008-ms for prefabrication of cs,tt & cn pipe spools.pdf

Pearl GTL Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT Contractor Project No : 5887 Project Document Number: T.4.250.903 Project Rev.: O Page 2 of 20

Purchase Order Number:

2MH127

Tag/Item Number(s): N/A

Unit(s): ASU

PCWBS: Z

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

C O 11.03.2008 Issued for Company Comments RO EE ZG ICC

B 21.02.2008 Issued for Review RO EE ZG IFR

A 17.02.2008 Issued for Internal Review RO EE ZG IIR

GAMA Rev.

Project Rev Date Description

Prepared By

Checked By

Approved By Status

No. No. ORIGINATOR

LINDEGINEERING AG

Document Title:

METHOD STATEMENT FOR PREFABRICATION OF CS, TT & CN PIPE SPOOLS Document No.

GAM MTS MEC GTL 008 C LOC470

Contractor

Gama Qatar Co. W. L. L. Org. Code

Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T.4.250.903

Rev No: O

Doc. Title : METHOD STATEMENT FOR PREFABRICATION OF CS, TT & CN PIPE SPOOLS

Date/Rev. No : 11 March 2008 REV-C

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TABLE OF CONTENTS 1. INTRODUCTION _______________________________________________________5

1.1. GENERAL_______________________________________________________________5 1.2. SCOPE _________________________________________________________________5 1.3. PURPOSE_______________________________________________________________5

2. REFERENCE __________________________________________________________5 3. DEFINITIONS__________________________________________________________6 4. RESPONSIBILITIES ____________________________________________________7

4.1. PIPE PREFABRICATION SUPERVISOR ______________________________________7 4.2. PLANNING ENGINEER ____________________________________________________7 4.3. FABRICATION ENGINEER(S) AND FOREMEN _________________________________7 4.4. PIPING ENGINEERS ______________________________________________________7 4.5. WELDING SUPERVISOR AND FOREMEN_____________________________________7 4.6. QC MANAGER, ENGINEER & TECHNICIANS __________________________________8 4.7. SPOOLGEN SUPERVISOR _________________________________________________8

5. METHOD OF EXECUTION _______________________________________________8 5.1. PIPE CUTTING___________________________________________________________8 5.2. WELD EDGE PREPARATION _______________________________________________8 5.3. BRANCH CUT-OUTS______________________________________________________9 5.4. FIT-UP AND ALIGNMENT __________________________________________________9 5.5. TACK WELDING _________________________________________________________9 5.6. PREHEAT AND INTERPASS CONTROL _____________________________________10 5.7. WELD INTERRUPTION ___________________________________________________10 5.8. WELDING ______________________________________________________________10 5.9. PWHT _________________________________________________________________10 5.10. REWORK ______________________________________________________________10 5.11. NDE___________________________________________________________________10 5.12. MATERIAL HANDLING AND STORAGE _____________________________________11

6. QUALITY ASSURANCE ________________________________________________12 7. HSSE _______________________________________________________________12 8. ATTACHMENTS ______________________________________________________12

8.1. JOB SAFETY ANALYSIS _________________________________________________12



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1. INTRODUCTION

1.1. GENERAL This document describes the methods proposed to be used for the prefabrication of spools.

1.2. SCOPE This method statement defines responsibilities within GAMA-QATAR for the prefabrication of spools

1.3. PURPOSE The purpose of this method statement is to ensure correct and safe implementation of project specifications and the procedures for the prefabrication of spools.

