in accordance with the latest approved IFC drawings. Pipe Supports to be Over Head welded by only trained welders and cleaning will by means mechanical cleaning. For supports directly weld to Alloy pipes, PMI (If Required) shall also be conducted Pipe stoppers and guides shall be full welded and painted. Prior to closure of piping section, full compliance with internal cleanliness inspection and documentation shall be ensured in. Piping installation at pipe rack areas 640,565,500,700,445,305,440,235,350,400,200,150,905,850,etc., will be done as applicable.

SAFETY PRECAUTIONS x x x x x

Obtain the approval of the work permit from the concerned PERMIT department before starting any work. Fire watcher with fire extinguisher shall be at work area whenever there is hot work. All electrical tools shall be checked and color-coded. Continuous monitoring and inspection shall be implemented to detect and correct unsafe practices while performing the work activities. Provide warning signs and sufficient barricade on working area and only assigned personnel will be allowed in the area.

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 11 of 12

SADARA Polyethylene LSPB-1 Project METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS x x

x x 11.

Welding location shall be enclosed with wind barrier and provided with nonasbestos fire blanket to prevent spread of any welding sparks. Safety officer shall monitor the work activities to help and to protect all assigned workers against exposure to safety hazards. He shall ensure that personnel protection equipment (PPE’S) are supplied and used and comply with L & T/SADARA applicable general instruction and standards. Safety harness with double lanyards shall be used all the time when working at elevated temporary platforms. Man-lift users shall be trained and certified to operate.

ATTACHMENTS x x

JSA for AG Piping Installation works Lifting plan of AG Piping

Date

Doc. No

Rev. No

Page

28-May-13


1

Page 12 of 12

Signed :

1. D K Upadhya 2. Rama krishna 3.Christian 4. Mahesh pingali

JSA TEAM MEMBERS

NAME (print)

SIGNATURE

WORK TEAM MEMBERS

Fork lift Chain blocks Nylon Belts

DPT, MPT tool kit

Confined Spaces Excavation Isolation

Cold Work Gas Hot Work

Handtools Power tools Welding Generator Oxy-Acetylene cutting set Air Compressor Fire Extinguisher Fire Blanket Pipe Supports Pipe Adjustable stand

PLANT, EQUIPMENT & TOOLS

Safety Helmet Safety glasses ( Clear / Black) Safety Shoes ( with steel toes) Hand gloves (Leather/welding) Dust mask , Welding Helmet Hi viz vest, face shield Hearing Protection. Leather Apron,Leg guard PERMITS

PERSONAL PROTECTIVE EQUIPMENT REQUIREMENTS

JOB DESCRIPTION: Piping Erection & fabrication works –Gas cutting, grinding, welding

JOB LOCATION: Sadara, Polyethelene Project – AG Piping Installation work

Signed :________________________________

AUTHORISATION: (Team Leader / Coordinator / Supervisor)

REVISION NO: 04

DATE : 26-05-2013

JSA No: 66

LARSEN AND TOUBRO ATCO JOB SAFETY ANALYSIS (JSA)

Permit ( Hot work) Barricades Sign Boards Fire watcher Certified flagman Scaffold tags

ISOLATION, TAGGING, BARRICADES, SIGNS & LICENSES

Waste Bin Fire fighting equipments

Environmental Controls (Bunding, Waste Disposal, Discharge Prevention, etc)

(JSA Team Leader)

JOB STEP

Permit to work / Pre-start meeting

Mobilization of manpower and equipment.

Forklift movement with Materials. (Structural, Pipes Spools & Project materials etc.)

Grinding job by using of Angle grinder and pencil grinder with 110V

SL. No

01

02

03

04

Disc breakage Inhalation Hazard(Fumes & Dust) Fire Hazards

Struck by loads. Rollover of pipe from the fork. Fall of loads. Vehicular collision equipment Tumble down.

Incompetency or lack of training. Equipment collision.

