method statement for repair of underground 14rev 2

8/19/2019 Method Statement for Repair of Underground 14rev 2

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PETROL& GAS CONSTRUCTION CO. DOC. REF. NO. MS-001

Rev. 02

METHOD STATEMENT FOR REPAIR OF UNDERGROUND14” GRE FIRE LINE

DATE 12/23/2015

PAGE 1 of 10

METHOD STATEMENT FOR REPAIR OF UNDERGROUND 14” GREFIRE LINE

AT

AT RAS LAFFAN LOADING & RECEIVING FACILITY (RALF)

CLIENT: WOQOD

Title SignatureDate

Issued By: Site ngineer

Reviewed by Project ngineer

Approved By: Project Manager

Client

approval


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C O N T E N T S

1. PURPOSE

2. SCOPE

3. Resources

4. RESPONSIBILITIES

5. PROCEDURE

6. HEALTH & SAFETY

7. RECORDS

8. ATTACHMENT(S)


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1. Purpose-

This method statement describes the steps to be followed in repair of 14” GRE pipelines in a safeway to handle the job with qualified supervisors and Technicians with high experience in GRP/GREworks.

This Method Statement must be used and referenced in the pre-work “Tool Box talk” briefing.

Any changes to the MS must be noted and addressed in the pre-work meeting.

A copy of this MS must be kept either on site.

All personnel must be familiar with this document prior to commencing any work.

Any risks identified as part of this MS must have adequate control methods identified prior to

commencement of work.

This Safe Work Method Statement must be explained to all personnel involved in the work process,

prior to commencing work.

2. Scope-

This method statement describes the steps to be followed in excavation and repair of 14” GRE pipelines

pipes.

This Method Statement generalizes the different recipes prepared specifically for this project. Therecipe specifies the minimum laminate thickness, the bonding and the number of layers will becalculated after physical inspection, the resin type will be isophtalic polyester resin (siropol 7440 )according to specification. All parameters to be considered as per the joint diameter (14”) and the linepressure

The laminators should make sure that they are carrying the right recipe related to the jointdiameter & line pressure rating.

3. Responsibilities-

Project EngineerProject Engineer is responsible for assisting Project Manager to control the project and a co-ordination

between site and management.

Site EngineerSite Engineer is responsible for executing the job and manpower control according to plan schedule to

work and client/customer standard.

QC Engineer:QC Engineer is responsible for maintaining the job according to Customer quality need.

Safety Officer

Safety Officer is responsible to maintain the site in safe condition and keep monitoring the ongoing workaccording to Customer Safety Standards.


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Site Supervisor:

Site supervisor is responsible to execute the job according to method statement. Review and approvelifting plan and operation submitted by contractor/crane supplier via the Executing Department as and whenrequired. Constantly monitor the approved plan and identify improvement for future.

4. Resources

A. Man Power

Project Engineer

Site Engineer Mechanical Supervisor

Site Foremen

Mechanical Fitter

GRP/GRE Laminator

Piping Fabricator

Material controller

Safety Officer

Fire Watchman

Riggers, Helper.

B. Tools & Equipment

4”, 6” & 9” diamond cutting disc.

4 ½” & 7 ½ “angle grinder, 220 V.

Spirit Level

50 M long Electrical Cables with industrial plug

Exhaust or blower fan for internal lamination, 220V

Halogen Light / Torch

Curve O mark

Scissors

Measuring tapes

Wrap-Around

Calibrated Barcol Impressor

Right Angle 12”

100 ml Graduated Cylinder

Catalyst Dispenser (for Vinyl ester lamination)

Safety shield

Portable Blower

Ventilation fans

Steel serrated roller

Hard cotton gloves

Ø2” x 7” Lamb wool Rollers (Refill)

4” & 6” Backing Pad

10 liters mixing buckets (graduated)

Polyethylene Gloves

4” & 6” Emery Disc, grit 60

Dust Mask, 3m 8710 Marker

Line string


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Paint Brush, 4”

Tarpaulin sheet for shed, 10m x 10m

Cleaning Rags

Masking Tape

Fire Retardant Paper Roll

Ø2” x 7” Lamb wool Rollers handle

Measuring Tools/ Precision Scale

Nylon rope

Misc. Tools & Tackles

Lifting Tools & Tackles

C. Safety PPE

Safety Helmet

Safety Harness

Safety Shoes

Safety Goggles/Glass

Hand Gloves

Face Shield

Respirator (If required)

Ear Plugs/Muffs (if required)

Dust mask

Toxic Clip

Fire Blanket

Fire Extinguisher

Chemicals Apron

5. PROCEDURE

A. PREPARATIONS

All necessary work permits will be secured from WOQOD Operations prior to start of any

activity.