2. REFERENCE ASME B 31.3 Process PipingASME Sec. V Non Destructive Examination ASME Sec. IX Welding and Brazing QualificationASME Section II, Part C Specification for Welding Rods, Electrodes & Filler MetalsT-13.377.441 Quality Control Requirements for Welding T-13.377.438 Specification for Traceability, Alloy Verification and Material

Substitution

T.4.250.931 Welding Consumable Control DEP 30.10.60.18 Welding of Metal(Amendments/Supplements to API RP 582)DEP 31.38.01.11 Piping-General Requirements

DEP 31.38.01.31 Shop & Field Fabrication of Piping Amendment T.13.376.796E T-4.250.930 Cleanliness Procedure Piping Systems T-4.234.542 Project Quality PlanT-4.250.927 Material Handling and StorageT-4.250.928 Material Traceability & MarkingT-4.250.932 Equipment PreservationT-4.250.938 General Welding ProcedureT-4.250.939 Welders Performance QualificationT-4.250.913 Post Weld Heat Treatment ProcedureT.4.250.940 Weld Repair ProcedureT.4.250.920 ITP - Fabrication of Piping A/G & U/GT.13.377.360 Flawless Start-up Initiative(FSI)T.4.250.935 QCP - Procedure of Piping Fabrication A/G and U/GT.4.129.857 Road Safety ProcedureT.4.129.872 Heat Stress Disorder Prevention Procedure T.4.129.868 Work at Height ScaffoldingT.4.095.303 HSSE Plan Construction



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T.4.095.807 Nozzle Assemblies for Instrument Connection, Drain and Vents T.4.219.660 Permit To Work Handover Implementation Plan T.4.129.855 Emergency ResponseT.4.184.595 Land Road Transport HSE CaseT.4.129.859 Lifting OperationsT.4.129.854 Risk AssessmentT.4.129.864 Safe Use of Compressed GasesT.4.129.850 Accident/Incident /Near Miss Reporting and InvestigationT.4.129.860 Manual HandlingT.4.129.865 Portable Power ToolsT.4.129.856 Hygiene and HousekeepingT.4.129.861 Handling of Hazardous MaterialsT.4.129.866 Use of Grinding Machines and Abrasive Wheels T.4.129.871 Environmental AccountingT.4.129.656 Construction Waste Management Plan T.4.129.852 Entry into Confined SpaceT.4.129.861 Working with ElectricityT.4.129.867 Hand ToolsT.4.129.853 Personal Protective EquipmentT.4.129.863 Welding and Flame Cutting

ANSI / ASME B 16.25 Butt welding ends Amendments and/or Supplements to DEP 31.38.01.31 GEN (April 2003) Shop and Field Fabrication of Piping.

3. DEFINITIONS

Company : QSGTL or its PMC Contractor : LINDE ENGINEERING AG Sub Contractor : GAMA QATAR Contract : QSGTL Pearl Plant C2 ASU Project QCP : Quality Control Procedure ITP : Inspection and Test Plan QA/QC : Quality Assurance / Quality Control WPS : Welding Procedure Specification PQR : Procedure Qualification Record PWHT : Post Weld Heat Treatment CS : Carbon Steel TT : Low Temperature Carbon Steel CN : Chrome Nickel Alloys, Stainless Steel RT : Radiography Test MSDS : Material Safety Data Sheet RAT : Risk Assessment Team



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JSA : Job Safety Analysis TBT : Tool Box Talk RA : Risk Assessment PT : Penetrant Testing MT : Magnetic Particle Testing T : Thickness NDE : Non-Destructive Examination NDT : Non-Destructive Test

4. RESPONSIBILITIES As per organisation chart, starting from Site Manager and ends at welding, piping foremen level, including QC personnel, all the people within this link is responsible for execution of this method statement. Site Manager, Assistant Site Manager and Mechanical Works Coordinator are responsible for the fulfilment of this procedure.

4.1. PIPE PREFABRICATION SUPERVISOR Pipe Prefabrication Supervisor is responsible for implementation of piping works in accordance with schedule, procedures, specifications, priorities and isometrics issued for construction.

4.2. PLANNING ENGINEER Planning engineer is responsible for planning the spool fabrication according to priorities of piping activities of site, informing Spoolgen Supervisor to provide the spool drawings and Isogen data accordingly. He is also responsible to release the request of piping materials according to fabrication schedule.

