method state fab 123

Method Statement for Piping Fabrication & Installation

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A) FABRICATION

1. PURPOSE

This procedure describes the general requirements for shop & field fabrication, installation and inspection including, carbon steel and stainless steel for Integrated Gas Development (IGD) Project, Das Island (except for FRP piping and HDPE piping).

2. SCOPE

It should be noted that this document is intended to present CONTRACTOR's plan for accomplishing the work but is not intended to provide every detail on how the work will be executed. In addition to the information contained in this procedure, CONTRACTOR will carry out fabrication and installation work to meet the requirements of drawings, technical specification, standards and codes as set out in the contract. In case there are any conflicts between this procedure and contract document, the later shall govern.

3. DEFINITIONS

Company: ADGAS / IGD Das Island Project.

Project: This shall refer to the subject contract for Integrated Gas Development (IGD) Project.

Contractor: Hyundai Heavy Industries.

Document: Include output in the form of hard copy, drawing, tracing, reproducible, & field inspection reports.

4. RESPONSIBILITIES


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4.1 Construction Manager

Constructions Manager has the overall responsibility for this Method Statement and is responsible for supporting it and for ensuring that all entitles at the Worksite actively participate.

4.2 Deputy Construction Manager (Piping)

Deputy Construction Manager (Piping) has the responsibility for compliance with this Method Statement and shall ensure that review contract documents and provide all resources necessary to effectively implement throughout the construction period.Deputy Construction Manager (Piping) shall review the construction details and specification with piping Engineers & ensure they should fully understand the requirements of the job. Deputy Construction Manager (Piping) shall ensure that all personnel involved in the project are fully aware of all quality control requirements. Deputy Construction Manager (Piping) shall monitor the quality and progress of the work plus ensure projectSchedules are achieved. Deputy Construction Manager (Piping) shall identify any problem, which may affect completion or progress of the job & produce proposals for submission to ADGAS / IGD Construction Manager for resolving the problem.

4.3 Piping Engineer / Supervisor

Piping Engineer / Supervisor shall ensure that relevant quality control check sheets / report formats are available and duly completed where identified on Inspection and Test Plans (ITP). Piping Engineer / Supervisor shall report any problem that may affect quality, completion or progress of the job to the Deputy Construction Manager (Piping). Piping Engineer / Supervisor shall give support to QC Inspector for ensuring that required inspection and tests are attended and any defects noted are rectified to the satisfaction of the Company. Piping Engineer / Supervisor shall coordinate receipt of materials with Material Controller and supervise lifting and offloading to the site. Piping Engineer / Supervisor shall ensure that the equipment and tools required for carrying out the job are available, maintained and used in safe manner. Piping Engineer / Supervisor shall produce all necessary records / diaries for the confirmation of workscompleted and pass to QC inspector as required.


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4.4 QC Manager

QC Manager has overall responsibility for all QC activities of the project. He shall beinteracting with related to all Piping QC activities. He shall be responsible for Non conformance management and Quality Audit.

4.5 QC Engineer

QC Engineer shall be responsible for the QC activities, material control and traceability, Nonconformance management and compilation of test packs for Hydro / Pneumatic Test.

4.6 QC Inspectors

QC Inspectors shall be responsible for Site QC activities, co-ordination with HSSE authorities for NDE works, Piping/Welding department for inspection activities and NDE sub contractor for NDE works at site.

4.7 Welding Engineer

Welding Engineer shall be responsible for welding control activities. He shall be responsible for the execution of correct welding techniques / control with strict adherence to this Method Statement and reference documents.

4.8 HSSE Officer

HSSE Officer shall monitor the HSSE aspects of the work and ensure that they are carried out, and advice supervisors for corrective measures, if required. He shall ensure holding of pre task TSTI covering details of specific tasks and specific job risks involved to the work force involved. He shall also ensure appropriate mode of communication in case emergency.

5. RELEVANT SPECIFICATIONS AND CODES


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HHI (and subcontractors) shall apply the most recent applicable standards and codes issued by the following associations and approval bodies as part of this specification.