Ensure all the workers and staffs that will be involved in the work have undergone WOQOD

Safety Awareness Induction given by the Authorized in WOQOD organization prior to work.

Ensure all the needed materials, tools and equipment are available and that vehicle(s) to be

used on site have been inspected and approved by WOQOD Safety. Install all needed safety

barricades and signage.

Check for pipes identification code/class etc., and ensure that they are as per approvedisometrics.


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B. WORK EXECUTION

Mobilization to WOQOD site and arrange laydown area.

Site survey and taking dimensions, check the location for the joints, fittings and supports,barricade for excavation,

Excavation, inspection for leak.

Fabrication of GRP 14’’ pipes, fittings and flanges at GRE vendor’s workshop if applicable.

Start site lamination ,spool fabrication and fittings lamination

Reference drawings will be made available on site and planned activities will be discussed

and made clear to the understanding of each worker that will be involved in the work.

Check the alignment on the new supports, pipe rack and level of pipes.

After curing of the laminated joints, carryout barcol test.

Back fill of excavationPipe Cutting & Lamination

Cutting

The old GRE pipeline will be cut by grinder of steel disc, the tip below will be cut in order toremove any likely of water in the pipe, after the water has been removed, the whole pipe fittingswill be cut if applicable

External Lamination

Fit layer

a. Measure and mark the fit layer bond length of 50 mm from the end of each pipe.

b. Grind by angle grinder with emery disc the above area to remove the topcoat &surface layer of the pipes until the pipe glass fiber are exposed. The maximum depthof grinding should be within 0.3-1.0mm depth from top layer.

c. Clean this area by dry clean cloth or paintbrush and ensure that it is fullydry.Ensure that the gap between the two pipes to be laminated is within the allowablelimit of 0-3 mm for diameters up to & including Ø1800 mm.

d. Fill the gap, if any, between the two pipes with milled-glass fiber resin putty.

Note: The milled-glass fiber resin putty is compatible with desalinated water/seawater/ hypo chlorite solution.

e. Impregnate by lamb wool roller the roughened area with the resin catalyst mixturementioned in the recipe.


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f. Apply woven roving glass 270 using a 50% overlap between each two consecutivewindings so that wrapping the full surface will end up with two layers of glass.

g. Impregnate by lamb wool roller the above layers with the resin catalyst mixture.

h. Use aluminum roller to remove entrapped air and blisters.

i. Repeat the above two steps till the required number of layers is applied asspecified in the recipe.

j. Wait till the lamination is cured under ambient temperature. Once the fit laminate istack free, it is ready for the main laminate preparations.

Main Laminate

a. Measure and mark the bond length as specified in the recipe on each pipe fromthe middle of the fit layer.

b. Grind by angle grinder with emery disc the cured fit laminate and the pipeas per the mark bonding length until the pipe glass fiber are exposed in order toroughen the pipe surface to have good bonding prior to the main laminate. Themaximum depth of grinding should be within 0.3-1.0mm depth from top layer.

c. Special Note: If ground area is left under dusty weather conditions (with sand) or

left exposed for more than one day under any weather condition; it is mandatory toclean the grinded area with a dry clean cloth or paintbrush and ensure that it is fullyclean & dry.

d. A proper mixture of resin and catalyst is prepared as per recipe.

e. Impregnate by lamb wool roller the roughened area of the above area withthe resin catalyst mixture.

f. Apply woven roving glass 270 using 50% overlap between each two consecutivewindings so that wrapping the full surface will end up with two layers of glass.

g. Impregnate by lamb wool rollers the above layers with the resin catalyst

mixture.h. Repeat the above two steps till the required number of layers is applied as

specified in the recipe.

i. Apply woven roving glass 360 using 50% overlap between each two consecutivewindings so that wrapping the full surface will end up with two layers of glass

j. Impregnate by lamb wool rollers the above layers with the resin catalyst mixture.

k. Repeat the above two steps till the required number of layers is applied asspecified in the attached recipe at this stage as “initial winding”.

l. Apply the specified number of layers of woven roving 580 and 360 alternatively.