4.3. FABRICATION ENGINEER(S) AND FOREMEN They shall ensure safe and efficient working environment, monitor plant and equipment requirements and ensure that the productivity and the quality are maintained by their subordinates. They are responsible for ensuring proper material, welding consumables and welding procedures are applied.

4.4. PIPING ENGINEERS Are responsible for: - Ensuring proper documentation and control of spool drawings used for fabrication. - Request piping materials as per schedule. - Liaise with contractor representative(s) to solve related technical issues. - Coordinate with other sections and disciplines on site.

4.5. WELDING SUPERVISOR AND FOREMEN Welding Supervisor and foremen are responsible to ensure the quality of welding, for the safe working practices of welders, adherence to approved correct welding procedure. They will ensure corresponding welding consumables and responsible to following the consumable stock and ordering them. They are also responsible in monitoring the welders productivity.



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4.6. QC MANAGER, ENGINEER & TECHNICIANS QC manager is responsible for all Quality Control Activities related with pipe prefabrication activities together with his engineers and technicians.

4.7. SPOOLGEN SUPERVISOR Spoolgen Supervisor is responsible to produce spool drawings according to priority of the fabrication, defined by planning engineer.

5. METHOD OF EXECUTION

5.1. PIPE CUTTING Spool drawings approved by GAMA-Qatar and LINDE ENGINEERING AG QC departments will be released by planning engineer to fabrication engineer(s) according to priorities of erection and fabrication. The Spool lengths will be determined according to the pipes in stock and these lengths will be stated in the erection drawing, as a result there will be minimum length adjustment during site erection.

Fabrication (piping) engineer will prepare cutting plan for pipes accordingly, request the pipes, fittings from material supervisor and will give the same information to cutting foreman. Cutting foreman will arrange cutting and planning activities according to RFC drawings. CS and TT pipes will be cut to the length either by cutting disc or by saw cutting or by plasma cutting or by motorized flame cutting or by automatic pipe cutting & beveling machines. After flame cutting a min. 2mm material will be removed from the cut surface by grinding. Ref. DEP 31.38.01.31 for cutting and beveling preparation. CN pipes will be cut to the length either by inox cutting disc or by plasma cutting or by inox saw cutting or automatic pipe cutting & beveling machines with inox apparatus. Flame cutting of CN is not allowed. Marking for traceability: Identification mark that is composed of spool number, part/pos. number, quality and heat number of the pipe will be written on the part with a permanent marker by the operator who cuts it. Permanent free of chloride markers or markers suitable to S.S. will be used to for heat nos. traceability in S.S. Pipes.

5.2. WELD EDGE PREPARATION CS and TT pipes will be beveled either by portable pipe lathe or on by portable grinding disc or by automatic pipe hot or cold cutting or beveling machines or by CNC operated pipe beveling machine. CN pipes will be beveled either by portable pipe lathe with inox apparatus or on by portable inox grinding disc or fixed inox cutting or beveling machines with inox apparatus or CNC operated pipe beveling machine with inox apparatus.



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5.3. BRANCH CUT-OUTS It will be done for CS and TT pipes by either marking with templates and cutting by flame cutting devices, or by chip removal processes or by CNC plasma pipe cutting beveling machine depending upon the diameter and thicknesses. It will be done for CN pipes by either marking with inox templates or inox chip removal processes or if it is available by CNC plasma pipe cutting beveling machine will be used depending upon the diameter & thicknesses. During these procedures inside of pipes will be protected with suitable materials to avoid deterioration.

