002-ms nitrogen filling , cyrogenic vaporizer.pdf
TRANSCRIPT
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Pearl GTL Project
LINDE ENGINEERING
Shell Project No: HP-3000-QAT Contractor Project No : 5887 Project Document Number: T-4.305.139 Project Rev.: O Page 2
Purchase Order Number:
2MH127
Tag/Item Number(s):
0E-2091 A 0E-2091 B 0E-2091 C 0E-2091 D 0E-2091 E 0E-2091 F 0E-2091 G 0E-2091 H 0E-2091 J 0E-2091 K 0E-2091 L 0E-2091 M 0E-2091 N 0E-2091 P 0E-2091 R 0E-2091 T 0E-2091 U 0E-2091 V 0E-2091 W 0E-2091 X
0E-2092 A 0E-2092 B 0E-2092 C 0E-2092 D 0E-2092 E 0E-2092 F 0E-2094 A 0E-2094 B 0E-2094 C 0E-2094 D 0E-2094 E 0E-2094 F 0E-2094 G 0E-2094 H
Unit(s): ASU
PCWBS: Z
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QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION
C O Issued for Company Comments OD MEY AG ICC
B Issued for Review OD MEY AG IFR
A Issued for Internal Review OD MEY AG IIR
GAMA Rev.
Project Rev
Date Description Prepared
By Checked
By
Approved By
Status
No. No. ORIGINATOR
LINDE ENGINEERING AG
Document Title:
METHOD STATEMENT NITROGEN FILLING, CRYOGENIC VAPORIZER
Contractor
Gama Qatar Co. W. L. L.
Document No. LOC470
GAM MTS PRE GTL 002 C Org.
Code
Doc.
Type
Disc. Code
Geogr. Area
Seq.
No
Rev. No
Vendor Code
Project Document Number: T-4.305.139 Rev No.: O
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Doc. Title :
GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer
Date/Rev. No :
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TABLE OF CONTENTS
1 INTRODUCTION ____________________________________________________________________ 5
1.1 GENERAL ____________________________________________________________________ 5 1.2 SCOPE AND PRECAUTION _______________________________________________________ 5
2 HSSE ____________________________________________________________________________ 5
3 REFERENCES _____________________________________________________________________ 6
4 DEFINITIONS ______________________________________________________________________ 6
5 RESPONSIBILITIES _________________________________________________________________ 6
5.1 SITE MANAGER _______________________________________________________________ 6 5.2 FSI MANAGER ________________________________________________________________ 6 5.3 CLEANLINESS & PRESERVATION ENGINEER _________________________________________ 7 5.4 LIFT SPECIALIST ______________________________________________________________ 7
6 RESOURCES ______________________________________________________________________ 7
6.1 EQUIPMENT & MANPOWER _______________________________________________________ 7 6.1.1 EQUIPMENT ________________________________________________________________ 7 6.1.2 MANPOWER _______________________________________________________________ 8
7 METHOD OF EXECUTION _____________________________________________________________ 8
7.1 PRE-COMMENCEMENT WORKS ____________________________________________________ 8 7.1.1 WORK PERMIT _____________________________________________________________ 8 7.1.2 TRAFFIC MANAGEMENT PLAN ________________________________________________ 8 7.1.3 EQUIPMENT AND PERSONNEL ________________________________________________ 8
8 MEASURING AND FILLING PROCEDURE __________________________________________________ 8
8.1 GENERAL ____________________________________________________________________ 8 8.2 ASSEMBLY AND CHARGING ______________________________________________________ 9 8.3 DISASSEMBLY AND DELIVERY ____________________________________________________ 9
9 QUALITY ASSURANCE ______________________________________________________________ 10
10 ATTACHMENTS ___________________________________________________________________ 10
10.1 JOB SAFETY ANALYSIS ________________________________________________________ 10 10.2 TAGS AND SIGNS (SAMPLE) _____________________________________________________ 10
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Doc. Title :
GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer
Date/Rev. No :
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1 INTRODUCTION 1.1 GENERAL
This document describes the methods proposed to be used for checking the pressure of and filling with nitrogen (as required) of Cryogenic Vaporizer as part of the preservation activities at ASU area that shall be carried out as part of ASU Construction works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City (RLIC) of Qatar including similar works up to the time of commissioning. The preservation shall be performed at ASU Area. The nitrogen filling and tagging activities shall be carried out by GAMA QATAR in coordination with the Contractor. All parties (LINDE Contractor, GAMA Logistics, Mechanical and FSI disciplines) involved in the preservation of the Cryogenic Vaporizer will conduct minuted coordination meetings as required.