Each type of glass should be applied in four consecutive layers before changing tothe other type. Every two layers should be impregnated before applying the secondtwo layers of the same type


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m. Apply two “sealing layers” of woven roving glass 360

n. Impregnate by lamb wool roller the above layers with the resin catalyst mixture

o. Wind 2 layers of top tape glass around the laminate to extract the excess quantityof resin and to provide smooth surface.

p. The lamination will harden under ambient temperature .Make sure that the joint isundisturbed for a MINIMUM of 12 hours.

q. Once the curing of the lamination is completed, inspection and the required test ofthe lamination joint can be carried out as per the Inspection & Test Plan; thelaminated joint shall be considered accepted only after passing the hydrostatic test.However, as per document Inspection & Test Plan, FPI Qatar supervisor shallcertify at site each joint prior to the hydrostatic test.

Operations will have to pressurize the line after the connection is made complete and quality

inspections are done and comments satisfied.

Re-check laminated connection after 24 hours the line is put in service.


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6- HEALTH AND SAFETY MANAGEMENT AND CONTROL MEASURES

General Safety Requirements

All personnel involved shall use necessary PPE as required and supervisors shall ensure regularinspection of workers PPE.

Ensure that all staff and workmen assigned to carry-out the task have undergone the requiredWOQOD trainings.

The workers shall be made aware of safety requirements related to this activity through daily,weekly and monthly toolbox and safety talks. The JSA shall be used to the site supervisor as thebasis of conducting his daily Tool Box Talks.

All equipment, plant, machineries and tools that shall be utilized in the job shall be kept in goodworking condition having relevant and valid documents and should pass WOQOD inspectionrequirements and certifications.

Access and good housekeeping should be maintained in all erection areas.

Waste Management Procedure shall be strictly followed to keep the job site neat and clean.

The required Process / Mechanical, Electrical and Instrumentation LOTO shall be obtained andattached with the PTW.

Working area shall be barricaded with Warning Tape.

Safety watch shall be present from start up to the completion of the installation/erection work.

All lifting equipment required valid third party certificate and to be maintained at site.

Proper fire protection to be employed at site while hot and open flame activity.

Personal protective equipment: All workers will be wearing appropriate PPE. (Rubber safetyboots whilst working with concrete or in the mud area, dust mask, chemical mask, safetyhelmet, high visibility vest, gloves and overall

a. The lamination bond area should be provided with adequate cover to protect the joint from desert conditions. (Sand, dust, humidity etc.). Aluminum frame or similarimprovised mobile scaffolding should be arranged to straddle the pipe withinterconnecting pipes and planks/platforms at suitable height to aid lamination effortof workmen.

b. Proper provision of a safe means of access to the work area

c. All workers will be informed (via a site induction / toolbox talk) of and expected tocomply with the client site rules.

d. The prepared bond surface area should be free from grease, oil, dust, moisture,water etc. Clean the surface using a clean and dry cloth or a dust brush.

e. Do not distu rb the joint before the lamin ate is cured.


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LIST OF CONSUMABLES

CONSUMABLES

a. Resin

b. Hardener

c. Cobalt

d. Fiber Mat

e. Combination Fiber

f. C Glass

g. Hard cotton gloves

h. Ø2” & 7” Lamb wool rollers handle

i. Ø2” x 7” Lamb wool rollers (Refill)

j. 4” Backing Pad

k. 10 liters mixing buckets (graduated)

l. Polyethylene Gloves

m. 4” Emery Disc, grit 24

n. Dust Mask, 3m 8710

o. Marker

p. Tarpaulin sheet for shed

q. Cleaning Rags

7- Records-

a. As Built Drawing b. Barcol Hardness Test Reportc. Hydro Static Test Report

8- ATTACHMENTS-

MSDS of chemicals

method statement for repair of underground 14rev 2

Documents