Incorrect Information

HAZARD

JOB HAZARD ANALYSIS (JSA) WORKSHEET

Personnel injury

Personnel Injury / Assets Damage

Personal Injury Property damage

Injury / Damage as a result of incorrect information

RISK

Engage competent manpower. HSE Induction of employees to be completed. Permit to Work to be obtained for the specific job. Area to be cordoned off to prevent entry of the unauthorized persons. Access to emergency vehicle shall not be blocked. Mandatory PPE (Coverall, Hard hat, Safety Shoes. Safety spectacle Gloves) to be used. Route survey to be done before transportation. Trained flag man shall be assigned to control the Traffic & vehicles with fluorescent jacket. All movements to be made slowly, smoothly & without jerking. While travelling with the load, keep the mast tilted back and low with the forks 15cm to 20cm above the ground. Don’t raise or lower the load while moving. (This effects stability of machine) Trained forklift operator only to use forklift. Ensure Flagman is qualified and attended the training for Flagman. Flagman ensures that unauthorized personals are away from the route. Flagman shall be equipped with high visibility vest, whistle & flags(red & green) Topics on safe lifting and forklift movement shall be discussed regularly during daily tool box talk Ground soil shall be levelled compacted. Ensure that ground soil to be re-levelled compacted if it was spoiled /disturbed by rain. Lifting appliance must not be allowed to be operated in uneven surface Where/when possible secure level when moving. Grinding Disc should have higher RPM rating than the grinding machine’s RPM. Ensure the disc is thoroughly inspected against any damages prior to installation. Ensure inspection/colour code (Fit to use) Make sure that the disc guard is in sound condition and in place. Ensure disc is well tightened to grinder Ensure only trained person shall operate the grinding machine.

REQUIRED CONTROL MEASURES Obtain correct hot work permit. Daily basis Pre start meeting and START card

05

Welding of Pipes & structures

Flying debris can cause serious damage to eyes.

Serious injury to personnel

Death or serious injury

Sparks and flying debris

Disintegration of wheels or accessories in chuck of tools

Electric shock from damaged tool or cable

Burn, Property Damage

Clothing, hair or limbs can become entangled in equipment resulting in injury

Rotating wheel/ Damage to wheel

Fire

High level of noise can result in temporary or permanent hearing damage. Exposure to vibration can cause work related upper limb disorders

Personal injury

Noise and vibration

Airborne dust and bits of metal particles coming from the structures

All permit requirement shall be in place before start the hot work, Area HSE shall inspect the work area before start any hot work activity. Remove flammable materials. Ensure proper supervision is in place. Ensure correct usage of mandatory PPE's (Fire Retardant Coverall/Apron, Hard hat, Safety Shoes, Safety spectacle, Gloves) and specific PPE such as , welder’s leather gloves,

Inspect equipment/ cables before use. Only 110V equipment is allowed for Hand Tools Do not use equipment in wet condition No connection/joint cable not allowed. Ensure over ride switch is removed.

Ensure proper wheel of correct size and speed. Wear proper PPE, especially for the eyes, Never use cutting wheels for grinding, never remove guards, drop wheel, etc.

Wear safety goggles & face shield.(Double eye protection) Provide Fire Extinguisher Ensure that there is no combustible material in work area. Ensure firewatcher inspect the area,30-60 minutes after work is finished.

Inspect the grinder before use. Only trained and competent persons to operate equipment

Appropriate hearing protection must be worn at all times. Alternate warning system to be put in place. Wear safety goggles & ear plugs Safety guards to be fitted Ensure signage is in place.

Ensure the disc is thoroughly inspected against any damages prior to installation. Make sure that the disc guard is in sound condition and in place. Wear Hand and eye protection. Ensure handles are used as grinders.

Personal injury

Injury to the personnel/ crash injury

Electric shock/ serious injury/ fatal incident

DPT & MPT Testing on weld.

Fall of job piece (the job being welded)

Electrical Shock.

Electric Burns / Shock

Burns injury to the skin

Splinters/slag

Proper maintenance Ensure welding machine is being earthed. Ensure that electrode holder is insulated Ensure that there are no exposed wires. GFCI Required.

