method statement

METHOD STATEMENT FOR

INSTALLATION OF CATHODIC PROTECTION

CONTRACTOR IDENTIFICATION CODE

3591-LZ-PF-L3-00126

LDPE UNITBOROUGE 3 PROJECT – RUWAIS, U.A.E Sheet 1 of 8 Rev. L

Abu Dhabi Polymers Company Limited (Borouge) BOROUGE IDENTIFICATION CODE

L3-SY-109-00126

METHOD STATEMENT

FOR


KCE Document Reference:

BO3-MST-S-CIV-0024-AKETTANEH TSJ REVIEW BO REVIEW

L1 IFA 07 JULY ‘11 UK FDD

L IFR 18 JUNE ‘11 UK FDD

Rev. Status Date Prepared Checked/Approved Review Initial Date Review Initial Date

Review Legend: Code 1 – Rejected ; Code 2 – Approved as Noted Revise & Resubmit ; Code 3 – Approved as Submitted

This document is only considered a controlled copy if bearing the live QA/QC stamp duly signed by authorized person.




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T A B L E O F C O N T E N T S

1. INTRODUCTION..........................................................................................................................................................3

2. SCOPE.............................................................................................................................................................................3

3. SPECIFICATIONS CODE AND STANDARDS.........................................................................................................3

4. DEFINITIONS................................................................................................................................................................3

5. RESPONSIBILITY........................................................................................................................................................3

6. LIST OF REQUIREMENTS FOR EXECUTION......................................................................................................4

6.1. WORK PERMIT (GENERAL ACTIVITIES / HOT WORK ACTIVITIES)...........................................................................46.2. EQUIPMENT INSPECTION AND PERSONNEL TRAININGS (GENERAL ACTIVITIES)......................................................46.3. MANPOWER LIST......................................................................................................................................................46.4. EQUIPMENT & TOOLS...............................................................................................................................................5

7. PROCEDURE.................................................................................................................................................................5

7.1. REBAR CONTINUITY TEST........................................................................................................................................57.2. INSTALLATION OF BOSS CONNECTORS.....................................................................................................................57.2.1. CRITICAL STRUCTURES:.......................................................................................................................................67.2.2. NON CRITICAL STRUCTURES:..............................................................................................................................6

8. BONDING PROCEDURE.............................................................................................................................................6

8.1. STRUCTURAL CONTINUITY BONDING IN CRITICAL STRUCTURES............................................................................68.2. STRUCTURAL NEGATIVE CONNECTION POINT (BOSS TERMINAL)...........................................................................68.3. POST INSTALLATION CHECKS...................................................................................................................................6

9. QUALITY CONTROL..................................................................................................................................................6

10. HEALTH, SAFETY & ENVIRONMENT (HSE)...................................................................................................7

10.1. COMPLIANCE............................................................................................................................................................710.2. PROTECTIVE MEASURES...........................................................................................................................................710.3. PLANT & EQUIPMENT CONTROL..............................................................................................................................810.4. ACCESS TO SITE.......................................................................................................................................................8

11. ATTACHMENTS.......................................................................................................................................................8

11.1. DATA SHEETS FOR CATHODIC PROTECTION............................................................................................................811.2. Job Safety Analysis..................................................................................................................................................8





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1. INTRODUCTION

The objective of this method statement is to explain the procedure for the Installation of Cathodic Protection System for LDPE UNIT BOROUGE 3 PROJECT with compliance to Health, Safety and Environment (HSE), local and international regulations.

2. SCOPE

This Method Statement (MST) identifies the works general steps, arrangements involved but not limited to the following:

Preparation of Equipment, Manpower, Installation & Testing for;

Rebar Continuity Test for critical & non critical structures, Boss Connectors for Concrete Foundations, Corrosion Monitoring Probe pre & post Installation record

3. SPECIFICATIONS CODE AND STANDARDS

Works will be in accordance with following:

BOROUGE 3 Specification

BGS-CU-010 (20.3)

BS 7362 Part1

3591-AA-DC-L300000-001

4. DEFINITIONS

Company : ABU DHABI POLYMERS COMPANY LTD. (BOROUGE)

Contractor : TECNIMONT-SAMSUNG JOINT VENTURE. (TSJ)

Sub-Contractor : KETTANEH CONSTRUCTION EMIRATES L.L.C.

An organization providing specific services to the TECNIMONT- SAMSUNG JV.

Bin Sari Specialized Technologies: Specialized Advisor for Cathodic Protection

Contract : L3 UNITS & BUILDINGS INSIDE PLANT AREA.

BGS : BOROUGE GENERAL SPECIFICATION

QA/QC : Quality Assurance / Quality Control

HSE : Health, Safety & Environment

ITL : Independent Testing Laboratory

ITP : Inspection and Test Plan

RFI : Request for Inspection

AFC : Approved for Construction

MST : Construction Method Statement

5. RESPONSIBILITY

Project / Site Manager shall be responsible for the execution of this procedure and to ensure that works are undertaken in a safe manner, to the requisite quality and to the agreed timescale. He shall advice and





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co-ordinate with other subcontractors pertaining to access and interface requirements related to the Cathodic Protection works to be undertaken.