5.1 Specifications

1) GD-100-A4L-5-94043: Specification for piping design2) GD-100-A4L-5-94097: Specification for pipes3) GD-100-A4L-5-94099: Specification for flanges4) GD-100-A4L-5-94098: Specification for fittings5) GD-100-A4L-5-94100: Specification for Bolt/nut6) GD-100-A4L-5-94101: Specification for gaskets7) GD-100-A4L-5-94096: Specification for valves8) GD-100-A4L-5-94049: Specification for hot insulation9) GD-100-A4L-5-94050: Specification for cold insulation

5.2 Codes

5.2.1 American Petroleum Institute (API)

API RP14: Recommended practice for design and installation of offshore production platform systems

API SPEC 5L: Specification for line pipeAPI STD 590: Steel line blanksAPI STD 598: Valve inspection and testing

5.2.2 American Society of Mechanical Engineers (ASME)

ASME B1.1 Unified Screw ThreadsASME B1.20.1: Pipe Threads, General PurposeASME B16.5: Pipe Flanges and Flanged FittingsASME B16.9: Factory made Wrought Steel BW FittingsASME B16.10: Face to Face & End to End dimensions of valves (for Dummy spools)ASME B16.11: Forged Fittings, Socket Welded and ThreadedASME B16.20: Metallic Gaskets for Pipe FlangesASME B16.21: Non Metallic Gaskets for Pipe FlangesASME B16.25: Butt-Welding EndsASME B16.36: Steel Orifice FlangesASME B16.47: A Large Diameter Steel FlangesASME B31.3: Process PipingASME B36.10M: Carbon Steel PipeASME B36.19M: Stainless Steel PipeASME Ⅱ Part A: Materials-Ferrous Materials Specifications


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ASME Ⅴ: Non-Destructive ExaminationASME Ⅸ: Welding and brazing qualifications

5.3 Project Documents

1) GD-100-A4L-5-94045: Piping Material Classes.2) GD-100-A4Z-5-90102: Project quality Audit Procedure.3) GD-100-A4Z-5-90104: Material Receiving Inspection Procedure.4) GD-100-A4Z-5-90105: Non conforming item control procedure.5) GD-100-A4Z-5-90107: Material Identification and Traceability procedure.6) GD-100-A4Z-5-90109: Welding consumable control procedure.7) GD-100-A4Z-5-90110: Qualification procedure for welder and welding operator.8) GD-100-A4Z-5-90116: NDE procedure for piping.9) GD-100-A4Z-5-90121: Inspection and Test Plan for Piping.

10) GD-100-A4Z-5-90504: PWHT procedure for Piping.11) GD-100-A4Z-5-90505: Flushing and HYDRO test Procedure for Piping.12) GD-100-A4Z-5-90506: Bolt tightening procedure for piping.13) GD-100-A4Z-5-90507: Chemical cleaning and Oil-flushing procedure.14) GD-100-A4Z-5-90013: Painting procedure.

6.1 General


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The procedure applies to all piping fabrication including carbon steel and stainless steel within packaged units or other sub-assemblies. It does not apply to FRP and HDPE piping or to instrumentation piping and tubing downstream of the first block valve.

6.2 Fabrication Area

Fabrication of different materials like carbon steel and stainless steel materials will be carried out in separate designated areas in the fabrication yard.

Carbon steel, stainless steel and high alloy materials and low-alloy ferrite steel will be fabricated in separate areas.

Welding of carbon steel and stainless steel shall be kept separated by using cubicle type isolation, at least 1800 mm high to ensure that all possibilities for contamination of stainless steel and high alloy materials with ferrous materials i.e. carbon steel grinding particles are eliminated between carbon steel and stainless steel. Stainless and high alloy materials will be stored in separated areas on the timber lined floor of the stock area and will be moved by the use of web slings or by hand into clean timber/rubber lined trestles/work benches. There shall be no direct contact between carbon steel and stainless steel material under any circumstances. Tools for use on stainless steel and high alloy materials will be kept in separate tool boxes under the control of the material controller and foreman. All tools such as wire brushes, cutting tools for facing machines will be identified by color codes for carbon steel, stainless steel materials as per the material control procedure.