Provide proper clamp and support. Ensure welding equipment inspected.

Ensure correct usage of mandatory PPE's Safety Shoes, Safety spectacles, Gloves, Masks etc.

welding helmet etc: Ensure proper house keeping all the time. Ensure proper earthling connections. Ensure that all cables, electrode holder, electrode ovens are in good conditions Ensure adequate fire fighting equipment and fire blankets and fire watch are in place. Ensure the welding generators are equipped with ELCB DB. Never place electrode oven on wooden surface when in use. Electrode stubs shall be properly collected in containers, tins. Before starting the job ensure that all cables & equipment are in good condition Ensure that all cables are routed properly and protected from sharp edge Cable joint is not allowed. Trained Fire watcher shall monitor the work activities and ensure that all the safety devices has been inspected and in working condition 30-60 minutes after work. Remove all the flammable materials within the 50 feet of hot work activities. Ensure that there is no combustible in work area within 50 feet perimeter, Provide fire extinguisher. Welders wear clear safety glasses under foods. Inspect work place for any flaming items at the end of the shift Fire proof apron/ gloves/ screen. Remove the REFLECTIVE JACKET, is flammable!

Using U- Foams for S.S. welding

Electric shock/ serious injury/ fatal incident

Burn and personal injury

Fire hazard

Personnel Injury

Ultra violet radiation.

Tripping Hazards

Respiratory illness Dermatitis.

Harmful fumes Poor ventilation

The foam shall be stored in a designated area, away from hot work. Make sure that the heat from welding will not reach up to the foam in use.

All cables, hoses, and other portable equipment should be placed in a safe area. All cables and hoses must be above head height. Cannot Impose any trip or entanglement Hazards.

Use correct filter lens and always use helmet. Provide non-flammable shielding (Fire blanket or G.I sheet) to protect others.

Use ventilation or exhaust to keep air-breathing zone clear and comfortable. Crew while working must place them in the wind direction, so the fumes and gases are blown away from them. Extraction systems must be provided to remove smoke/ fumes if natural ventilation is inadequate.

Use double insulated or properly grounded equipment .Ensure all electrical tools and cables are checked and tagged. Do not touch electrically hot parts or electrode with bare skin or wet clothing. Insulate crew from workplace and ground using dry insulation. Rubber mat or dry wood in case of wet working area. Use correct voltage tools and circuit breakers. All welding holders, cables and connections must be checked on daily basis.

Gas Cutting

Handling of Compressed Gas Cylinders

Working around with electricity associated by an electrical power driven tools

06

07

08

Metal fume fever, dizziness, nausea

Flying metals, sparks

Potential for electric shock

Fire

May cause injury, burns or even death

Personal Injury / Property damage

Suffocation, Fire.

High Temperature

Gas Leakage

Major fire, Explosion Burn Injuries to the eye

Back Fire, Flash Back

Use flash back arrestors and regulator and ensure it is regularly maintained. Fabricators shall check the cutting set before use. Only use flint stones to start flame Use welding gloves (Red colour) and Apron Use safety glasses, face shield must also be used while using portable tools. Check regulator, hose, hose connection and joints inspection and colour coded. Store cylinders securely in open air and in upright Position, shielded from direct sunlight or other heat source. Position the body with the wind direction or in such a manner that harmful gases are blown away from the body. Area must be well ventilated. Keep exposure as low as possible. Use respirators Trained fire watch man shall be assigned to control the hot work activity Flammable materials shall be removed within 50ft vicinity Leak test should be conducted with hose connections. Acetylene pressure should not go more than 15 Psi. All gauges shall be properly calibrated with valid date. Use only crimped hose connections,( jubilee clamps shall not be use) Do not laying the hoses in cutting of flammable area. Maintain the safe distance from the hot work location for the compressed gas cylinders. If it is close to the hot work, cylinders shall be protected with wet fire blankets. Compressed gas cylinders shall be protected Provide cylinder caps on all cylinders not in use. Properly secure cylinders in an upright position During movement. Do not strike cylinders together. Use cylinder trolleys to transport cylinders. All electrical equipment shall have ground fault circuit interrupters and assured equipment grounding Must ensure that the electrical tools are inspected for worthiness of use at site prior to proceed of work activities Use only non – conductive ladders Conductive items of jewellery or clothing shall not be worn during the work activity.