5.4. FIT-UP AND ALIGNMENT Before fit up, all parts of spools will be checked for inside cleanliness. For But-welding of all piping components (e.g. pipe ends, fittings and welding neck flanges), a uniform root gap shall be provided as specified in the relevant welding procedures specification and ANSI / ASME B 16.25. Fit up of spools will be done on the benches or on working tables or on tripods whose heights are adjustable. Careful attention will be given to the CN pipes and spools which are not allowed to contact to CS and TT steel spools, during fit up and store CN spools and pipes will get in contact with wooden timber or suitable materials. First, the high low conditions and matching faces are going to be checked. If some mismatch higher then below the mentioned tolerances is detected. This will be corrected and ensured that the wall thickness after alignment is not reduced below the minimum required wall thicknesses. End profile of the pipes & fittings will be butt welded and will be maintained according to the requirement of ASME B 16.25.

5.5. TACK WELDING Tack welding shall be carried out by qualified welders. Tack welds will be 25mm in length and equally spaced around circumference in sufficient number to support pipe. Tack welds, which are to be incorporated into the final weld, will be ground to a feather edge. Defective tack welds will be ground out prior to welding and PT or MT will be applied for surface inspection. All Surfaces to be welded shall be thoroughly cleaned from oxide scale, oil or other foreign matter and kept dry. Weld number will be marked on each connection and spool reference Number shall be stenciled in black color as follows in all cases: Spools up to 18 Dia. On the outside of the spool. Spools above to 18 Dia. On the inside of the spool. For material traceability, material Check list will be filled out during the process. The QC will be called for fit-up inspection and the drawing dimensions: beveled ends, tack weld and marking visual checks will be performed. With the satisfactory result by QC inspection, release for weld will be given by writing FT OK on each connection.



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5.6. PREHEAT AND INTERPASS CONTROL Preheat will be applied by gas torches and maintained over a distance of 2t or 100 mm whichever is larger either side of the joint, measured on the outside surface. Preheat temperatures will be measured temperature indicating crayons.

5.7. WELD INTERRUPTION At least 50% of the joint or the root and second pass, whichever is the greater will be completed before welding joint is cooled to ambient temperature.

5.8. WELDING Welding will be performed with approved WPS as mentioned on welding plan table by qualified welders. Welder ID, filler material batch no, PWHT, NDT results will be filled out during fabrication. The main pipe will be welded. Then the branch connections will be done. Welder numbers will be marked on each connection. All root pass should be done by GTAW welding. After welding in S.S. the root pass should be checked with magnet which is a witness point by QCI. After completion of welding inspections described in ITP will be applied. With the satisfactory results of inspection the spool or part will be forwarded to PWHT, if required.

5.9. PWHT Heat treatment will be applied in compliance with the drawing requirements with the proper means, either by mobile or by stationary equipment, according to approved Preheat Treatment Procedure. The time-temperature diagram will be checked for prescribed parameters. Upon satisfactory results of heat treatment, NDT of the welds will be carried out.

5.10. REWORK If it happens that unsatisfactory results were obtained by inspections, non conformance will be reported by QC and the necessary method of rework will be decided. Upon approval of the COMPANY, it will be applied. After eliminating the non-conformance and repeating the remaining manufacturing and inspection operations, PWHT and NDT operations will be applied.

5.11. NDE NDE of process and power pipe work shall be in accordance with LINDE ENGINEERING AG approved procedure. Certified operators shall be employed for NDE



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Radiography shall be taken normally at night hours and in dedicated area specified for the work. On approval of RT joints by LINDE ENGINEERING AG, the same shall be offered for radiography on specified format to NDE contractor. All joints to be RT checked shall be tagged with Blue ribbon for identification. The RT operator shall remove the Blue ribbon on completion of radiography. The radiography film shall be submitted the next day for approval to LINDE ENGINEERING AG. Repair joints if any shall be tagged with Red ribbon. Radiography repair shall be carried out under the supervision of welding inspector and reoffered as above. After NDT clearance, prefabricated spools shall be released for painting/storage. Prefabricated and painted spools shall be released to field on request with traceability. Before releasing for painting there should be a check by piping QC for any distortion. The Piping spools should be tagged with line no. & spool no. for traceability.