6.3 Material Control


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In regard to the material control, HHI and subcontractors will refer to the material receiving inspection procedure. (GD-100-A4Z-5-90104)All materials, whether loose or pre-fabricated will be stored as per the HHI material control standards

Material found to be defective or incorrectly marked or lacking relevant documentation shall be immediately placed in a quarantine area, separated from accepted material with sufficient safeguards to preclude it being used.

6.3.1. Carbon steel and non ferrous materials will not be transported stored in such a way as to cause cross contamination of the materials as per the material control procedure.

6.3.2. All flange faces including gasket grooves in ring joint flanges shall be prevent direct contact with foreign materials

6.3.3. All materials, whether loose or prefabricated will be stored as per the material control procedure.

6.3.4. Any re-facing that reduces the flange thickness to less than minimum thickness allowed by the relevant code or standard will be rejected. Edge thickness of flange will be checked after re-facing.

6.3.5. Materials (pipes, fittings and others, etc.) shall be received separately from the material control department as specified on the material requisition sheet, issued by the production design department. Material control department shall control and issue the material in accordance with the COMPANY approved material control procedure.

6.4 FABRICATION SEQUENCE


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Spool Fabrication Flow:

Note: Insulation for Welded joints should be carried out after the Hydro Test.

6.4.1 Marking:

Marking shall be clearly painted in characters 50 mm high, where spool size permits. For small bore Piping, tagging (Aluminum strip with punch marking) shall be used.

6.4.2 Cutting and Edge preparation:

6.4.2.1 Carbon steel shall be cut by of flame cutters, high speed cutters, and grinder or band saw machines.

6.4.2.2 Stainless steel, high alloy steel shall be cut by high speed cutters, grinders or band saw machine. Saw blades used for cutting carbon steel are not to be used for cutting non-ferrous material.

A) Large sized pipes (above 28" NPS) and holes of branch connections shall be cut by a plasma arc cutting machine. When cutting starts, if access permits, a receiving basket for spatters shall be inserted in the inner cutting area of the pipe to avoid adherence of spatters to internal wall of pipe.


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A detailed sketch / drawing is shown in Figure 1

B) If the cutting area is inaccessible, a spatter compound is applied to the inside cutting area by brush, roller or swab. The application of the compound is applied completely around circumference, a minimum of 200mm on each side of the cutting area. After cut, the anti-spatter compound shall be removed by cloths or other methods.

6.4.3. All materials cut by a flame or arc shall have the edge ground back to clear the affected zone.

The grinding wheel is marked by an impregnated red dye in the make-up of the disc which denotes chloride and sulfur free material when used for stainless steel and high alloys. Wire brushes with stainless steel bristles will be used, dedicated to stainless steel and high alloy materials.

Files for use on stainless steels and non ferrous alloys shall be new and dedicated to a particular alloy only. Certificates for chloride and sulfur free construction materials. (Doc no: GD-100-A4Z-5-9________)

6.4.4 All edges shall be accurately maintained as per design requirement with a smooth even surface with all slag removed.

6.4.5. Edge Preparation for Welds

6.4.5.1. The preparation of edge for welding shall be done by machining or grinding.


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6.4.5.2. Edge preparation shall be performed in accordance with the approved W.P.S & ASME B 16.25

6.4.5.3. The surfaces of the edge shall be free from tears, grease, oil slag, scale or internal burrs.6.4.5.4. Stainless steel and high alloy pipe shall be beveled by a grinding or beveling machine only. Separate machines will be used for carbon steel and stainless steel.

6.5. Fit up.

Fit-up inspection of assembly.

Inspection of fit up assemblies shall be done and the relevant reports shall be duly filled in. (DOC No: GD-100-A4Z-5-9________)

6.5.1. Alignment for the fit-up of the piping components shall be executed on a steel floor or steel jack stand for carbon steel spools.For stainless steel and high alloy spool fabrication, the floor will be covered with wooden planks or rubber. All stands will be insulated with clean rubber sheet to prevent contamination of the spools. Under no circumstances stainless steel, high alloy & non ferrous materials shall be allowed to come into contact with carbon steel.