1.2 SCOPE AND PRECAUTION N2 (Nitrogen) is hazardous, especially in confined spaces. All measures will be taken prior to start of operations. During the work on and in the vicinity of open flange connections, care will be taken so that dust and moisture can not get inside the equipment. Nitrogen filling will be performed by the GAMAs Cleanliness and Preservation Engineer. The methodology will be presented to the Contractor and will be approved prior to execution. Wind intensity and velocity is to be taken into consideration. It is important in order to be able to decide if certain works can be carried out safely. Area influenced by the operation of the man-basket will be taken into consideration. Competency of personnel to execute the works on the equipment will be assessed. Availability and safety of man-basket, operator, hand-tools, measuring equipment, connectors, hoses and the N2 Bottle will be ensured.
2 HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL and/or its PMC requirements and instructions.
In addition all employees and GAMA subcontractor employees on site will have gone through GAMA Qatar Site Safety Induction, LINDE ENGINEERING AG Site Safety Induction and QSGTL Safety induction for site safety, health, environmental and security prior to resuming work activities at site. Other training courses (i.e. Working in Confined Spaces, Working at Heights, etc.) will be attended as required by LINDE ENGINEERING AG or QSGTL and/or PMC.
Risk Assessment will have been prepared by the Risk Assessment Team (RAT) ranking the hazards associated with project works and control measures to be taken to mitigate the hazards to an acceptable level.
Each scope work or task will have a completed and approved Job Safety Analysis (JSA)
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identifying the potential hazards and control measures that will be implemented to protect people and environment.
The JSA (RA) will be used by Supervisor as the basis of conducting his daily TSTI meeting and his weekly Tool Box Talk.
For additional safety requirements for a particular or specific task please refer to the JSA prepared for that task.
All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves) at site at all times as required.
3 REFERENCES T-4.233.760 : Cryogenic Vaporizer Steam Heated-O2 Vaporizer and
Condensate Vessel T-4.233.891 : Cryogenic Vaporizer Air Heated N2 Vaporizer Preservation
Procedure T-13.376.921 : Preservation of New Equipment, Technical Specification T-13.377.539 : Flawless Start-up
4 DEFINITIONS
Company : QSGTL and/or its PMC
Contractor : Linde Engineering AG
Sub Contractor : GAMA QATAR Co. W.L.L.
Contract : QSGTL Pearl Project C2 ASU Construction Works
QCP : Quality Control Procedure
ITP : Inspection and Test Plan
QA/QC : Quality Assurance / Quality Control
HSSE : Health, Safety, Security and Environmental
JSA (RA) : Job Safety Analysis (Risk Assessment)
FSI : Flawless Start-up Initiative
CA : Construction Area
Package Unit : Major components assembled at the manufacturers plant e.g. Linde Engineering AG
CV : Cryogenic Vaporizer
ASU : Air Separation Unit
MSDS : Material Safety Data Sheet
5 RESPONSIBILITIES
5.1 SITE MANAGER The Site Manager will provide inputs to the project execution plan to ensure that strategies & philosophy of the project are properly addressed.
5.2 FSI MANAGER The FSI Manager is responsible for the overall management of the Preservation Team to ensure that safe and effective operations are conducted and properly documented.
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GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer
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5.3 CLEANLINESS & PRESERVATION ENGINEER
He will be overall responsible for planning and safe execution of the whole job including:
Organizing of equipments, material and tools needed for the job.
Confirming the preservation location.
Assigning skilled personnel for the job.
Conducting TSTI with the concerned work force prior to start of work.
Ensuring that relevant work permits and Method Statement for the job are obtained prior to start of work and made available at site.
Conducting of activities to be carried out for the work in a safe manner as per this method of statement.
Tagging of the vessel(s) and keeping the records. Records are auditable by Company.
Conduct inspection and surveillance.
Notify to Contractor engineer for inspection as applicable.
Ensure that all Contractor and Company regulations are followed.
Ensure that all personnel involved are in safe working condition at all times.
5.4 LIFT SPECIALIST Shall be operating the man-basket (if and as required), to achieve a safe measuring and filling of N2 gas in the Cryogenic Vaporizers.