Working in hot environment

Emergency response

12

13

Medical Emergency

Fire

Heat stress

Cold

Heat stress

Adverse weather condition

Environment

11

Personal Injury / Property damage/Injury to others

Hose connection Detouching.

Property damage Fatality Serious injuries

Heat cramps Heat stroke Heat exhaustion Causing personnel’s injury

Sand storm Heat cramps, stroke, Exhaustion causing personnel injury

Personal Injury / Property damage/Injury to others

Personnel Injury

Eye Irritation

Horse Playing

Personnel Injury

Dust inhalation

Air Compressor operation (Cleaning purpose)

Personnel Injury

Use of crimping tools may cause injury

Connecting of cables using terminal lugs or connectors

10

09

Make sure emergency contact numbers are placed and Emergency Protocol to be followed Ensure rescue equipment are available on site Area to be barricaded, no one will be allowed to enter the area ERP should be activated and followed. In the event of Emergency Call Ambulance -0594331735 Mr. Kannan -0505647117 Mr. D.K. Upadhyay-0535300306

Ensure all personnel have correct PPE such as hard hat, safety glasses, coverall, safety shoe, hand gloves, & ear protection. Rest shelter not to be more than 50 feet away from the work. Ensure plenty of drinking water is provided. Heat stress awareness will be given to all workers prior to start tha work. Regular monitoring of heat index.

If visibility became poor, work will be suspended Dust mask will be provided Proper rest, Heat stress index will be monitored and act accordingly Drinking water station. Proper winter PPE

Use the proper respiratory protection.(N-95 3M dust mask) Use the proper PPE with double eye protection.(Goggles &face shield) Use the standard connector. Fixed wire rope connector with eye both side. Make sure that hose is in good condition. Working area must be isolated and make sure no other job in that isolated area. Engaged experienced worker to execute the job. Make sure there no horse playing is happen. Make sure the equipment is inspected and colour coded.

Ensure proper use of hand tools an advice wearing of hand gloves at all times. Use approved cables. No splicing. Connectors only we can use.

15

14

Working at Heights with Hot works

Finishing, housekeeping

Fire Hazard

Hot splatters falling from height

Slippage of Tools and tackles from Working platforms

Properity Damage/ Injury to others

May cause injury, burns or even death

Serious injury.

Personal Injury and may cause to fatalities.

Ill health Personnel injury

Fumes Air bowls and particles

Falling from Heights

Slips trips and falls on to unprotected materials which may cause personal injury.

Materials left on the ground unprotected.

Usage of proper PPE is while handling the job.

Fire blankets should be properly placed beneath the Hot work area inorder to stop the spillage of the splatters.

House keeping should be maintained on working platforms

Before using scaffolding for height works, Ensure that “Green Tag” should be present. Heights from 1.8 Mtrs and above every personnel should wear Full Body harness (It is to be inspected and monthly color tag should be maintained) Ensure that full body harness must be hooked to Rigid platform or Life line. Toe guards must be placed in aligned to platform. Flammable materials should be removed from the platforms and fire extinguishers must be duly placed near to the working area.

Review explode units with PPE include respective.

Ensure that all waste materials have been removed from the work area to the designated waste area. Carried out proper housekeeping all the times Fire watcher shall monitor the work area 15 minutes after completion of hot work and ensure work location is in safe condition before leave the site.

Job Description :

Name

JSA No :

Sr. No

Designation

Date :

JOB SAFETY ANALYSIS ATTENDANCE SHEET

Signature

Supervisor:

Piping Installation Works on Pipe Racks

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