5.12. MATERIAL HANDLING AND STORAGE

Raw pipes and fittings will be transported from the warehouse/yard to the shop yard using mobile cranes, trailers and boom trucks. Handling of the pipe materials/spools inside the shop shall be with E.O.T. crane, fork lifts and manual trolleys. Spools shall be shifted from the shop to the radiography area to painting/storage/field, painting to storage with mobile crane, trailer and forklifts. Spools shall be stacked on wooden sleepers with identification markings on top. Spools shall be stacked unit wise and area wise. Register shall be maintained for storage showing spools numbers stored in each location and issue to site. All open ends of spools shall be covered using end caps/plastic sheets or suitable material. All flange faces shall be protected with wooden/plastic covers.



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6. QUALITY ASSURANCE

A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented through relevant QCP T-4.250.935, ITP T-4.250.920 and relevant QCRs.

7. 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 through GAMA Qatar Site Safety Induction, LINDE ENGINEERING AG Safety induction and QSGTL Safety Induction for site safety, health, environmental and security prior to work activities. Other training courses will be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as required. At a minimum a generic Risk Assessment will have been prepared by the RAT ranking the hazards associated with project works and control measures to be taken to mitigate the hazards to an acceptable level. Each work scope or task will have a completed and approved JSA 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 Pre-Task meeting and his weekly TBT. In addition to the above, employees conducting survey works will wear required PPE and highly visible vest where traffic or other hazards may exist. For additional safety requirements for a particular or specific task please refer to the JSA prepared for that task.

8. ATTACHMENTS

8.1. JOB SAFETY ANALYSIS

JOB SAFETY ANALYSIS FORM

JSA For: T-4-250.903 Page No: 1 of 8 Job being analysed: Prefabrication of Spools

JSA Members: Department/Section doing JSA: HSSE & Construction Job Performers:

Normal Approvals: Name Signature Date JSA by:

General job requirements / Common Personal Protective Equipment.

Job Supervisor:

Additional Approvals (Determined by Job Supervisor in correlation with Linde HSSE Manager). Name Signature Date Discipline Superindent (Linde)

HSSE Representative (Linde)

1.The following Personal Protective Equipment shall be worn: Approved coveralls, safety goggles, safety helmet, safety shoes and gloves.

2.Permit To Work.

OTHERS (List Below):

Approval required for hazardous work detailed in the Linde Work Permit Procedure. Changing conditions and emergency procedures Stop work. Switch off 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. LINDE EMERGENCY TELEPHONE NO. HSSE MANAGER: 583 40 72 Pearl HOT LINE : 474 88 88

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JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T-4.250.903

SCOPE : METHOD STATEMENT FOR CS, TT & CN PIPE PREFABRICATION

Initial Risk Residual Risk

HAZARDS / POTENTIAL RISK MAIN ADDITIONAL ITEM ACTIVITY CONSEQUENCES P C RANK CONTROLS CONTROLS P C R

1.1 Personal injury, back injuries, muscle strains, sprains.

C 4 MED

1.1.11.1.2 1.1.31.1.41.1.5

Worker to wear appropriate gloves. Break the load into manageable portions. Lift with your legs not your back. Use the buddy system, Get help.Provide pictorial sign boards with correct lifting position.

1.1.3.1 Provision for lifting aids when practical.

B 2 LOW

1.2 Slip, Trip & Fall from same level

B 3 LOW

1.2.11.2.2 1.2.31.2.4

Adequate stacking of materials. Regular housekeeping practices and removal of trash and unnecessary items. Maintain access and walk paths. Housekeeping shall be a priority, walk and work areas shall be kept free of materials and supplies.

1.2.1.1 Remove unnecessary materials in the work place.

B 1 LOW

1 Manual handling of pipes materials.

1.3 Hand and finger injuries.

C 4 MED

1.3.1 1.3.2

Wear approved PPE, safety goggles, safety helmet, safety shoes, gloves, high-vis vests Keep away hand and finger from moving parts.