6 RESOURCES
6.1 EQUIPMENT & MANPOWER A list of equipment and manpower is given below.
6.1.1 EQUIPMENT
Manometer
T-piece
Hose
Gas Pressure Regulator
Atmospheric Monitoring Equipment
Nitrogen Bottle
Holding Clamps
Hand Tools
Full PPE and Safety Harness
Aerial Platform/ Manlift/ Man Basket
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Doc. Title :
GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer
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6.1.2 MANPOWER
Site Manager
FSI Manager
Cleanliness & Preservation Engineer
Man-Basket Operator
HSSE Personnel
Helpers
7 METHOD OF EXECUTION
7.1 PRE-COMMENCEMENT WORKS
7.1.1 WORK PERMIT The measuring of internal pressure and filling with Nitrogen gas of the Cryogenic Vaporizer starts with the preparation of Method Statement and issuance of a Permit to Work.
7.1.2 TRAFFIC MANAGEMENT PLAN Area will be soft barricaded and secured. Access road to operation area and enough space for movement of man-basket during operation will be arranged and made available.
7.1.3 EQUIPMENT AND PERSONNEL All equipment shall be inspected, tested and approved by the CONTRACTOR. All equipment and tools shall be available at the site. All personnel shall be inducted and trained before they commence work on site and have sufficient knowledge. All personnel shall be competent to execute all the works pertaining measuring N2 pressure and filling as required of Cryogenic Vaporizer.
8 MEASURING AND FILLING PROCEDURE
8.1 GENERAL The Cryogenic Vaporizer is filled with N2 gas to avoid oxidation of internals and needs to be kept at this state during storage and after erection up to the time of commissioning. The N2 pressure will be checked at intervals of one month by the CONTRACTOR, and will be refilled as required to achieve 0.5 bar internal pressure. Observations will be properly recorded, and copies will be forwarded to COMPANY. The vessel(s) (Cryogenic Vaporizer) and or the container will be tagged appropriately after
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Doc. Title :
GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer
Date/Rev. No :
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each inspection and/ or refilling to reflect the status of preservation. (See Attachment-2 for samples).
8.2 ASSEMBLY and CHARGING Read the dials supplied on Cryogenic Vaporizer and record the readings. If the readings are below 0.5 bar (50 kPa/ 7.25 psi/ 0.5 atm) fill as required.
Perform Gas Testing if the Cryogenic Vaporizer is in a confined space.
Adjust the filling nozzle to properly connect with filling equipment.
Position the N2 Bundle securely on ground.
Do not expose the N2 Bundle to direct sun-light for elongated durations.
Operate and position the man-lift so that the measuring and filling operation can be performed safely and effectively.
Remove the plug on the Ball Valve on a suitable charging nozzle. Attach the T-Piece on the Ball Valve.
Install the Manometer on one of the free ends of the T-Piece.
Connect the hose to the other end of the T-Piece.
Connect the other end of hose to the Isolation Valve. Ensure the Isolation Valve is at closed position.
Connect the Isolation Valve to the Gas Pressure Regulator. Check that Gas Pressure Regulator is at its lowest setting.
Connect the Gas Pressure Regulator to the N2 Cylinder .
Turn the Ball Valve (existing valve on the vessel) open.
Record the internal pressure displayed on the Manometer.
If it is less than 0.5 bar, open N2 Cylinder valve slowly to avoid pressure shock.
Increase output of the Gas Pressure Regulator to 0.5 bar. Turn the Isolation Valve slowly to open position.
Check the Manometer to read 0.5 bar.
Turn the Isolation Valve off, when 0.5 bar is reached.
Turn the Ball Valve on the vessel off.
8.3 DISASSEMBLY and DELIVERY Disconnect the T-Piece from the Ball Valve.
Plug the Ball Valve with the previously removed plug and use a gasket to ensure tightness.
Dismantle the arm of the Ball Valve and using a duct tape attach on or near to the Ball Valve to alleviate future operations.
Affix (if missing) an A4 size easily readable danger notice (supplied) on all sides of the vessel or on to the door of container, as required to ensure visibility at both sides of the vessel.
Affix (if missing) an A4 size easily readable warnings (supplied) on all sides of the vessel or on to the door of container, as required to ensure visibility at both sides of the vessel.
Affix (if missing) an 10cm X 10cm size easily visible safety signs (supplied) on all sides of the vessel or on to the door of container, as required.
Store the N2 Bundle as instructed on MSDS.
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Doc. Title :
GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer
Date/Rev. No :
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9 QUALITY ASSURANCE
A Quality Assurance System shall be operated conforming to related standards.