6.5.2. The number of welds in a spool shall be in accordance with approved spool drawing. The minimum spacing between circumferential weld joints shall be 2“ or 6 times the wall thickness of the pipe, whichever is greater, unless otherwise approved by COMPANY. Pipe lengths less than 3 m long shall not normally be welded together.

All flanges, fittings and pipe to be welded together should be provided for same internal bore. However internal radial alignment due to differences in tolerances for bore up to 100mm should not exceed 1.0 mm. If exceed, it shall be taper-trimmed, machining may be conducted to improve root alignment providing the taper is not steeper than 1 in 4.

Misalignment may be alleviated by the use of hydraulic or screw type clamps except where ASME B 31.3 paragraph 335 shall apply.

If component ends must be trimmed to correct internal misalignment, it should not reduce the finished wall thickness below the required wall thickness for the pipe or fitting including all mechanical, corrosion and erosion allowances.

Hammering, jacking or heating the pipe is not permitted.


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The bolt holes of flanges shall straddle the normal horizontal and vertical centerline of pipe.

Holes for attachment of weldolets and nippolets shall be made using drills or hole saw and all burrs shall be removed.

Welded branch connections including integrally reinforced branch connection fittings, which abut the outside surface of the pipe wall, or which are inserted through an opening cut in the pipe wall, shall have the opening contoured to the branch to provide a good fit.

6.5.2.1. Fit-up for maximization of auto welding (1G)

The above spool shall be separated into (1), (2) and (3) sub spools.W1 of (1) spool and W3 of (2) spool and W5 of (3) spool shall be fitted up by GTAW process as per approved WPS (Doc No.: GD-100-A4Z-5-90511) by COMPANY and taped-up to prevent contamination. After completion of fit-up (1), (2) and (3) spools shall be transported to welding area for automatic welding (1G).

6.5.2.2. At the welding area, W1, W3 and W5 of each sub spool shall be welded by 1G as per approved WPS by COMPANY. After completion welding of W1, W3 and W5 joints, the spools shall be transported to the fit-up area for completion.

W2, W4 and W6 joints of above sub spools cannot be welded by automatic welding process (1G). So, these joints will be welded by a manual welding process i.e., GTAW + SMAW or GT+SM+FC or GT+FC as per the approved WPS by COMPANY. The above method is established for maximum utilization of automatic welding (Doc No.: GD-100-A4Z-5-90511)

6.5.2.3. If the above work flow requires inspection, the component spools are inspected by inspection as per approved ITP.

6.5.2.4 Maximum fabricated spool dimension shall be 12 m x 2.5 m x 2.5 m or the largest transporter available on the site.


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6.6. Welding

All root runs in non ferrous pipe to be done by the GTAW process and carbon steel where cleanliness is concerned.

Welding shall not be allowed on piping after Post Weld Heat Treatment, unless specifically authorized in writing by COMPANY and in accordance with ASME B31.3 “Chemical Plant and Petroleum Refinery Piping”.

6.6.1. All welds shall be performed in accordance with the approved WPS which shall be displayed on a notice board close to the work.

6.6.2. The welding grooves shall conform to the ASME B 31.3 and ASME B 16.25 and approved WPS.

6.6.3. All edges of surfaces to be welded shall be cleaned to a bright metal finish, in a manner suitable to remove any oxides, scale, grease, oil or contamination due to flame cutting or machining.

Oil paint and dirt shall be removed from the pipe surface for at least two inches from the bevel before welding is started. Cleaning must be carried out just prior to tacking and repeated just prior to welding. Stainless steel wire brushes shall be used for all other materials except carbon steel and low alloy steel

6.6.4. No sealing or back-up rings shall be used.

6.6.5. Any cracks, blowholes, cold laps, unusual irregularities, slag, flux, or other impurities that appear on the surface of any welding bead shall be removed by grinding or chipping before depositing the next successive bead.