1.3.1.1 Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed. B 2 LOW

2 Mechanical movement to laydown area

2.1 Crushed injuries

B 4 MED

2.1.12.1.2 2.1.3

Provide warning sign. Personet to be trained in single/ banksman techniques in order to ensure the material is loaded in a safe manner Provide trained&qualified banksmen


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2.2 Falling materials.

D 4 HIGH

2.2.1 2.2.2 2.2.3

Ensure materials are fully secured by competent and certified rigger.Use of tag lines to control the load. Wear approved PPE, safety goggles, safety helmet, safety shoes, gloves, high-vis vests


2.3 Lifting hazard

C 5 HIGH

2.3.1 2.3.2 2.3.32.3.42.3.52.3.62.3.7 2.3.8

Ensure that crane operator is certified by Third party, valid certificates and driver's licenses. Ensure that all lifting gear/lifting tackle is properly inspected and color coded. Third party inspections. Competent Riggers. Daily crane inspections. Automatic safe load indicator. Tag lines are to be used to control loads. Barricade the working area with sign boards indicating crane lifting is in progress to prevent unauthorized entry.

2.3.1.1 2.3.1.2

Suitable equipment is to be used to lift the steelwork. Proper set up of crane; i.e. out riggers fully extended.

B 3 LOW

3 Cutting of pipes 3.1 Hand and finger injuries. C 4 MED

3.1.1 Wear approved PPE, safety goggles, safety helmet, safety shoes, gloves, high-vis vests

B 1 LOW

3.2 Manual handling of pipes.

B 3 LOW

3.2.1 Approved quality hand gloves, available in a full range of sizes to ensure proper fit to maintain dexterity.

B 1 LOW

3.3 Pipe cutting machine.

D 5 HIGH

3.3.1 3.3.2 3.3.3

Competent operators, trained on the machine they operate. Ensure that the guards are properly installed and are being used. Post near machine the manufacturers safe operating procedures in different languages.

3.3.1.1 3.3.1.2 3.3.1.3

Post the manufacturer safe operating manual near the machine and HSSE office. Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed. Ensure equipment were properly color coded and inspected prior to use.

B 3 LOW

3.4 Damage to eyes. Personnel injury. B 2 LOW

3.4.1 Personnel carrying out gas cutting operations will wear suitable eye protection/PPE.

B 1 LOW

3.5 Defective equipment.

B 3 LOW

3.5.1 3.5.2 3.5.3

Daily inspection of equipment by operator prior to use according to manufacturers recommendations.Current Contractor inspection certificate. Monthly equipment inspection and color code.

3.5.1.1 Proper maintenance performed by maintenance department according to manufacturers recommendations. B 1 LOW

3.6 Cylinders explosion or Fire

D 3 MED

3.6.1 3.6.2 3.6.3 3.6.4

Oxygen cylinder valves/fittings to be kept free from grease/oil.. Flash-back arrestors to be fitted at two ends of hoses and non-flow check valve near cutting torch. Gas hoses and gauges to be maintained in safe conditions & inspected daily. Defective hoses and gauges are to be replaced immediately. Cylinders to be used in the vertical position and secured against falling.

3.6.1.1 3.6.1.2

Proper maintenance performed by maintenance department according to manufacturers recommendations. Ensure equipment were properly color coded and inspected prior to use. B 2 LOW

3.7 Fire hazard.

C 2 LOW

3.7.1 3.7.2

Suitable measures e.g. Provision of fire blankets/fire watchers, will be taken to prevent the risk of fire during cutting operations. Provide suitable fire extinguishers at site.

3.7.1.1 Removal of combustible material near the area.

B 1 LOW

4.1 Grinding hazards

D 3 MED

4.1.1 4.1.24.1.3 4.1.4

Grinders to be maintained in good condition and inspected prior to its use. Provided with color coding for the month. Guards to be fitted to grinders. Changing of abrasive wheels to be carried out by trained & authorized personnel using proper disc spanner. Grinding operations will be controlled in order to prevent the risk of injury to other personnel from sparks/metal splinters.