10 ATTACHMENTS
10.1 JOB SAFETY ANALYSIS
10.2 TAGS and SIGNS (Sample)
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JSA Number: T-4.305.139
Normal Approvals: Name Date
JSA by: Mr.Emre Yazc 23.09.2008
Job Supervisor: Mr. Osman Davaslgil 23.09.2008
Name Date
Discipline Superindent(LINDE)
SHES Representative(LINDE)
2. Permit To Work.
LINDE EMERGENCY TELEPHONE NO. HSSE MANAGER: 583 40 72RLIC HOT LINE : 474 88 88
JOB SAFETY ANALYSIS / RISK ASSESSMENT
Page No: 1 of 5
Job being analysed: NITROGEN FILLING, MOLECULAR SIEVE ADSORBER
Additional Approvals (Determined by Job Supervisor in correlation with LINDE HSSE Manager).
Department/Section doing JSA: HSSE & Mechanical Dept. JSA Members: Mr. Oguz Baskoylu, Mr. Emre YazcJob Performers: Mr. Osman Davaslgil, Mr. Seyfettin Bayrak
General job requirements / Common Personnal
Protective Equipment.
Signature
Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work.
2) Use additional sheets as necessary.
3) Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and shell Safety and Environment Procedures.
Approval required for hazardous work detailed in the LINDE work permit procedure.Changing conditions and emergency procedures: -Stop work. Switch of equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing
employees are reported to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning to work.
1. The following Personal Protective Equipment
shall be worn while installing manbasket: Approved
coveralls, safety glasses, safety helmet, safety steel
toe shoes and gloves. Signature
OTHERS (List Below):
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NEW REVISED
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JSA Number: T- 4.xxx.yyy
RISKRANK
1 Using of Manlift 1,1 Mechanical Breakdown 1.1.1 Equipment shall be serviced maintained and inspected as per set
maintenance and inspection program.
1.1.1.1 Ensure equipment to be provided
with controls of the dead man type,
which only allow movement of the
machine to take place whilst they
are actually being operated.
1.1.2 Ensure E-Stop is in place through the
control system.
1.1.1.2 Dead man controls automatically
return to the neutral position.
1.1.3 Perform equipment daily check prior
to use.
1.1.1.3 Appropriate trained & certified
persons only to use equipment.
1.1.4 Supervisor shall ensure that work will
be properly supervised as per work
method statement.
1.1.5 Ensure an emergency stop should be
provided on the platform control
panel.1,2 Improper use of
equipment
1.2.1 Manlift shall not be used as cranes or
jacks unless they have specifically
been designed for this purpose by
their manufacturers.
1.2.1.1 Ensure equipment is inspected,
approved & colour coded as per
colour code chart.
1.2.2 Leaning out of the platform will not be
allowed.
1.2.1.2 Current inspection sticker must be
in place.
1.2.3 Colour code sticker to be available on
the equipment.
1.2.1.3
#####B 3 A 3 #####
RP CCURRENT
CONTROLSADDITIONAL
CONTROLS
JOB SAFETY ANALYSIS / RISK ASSESSMENTT-4.305.139
SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, CRYOGENIC VAPORIZER
Residual RiskInitial Risk
Job Performers: Mr. Osman Davaslgil, Mr. Seyfettin
Bayrak
CP
3##
ITEM ACTIVITY CONSEQUENCES
HAZARD / POTENTIAL
#####3A#####
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JSA Number: T- 4.xxx.yyy
RISKRANK
RP CCURRENT
CONTROLSADDITIONAL
CONTROLS
JOB SAFETY ANALYSIS / RISK ASSESSMENTT-4.305.139
SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, CRYOGENIC VAPORIZER
Residual RiskInitial Risk
Job Performers: Mr. Osman Davaslgil, Mr. Seyfettin
Bayrak
CP
3##
ITEM ACTIVITY CONSEQUENCES
HAZARD / POTENTIAL
#####3A#####
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1,3 Untrained personnel 1.3.1 Ensure platforms must only be used
by authorized personnel who have
been trained in the operation of the
type of platform in use.
1.3.1.1
1.3.2 Initial training should cover operating
principles, machine controls and
environmental conditions, which are
likely to be encountered.
1.3.3 Training and practice in this type of
work undertaken is essential.
1.3.4 Ensure that equipment operator is
certified by third party, valid
certificates.
1,4 Fall of personnel 1.4.1 Safety harness shall be provided for
the use of all personnel working from
mobile work platforms so that in the
event of any advertent movement of
the platform they are working from,
they will not be thrown from it.
1.4.1.1 Discuss working at height hazards
in TSTI.
1.4.2 Boxes, hop-ups or ladders will not be
used to gain additional height or reach
from the platform of manlift machine
work platform.
1.4.1.2 Supervisor shall ensure that work
will be properly supervised at all
times as per work method
statement.