QA/QC Manager shall be responsible for the implementation, documentation and scheduling of all tests and inspections. He shall assign a competent QA/QC Inspector to perform / supervise the inspections and tests as mentioned herein.

QA/QC Inspector shall be responsible in all inspection and testing. He shall report all activities to his QA/QC Manager before and after any activity involving QA/QC in the project.

Section Engineer shall be responsible for the site implementation of this procedure including control and safety of the workers. He shall assign a Site Engineer and Cathodic Protection Technicians to oversee daily work progress and safety.

Site Engineer shall be responsible for the activities such as, controlling manpower and equipment involved for the assigned activity, control personnel’s to implement a safe working method and prepares reports of daily activities

Safety Engineer – shall assist Site Engineer for the compliance of safe working methods. He shall assess the hazards in the workplace and formulate remedial actions to eliminate, contain or reduce them. He shall advise Construction Manager, Site Engineer and Discipline supervisors concerning all safety related matters on the job and has the authority to intervene, including stopping the job if work is being performed in an unsafe way. He shall ensure that the works must proceed in accordance with it and that works are undertaken in a safe and proper manner and are compliant with good working practices

Safety Officer shall be responsible for the implementation of safety working practices on site. He is assigned to ensure that all works are in accordance with HSE procedures.

Surveyor shall be responsible for giving an exact elevation and coordinates as per drawings.

Civil Foreman shall be responsible for the site implementation of civil works as per approved drawings. He shall supervise the gang leaders and skilled workers to complete the job in a proper manner with full control of safety pre-cautions and practices.

Technician / welder – He shall ensure installation as per the approved procedures and drawings and recording the required tests.

Labour / Helper shall be executing any activities assigned to him on site, (i.e. assist safety, Surveyor, etc.) and should follow instructions from his supervisor.

6. LIST OF REQUIREMENTS FOR EXECUTION

6.1. Work Permit (General Activities / Hot work Activities)

Before the start of each day’s operation, all necessary permits will be obtained from TSJ.

Permit to Work document must be updated and approved prior to proceed on a particular activity.

6.2. Equipment Inspection and Personnel Trainings (General Activities)

Equipments will have its own inspection sticker and shall be inspected and approved by TSJ before use.

Personnel shall have safety induction and trained to BOROUGE and TSJ prior to site mobilization.

6.3. Manpower List

- Construction Manager

- Section Engineer





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- Safety Officer

- Surveyor

- Civil Foremen

- Technician

- Welder

- Carpenters

- Labor/Helpers

6.4. Equipment & Tools

- Hand tools for this activity

- Potential multimeter

- Crimping tool

- Power Drill

- Generator

- Welding equipment

7. PROCEDURE

7.1. Rebar Continuity Test

The basic criteria are to measure resistance at each location and between locations.

Test conducted by precision ohmmeter, all instruments to be checked, calibrated, certified and approved by TSJ prior to use

Identify the locations and assign test location identifications.

Clean the rebar to metal finish by wire mesh

Check continuity between rebars at different locations and between locations and with terminals reversed and record resistance values.

Any rebars failing the below criteria will be made continuous by means of continuity connections and continuity of each rebars in a single structure will be achieved.

The maximum allowable value shall be 1 ohm, any value more than 1 ohm shall be repaired

Also fluctuating resistance values are treated ads fialed and to be repaired as above.

All the data obtained will be recorded in the attached format.

7.2. Installation of Boss Connectors

Based on the structure design, locations shall be identified and the reinforcement of the structure shall be bonded to achieve electrical continuity and negative connection for future cathodic protection. All reinforcing steel embedded in concrete shall be made electrically continuous during construction. The following sections explain the steps to be followed in achieving continuity and monitoring measures.





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7.2.1.Critical Structures:

Structures classifieds as critical structures the continuity shall be established between rebars embedded above and below ground concrete using galvanized steel wires, wrapped around and tied by GI Tie wires wrapping around to 5 times to the horizontal / vertical rebars

7.2.2.Non Critical Structures:

Structures classifieds as non critical structures the continuity shall be achieved by means of rebar to rebar contact by using GI wires used for normal Reinforcement steel work. The connection of Boss to the vertical rebars of column shall be Tack welded.

8. BONDING PROCEDURE

Continuity wire shall be connected between the horizontal rebars , as each vertical rebar is tied to each of the horizontal rebar by means of tie wire and horizontal rebar travels maximum spread compared to the vertical rebar. The following steps shall be followed to achieve electrical continuity.

8.1. Structural Continuity Bonding in Critical Structures

Identify the location for continuity bonding and negative connection

Cut the required length of the 6mm2 Galvanized steel wire

Fix the wire to the bottom horizontal rebars by means of GI tie wire used for normal rebars and wrapped around 5 times on both directions.