4.1.1.1 4.1.1.2

Provision of grinding shields to contain sparks in proximity Personnel carrying out grinding work will wear suitable eye protection.

B 2 LOW

4 Alignment, fit-up, and welding of random lengths pipes.

4.2 Noise hazards. B 2 LOW

4.2.1 Ensure employee wear appropriate hearing protection.

4.2.1.1 Provide warning sign. B 1 LOW

4.3 Electric shock C 2 LOW

4.3.1 Welding machine to be effectively grounded. Welding gear to be properly insulated.

B 1 LOW

4.4 Fire hazards

C 2 LOW

4.4.1 4.4.2

Suitable measures e.g. Provision of fire blankets/fire watchers, will be taken to prevent the risk of fire during cutting operations. Keep flames, sparks, molten slags and hot metal from coming in contact with combustible materials.

4.4.1.14.4.1.2 4.4.1.3

Discuss in TBT/ HIP. Provision of suitable fire extinguisher in the near area. Removal of combustible materials near the area. B 1 LOW

4.5 Pinch point

B 2 LOW

4.5.1 4.5.2

Ensure competent employee will carry out the task. Ensure employee wear appropriate hand gloves.

4.5.1.1 Discuss in HIP/TBT.

B 1 LOW

4.6 Slip, Trip & Fall from same level

B 2 LOW

4.6.1 4.6.2

All tools must be kept in a suitable holder to prevent it from being tripping hazard. Remove unnecessary materials in the work place.

4.6.1.1 Provide adequate stacking of materials.

B 1 LOW

4.7 Fall of pipe during fine alignment

B 4 MED

4.7.1 4.7.2 4.7.3

Use chain puller or chain block in lifting pipe during fit-up works. Cable sling shall be inspected before use. Provide adequate supports to hold pipe.

4.7.1.1 4.7.1.2

Use of A-frame connected to the chain block. Pipe jack to be used as secondary support for the pipe. B 1 LOW

5 NDT Work 5.1 Health risk due to radiation exposure.

B 3 LOW

5.1.15.1.2 5.1.3 5.1.4 5.1.5

Isolate/Barricade the area. Ensure competent persons will carry out the tasks. Protective shields (time & distance);Use/ shields (time & distance). Provide warning signs, proper access during testing. Schedule of NDE test requiring radiation should informed in advance to make aware the employees.

5.1.1.15.1.2.1 5.1.3.1

Discuss in HIP/ TBT. Ensure all work shall be supervised at all times. Obtain Permit to Work.

B 1 LOW

6 Grooving and Threading at Fabrication Shop

6.1 Fall of materials.

D 3 MED

6.1.1 6.1.26.1.3

Ensure materials are fully secured by competent & certified rigger. Use of tag lines to control the load.Wear approved PPE, safety goggles, safety helmet, safety shoes, gloves, high-vis vests


6.2 Slip, Trip & Fall B 2 LOW

6.2.1 Housekeeping shall be a priority, walk and work areas shall be kept free of materials and supplies.

6.2.1.1 Removal of unnecessary materials. B 1 LOW

6.3 Electric shock

B 3 LOW

6.3.1 6.3.2 6.3.3

Ensure all hand tools will be visually inspected prior to use, kept in good repair and used only for intended purpose. Check electrical equipment prior to use.Ensure it is properly inspected, color coded for the month and properly documented. Ensure all electrical equipment were properly grounded and built with ELCB at their source.

6.3.1.1 Ensure tools are of correct type, size and they are in good condition and color coded as required.

B 1 LOW

6.4 Cuts injury B 2 LOW

6.4.1 Ensure employee should wear correct leather hand gloves.

B 1 LOW

6.5 Eye, hand & finger injuries

B 2 LOW

6.5.1 Ensure employee wearing suitable safety gloves, safety glasses and safety shoes, safety helmet when handling steel pipe.