#####
Ensure supervisor/foreman who
will be using the manlift should be
particularly aware of the hazards
which may be encountered whilst
using these machines and of the
precautions which may be taken to
eliminate or minimize the hazards.B 3#####3 A
B 5 ##### A #####4
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JSA Number: T- 4.xxx.yyy
RISKRANK
RP CCURRENT
CONTROLSADDITIONAL
CONTROLS
JOB SAFETY ANALYSIS / RISK ASSESSMENTT-4.305.139
SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, CRYOGENIC VAPORIZER
Residual RiskInitial Risk
Job Performers: Mr. Osman Davaslgil, Mr. Seyfettin
Bayrak
CP
3##
ITEM ACTIVITY CONSEQUENCES
HAZARD / POTENTIAL
#####3A#####
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1,5 Overturning of Machine 1.5.1 Ensure no excessive force by the
operator on the platform by
introducing an element of side load.
1.5.1.1 When a manlift needs work in a
congested area, an approval for
the operation shall be obtained
from HSSE dept of Gama/Linde
authorized personnel's.
1.5.2 The outriggers or stabilizers, when
fitted, shall be fully extended and in
position, before the platform or boom
is raised.
1.5.1.2 Considering the effects of the
acceleration and deceleration of
the manlift.
1.5.3 The platform shall not be overloaded
exceeding the regulated safe working
load.
1.5.1.3 Discuss in TSTI.
1.5.4 Ensure the machine will be located to
the most suitable position for the job
to be carried out before any slewing
takes place.
1.5.5 Slewing of the boom to the extent that
causes the machine to overturn shall
be avoided.
1,6 Vehicle Movement 1.6.1 Ensure all vehicle movement to be
guided by competent banks men with
high visibility vests.
1.6.2 Ensure that each piece of equipment
is fitted with an automatic reverse
alarm and beacon or strobe light.
##### A
A 4 ##########
3
B 4
B 3 #####
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JSA Number: T- 4.xxx.yyy
RISKRANK
RP CCURRENT
CONTROLSADDITIONAL
CONTROLS
JOB SAFETY ANALYSIS / RISK ASSESSMENTT-4.305.139
SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, CRYOGENIC VAPORIZER
Residual RiskInitial Risk
Job Performers: Mr. Osman Davaslgil, Mr. Seyfettin
Bayrak
CP
3##
ITEM ACTIVITY CONSEQUENCES
HAZARD / POTENTIAL
#####3A#####
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2 Transportation of nitrogen bottle
2,1 Damaging of cylinder 2.1.1 Ensure the bottle is securly tied to the
vehicle.
2.1.1.1 Ensure the driver is warned to
avoid abrubt manouvers.
2.1.1.2 Ensure that the people are
instructed to avoid to drop the
bottle while carrying.
3.1.1 Ensure that the nitrogen bottle is tied
to the basket rails of the man-lift using
metal or plastic clamps.
3.1.1.1 Discuss in TSTI.
3.1.2 Barricade and secure the working
area with sign boards to prevent
unauthorized entry.
Nitrogen filling 4,1 Dropped tools
A 4 #####
4.1.1 Ensure that all hand tools are carried
in a tool box or attached to the
personnel.
4.1.1.1 Install barricades "exclusion zone"
with sign boards indicating
nitrogen filling works in progress to
prevent unauthorized entry.
4,2 Gas LeakageA 4 #####
4,2,1 Perform Gas Testing prior to start of
operation.
4,3 Inhaling nitrogen
B 5 #####
4,3,1 Ensure that the operation is carried
out in a well ventilated area or out
doors.
4.3.1.1 Install "INERT GAS WARNING"
signs, as necessary.
4,3 Handling pressurized
equipment
Ensure that valve protection cap is in
place.
4.4.1.1 Remove protection cap only to
connect the bottle to the filling
point.
Ensure the regulator is connected to
the bottle and operational.
4.4.1.2 Use a check-valve.
Ensure that the bottle is kept under 50
degrees Celcius and not in elongated
direct contact with sunlight.
4.4.1.3 Isolate cylider (bottle) at cylinder
valve when not in use.
Ensure that the bottle valve is opened
slowly to avoid pressure shock.
Ensure backfeed is not allowed into
the bottle.
##### A 4 #####
#####C 5 #####
A 4
3
A 4
Moving of the
nitrogen bottle to the
"filling position" via
man-lift
Dropped bottle3,1
#####
B 2 #####
4,4,1
4
A 3
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Doc. Title :
GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer
Date/Rev. No :
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