In the case of submerged arc welding of carbon steel and low alloy steel, the removal method used may be air arc gouging, which shall be cleaned out by grinding to shiny metal. Longitudinal weld seams shall be located to clear openings and external attachments.

6.6.6. The requirement of the finished weld reinforcement for all materials should comply with ASME B 31.3 specification for piping.

Longitudinal weld seams on seamed pipe shall be out of phase at inline butt welds, and any welded attachments such as branches, instrument connections or pipe support attachments shall not bisect any seam welds.


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The minimum rotation for welded long seams shall be 10 times the wall thickness of the pipe or 90 deg out of phase, whichever is less.

The alignment of the abutting ends shall minimize the offset between surfaces. The offset shall not exceed 1.6mm. Pipe longitudinal seams shall be positioned in the upper half of the pipe circumference. Adjacent pipe seams shall be separated by 90° or by a distance of 250mm, whichever is the less.For pipes of the same grade and diameter, but different wall thickness, alignment may be achieved by tapering the thicker pipe at a gradient of not steeper than 1 in 4.

6.6.7. Two welders may be required on pipe φ400 mm and above pipe, to be marked with welder's I.D No. for area welded.

6.6.8. If arc strike occurs, this shall be removed by grinding with COMPANY's prior approval. The ground area shall be inspected by MT (carbon steel & low alloy) or PT (stainless steels & non-ferrous alloys). The remaining wall thickness shall not be less than the stipulated minimum, as stated in specification ASME B 31.3. If pipe is ground severely to repair, the damaged part of the pipe shall be removed.

6.6.9. Internal purge of argon shall be used for the GTAW process root pass on stainless steels and non-ferrous alloys as specified by WPS.

6.6.9.1. Purging will be carried out by using the best method for the particular application during welding and shall be maintained until 6 mm of weld material deposited.

The sketch below demonstrates:


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6.6.9.2. Each end of the pipe adjacent to the weld of tie in spools shall be dammed by using water soluble paper or sponges at a distance of 150 mm from the weld prep.

6.6.9.3 For all materials, pipe butt joint of 2 inch and below shall be made

6.6.9.4The GTAW process shall be used for root pass of all diameters.6.6.9.5. Where purge dams are used a register of dams installed should be maintained and signed off when dams are removed particularly during spool erection.


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6.6.9.6. All sealing tape used shall be of a kind that is safe to use on stainless and alloy steels.

6.6.9.7. No undercut or overlapping (cold lap) is permitted.

6.6.9.8. The specification for weld projection and depression should be in accordance to ASME B 31.3, Table 341.3.2, as applicable.

6.6.9.9. Preheating and inter pass shall be maintained as per approved WPS.

6.6.9.10. Peening and hammering of weld runs are prohibited.

6.6.9.11. Branch connections and outlets

A. All welded branch connections shall be as allowed by the project piping material class and be welded with full penetration welds.

B. Stub-in connections shall be set-on type as per ASME B 31.3,

C. Reinforcement pads or saddles required by specifications and drawings shall be of the same material as the main pipe (unless specified otherwise) and shall be formed and countered to provide a good fit to both main and branch pipe.

D. Branch reinforcement pads or each segment thereof shall be provided with a minimum 6.0 mm drilled and tapped hole (hole to be filled with silicone or grease after testing to prevent ingress of moisture) prior to fitting to the pipe . The threaded opening shall be sealed with a piping plug after hydro test.

E. Attachment welds of non-pressure parts by welds, which cross existing main welds or for which the distance between the attachment weld toe and existing main weld is less than 50 mm should be avoided. If unavoidable the area to be welded over shall be subject to 100% radiographic or MPI as directed by CONTRACTOR and witnessed by COMPANY. After welding the welds an adjacent area shall be similarly examined.

F. In case of stainless steel, marking shall be done with weather proof chalk (chloride free crayon), low chloride marking pen (less than 100 PPM) or engraving.

G. The method will be used for the permanent marking for welder identification, in lieu of marking the weld, appropriate records shall be filed as per approved inspection procedure. After spool installation, testing and final reinstatement of stainless steels and


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non - ferrous alloys, all markings shall be removed using an appropriate solvent or pickling paste.