B 1 LOW

6.6 Overloading

B 2 LOW

6.6.1 6.6.2

Use safe rigging equipment for lifting of materials. Ensure that it is color coded for the month and properly documented and registered. Loading will be closely supervised with trained/certified banks men.

6.6.1.1 The weight of such load will be determined to ensure that overloading is prevented.

B 1 LOW

7 Welding works 7.1 Electric shock

B 3 LOW

7.1.1 7.1.2 7.1.37.1.47.1.5

Ensure100% grounding system. Grounding cable must be clamped near the joint to be weld. Welding cables, electrical cords must be properly insulated. Ensure equipment is of correct type, size and they are in good condition and color coded as required. Ensure good electrical connection.Ground the work being welded. Maintain the electrode holder, work clamp, welding cable and welding machine.

7.1.1.1

7.1.2.1

7.1.3.1

7.1.5.1

Ensure all electrical equipment were properly grounded and built with ELCB at their source. Dont touch electrically live parts with skin or wet clothing. Insulate yourself from work and ground. Dont allow any live electrical parts to touch the ground.

B 1 LOW

7.2 Burn Injury

B 2 LOW

7.2.1 7.2.2

Wear appropriate protective clothing, safety jackets, welding apron, gloves, face shield. Ensure work area properly barricaded and displayed warning signs to warn the workers.

B 1 LOW

7.3 Electrocution and burns.

B 2 LOW

7.3.1 7.3.2 7.3.3

Do not weld on containers having combustible materials (paints / thinner). Do not weld on containers having combustible materials (paints / thinner). Keep a fire watch

7.3.1.1 Maintained suitable fire extinguisher in the welding area.

B 1 LOW

7.4 Fumes & gases

B 5 MED

7.4.1 7.4.2

Provisions for mechanical ventilation. If not possible, use correct respirator. Ensure the right positioning of welders head & the used of electrode.

7.4.2.1 Refer to MSDS.

B 2 LOW

7.5 Arc rays

B 3 LOW

7.5.1 Ensure employee wear a suitable eye protection.

7.5.1.1

Only competent and trained employee will carry out the tasks. B 1 LOW

7.6 Slip, Trip & Fall from same level due to cluttered area. B 3 LOW

7.6.1 Keep cables, materials, tools neatly organised.

7.6.1.1 Housekeeping shall be a priority, walk and work areas shall be kept free of materials and supplies.

B 1 LOW

008-MECH-PIPING CS,TT & CN Pipe Prefabrication.pdf1. INTRODUCTION 1.1. GENERAL 1.2. SCOPE 1.3. PURPOSE 2. REFERENCE3. DEFINITIONS 4. RESPONSIBILITIES 4.1. PIPE PREFABRICATION SUPERVISOR 4.2. PLANNING ENGINEER 4.3. FABRICATION ENGINEER(S) AND FOREMEN 4.4. PIPING ENGINEERS 4.5. WELDING SUPERVISOR AND FOREMEN 4.6. QC MANAGER, ENGINEER & TECHNICIANS 4.7. SPOOLGEN SUPERVISOR

5. METHOD OF EXECUTION 5.1. PIPE CUTTING 5.2. WELD EDGE PREPARATION 5.3. BRANCH CUT-OUTS 5.4. FIT-UP AND ALIGNMENT 5.5. TACK WELDING 5.6. PREHEAT AND INTERPASS CONTROL 5.7. WELD INTERRUPTION 5.8. WELDING 5.9. PWHT 5.10. REWORK 5.11. NDE 5.12. MATERIAL HANDLING AND STORAGE

6. QUALITY ASSURANCE 7. HSSE 8. ATTACHMENTS 8.1. JOB SAFETY ANALYSIS

008-ms for prefabrication of cs,tt & cn pipe spools.pdf

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