The above shall be repeated with all the horizontal rebars in one location with single length of wire

Check the installation by pulling and also check continuity of the joints

Refer attached drawings for details.

8.2. Structural Negative Connection Point (Boss Terminal)

Structure negative bonding shall be achieved by connecting individual negative feeder cables to the boss connection. Boss connection shall be fixed to the rebar by either directly fixing with suitable C crimps or Galvanized tie wire crimped to the boss and other end crimped to the structure rebar.

Location of boss connections shall be installed minimum one each for 64 m2 concrete surface area.

One each boss connection shall be provided for foundation smaller than 64 m2.

Check the continuity and confirm the effectiveness of bonding by measuring the resistance at each location as per the procedure

8.3. Post Installation Checks

Visual inspection of installation

Rebar and boss connections and results shall be recorded in the test format given in procedure

9. QUALITY CONTROL

Site management, Site Engineer, QA/QC inspector and safety officer will closely supervise and monitor all phases of work to ensure full compliance with the procedures and safe methods of working.

Inspection, test and recordings shall be carried out in accordance with the approved procedures and in accordance with the project specification.

Request for Inspection will be issued to TSJ for the final inspection.





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Unless otherwise shown on the Engineering drawings, items shall be installed in accordance with Project Standard Drawings.

Continuity shall be checked and the results shall be recorded before and after concrete pouring.

Vertical rebars and spiral rebars shall also be connected with wire rope and GI Tie wire wrapped around 5 times

10. HEALTH, SAFETY & ENVIRONMENT (HSE)

10.1. Compliance

All works shall be in compliance with the local laws and regulations and international standards, codes, TSJ HSE requirements.

KCE shall comply with this method statement, Job Safety Analysis (JSA) and will follow good practice as per legislation.

A STARRT meeting with the working crew shall be complied with prior to commence of work.

All persons shall wear personal protective equipment (PPE), e.g. safety helmets, safety glasses, coverall, safety shoes, hand gloves, etc. shall be provided within the site, PPE must be of approved type.

Any incident/injury/near miss will be reported immediately to the appropriate authorities.

All works should adhere to the enclosed Job Safety Analysis. JSA will be discussed daily with crew to familiarize everybody with safe work procedures.

In case of injury and/or illness, notification will be corresponded.

KCE and his Subcontractor’s site engineer to ensure that his team follows safety rules and regulations. He will also initiate the daily tool box meeting and maintain record of periodic and monthly inspection records.

Waste dumping will be as per guidelines.

All mobile plant generators, machines will have drip trays open underneath, properly grounded and fire extinguishers available.

All power tools and if any lifting equipment available to be color coded as per procedure.

10.2. Protective Measures

KCE shall ensure that their own personnel are trained in:

Health, Safety & Environmental Requirements and Regulations:

Potential Risks and Impacts, Protection Measures, PPE Usage, Sanitation & Hygiene

Emergency Response Plan (ERP)

Any issues regarding HSE, KCE to keep TSJ fully informed at all times.

Sufficient shaded areas and drinking water to be provided to the workforce, in extreme hot weather, and working hours should followed those advised by government decree.

In severe sandstorm all works to be suspended.





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In addition all employees and KCE subcontractor employees on site shall have trainings through TSJ and BOROUGE Safety Induction for site safety, health, environmental and security prior to mobilization to work activities. Other training courses will be attended as required by TSJ and BOROUGE

10.3. Plant & Equipment Control

All drivers and operators shall be competent persons and must have a UAE Drivers License and 3rd Party Certification and Competency Certificates where appropriate.

All the traffic rules set by TSJ shall be strictly obeyed.

Vehicle/equipment Speed Limit as per regulations in site.

No Overtaking on site unless the other vehicle is in stationary position.

Plant and equipment to be fully licensed and regularly serviced and inspected also must have third party certificates.

Any accident / injury / near miss will be reported immediately to the appropriate authorities.

KCE shall comply with this method statement and shall follow rules and guidelines as set out in the approved TSJ HSE plan.

KCE shall ensure that their own and his subcontractor and personnel are educated and trained in:

Health, Safety & Environmental Requirements and Regulations

KCE to keep TSJ fully informed at all times of any issues regarding HSE.

10.4. Access to Site

KCE and his subcontractors will strictly follow the approved procedures for site access of all plant, equipment and operatives.

11. ATTACHMENTS

11.1. Data Sheets for Cathodic Protection

BSST-QAQC-CPJ1123-031FR

BSST-QAQC-CPJ10138C-1-087FR

BSST-DR-CP10138C-1-001

BSST-DR-CP10138C-1-002

11.2. Job Safety Analysis


method statement

Documents

rejected code

specifications code

project ruwais

uk uk fdd fdd

live qaqc stamp

controlled copy

authorized person

equipment inspection