6.6.9.11. Storage and issue of consumables shall be done by COMPANY approved procedure.

6.7. Qualification of welders and welding operators:

6.7.1. All welding procedures, welders & reference to be used shall be qualified in accordance with ASME B 31.3 paragraph 328.2 and ASME IX articles II and IV.

6.7.2. Performance qualifications will be carried out for all welders and welding operators in accordance with the requirement of ASME IX.

6.7.3. All welders should always keep their identification cards at all times with their name, number, photograph signed by CONTRACTOR surveyor.

6.7.4. The qualification limits and ranges for WPS / PQRs and welders will to be based on ASME IX.

6.7.5. For acceptability of the test weld shall be judged, , Please refer the Doc no………………………………………..

6.8. Tack Welds6.8.1. Prior to performing main welding, tack welds shall be done by either GTAW or SMAW as determined by the approved W.P.S.

6.8.2. For tack welds, preheating shall be performed in accordance with WPS. Where tack welds are made, the preheat temperature shall be 25 ° C h i g h e r than the preheat temperature for the weld joint.

6.8.3. Tack welds shall be made by qualified welders.

6.8.4. The length and number of tack welds for the diameter of pipe being welded shall be specified as follows (see table):


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DIA (mm) L.T. (Length of Tack) Number of Tacks

Up do 50 mm Min 10 mm Min 3

50 -150 mm 10-15 mm 3-4

Over 150 mm 20-25 mm 4-6

6.8.5. Permanent tacks of the desired penetration and workmanship, and conforming to 3.2.7.1 ~ 4 need not be removed before welding unless handling may have caused the tacks to crack. Any crack tacks will be completely removed by grinding and grinding areas to be checked by MPI or PT.

6.9. Temporary Attachment

Piping fabrication and installation shall be achieved by use of clamps, Jigs, fixtures, etc., without welding to the pipe or fitting.

6.9.1. The use of cleats, bridge pieces, tacking strips or other attachments welded temporarily to pipe work to facilitate fabrication shall be of the same or equivalent material as the pipe work to which they are supposed to be attached. Temporary attachments shall be completely and carefully removed prior to any PWHT that may be required. Where removal is by air-arc gouging or flame cutting, the cut shall be such that 3 mm of the temporary attachment is left for final removal by grinding. Removal by hammering or bending is not permitted. Initial fitting up can be achieved using temporary bridge tacks across the groove, with certification material same type & grade as parent material.

6.10. Threaded and Socket Welds

6.10.1. Screwed or threaded connections shall not be used on process piping. Threads shall be concentric with outside of pipe, per ASME B 31.3, tapped and cleaned out.


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6.10.2. All surfaces of threaded joints shall be checked before connection, and any dust, oxide and grease shall be removed

6.10.3. When socket weld fittings are used, pipe shall be spaced approximately 1/16 inch (1.6 mm) away from the "bottom" of the socket. Minimum gap is to be 3/64 inch (1.2 mm) and maximum gap to be 1/8 inch (3.2 mm).

6.10.4. All threaded joints, where no seal welding is provided, shall be packed with fiber reinforced gasket-seal compounds (Loctite 577 or equal).

6.10.5. Screwed connections subject to seal welding shall be made without the use of sealing compound.

6.10.6. Seal welding of threaded connections, when specified, shall include the first block valve, cover all threads using the GTAW process with a minimum of two passes and be done with electrodes not to exceed 1/8" inch (3.2φ) in diameter.

6.10.7. The joint shall be cleaned of all cutting oil and other foreign material and made up dry to full thread engagement, before seal welding.

6.10.8. Thermo wells shall be attached as per approved spool drawing.

6.10.9. Seal welded and threaded piping shall not be substituted for socket weld piping connections without prior written approval by COMPANY.

6.10.10. Unless otherwise stated on approved drawing or specifications, pipe threads shall conform to ASME B 20.1 and ASME B16.11.

6.11. Material Segregation

All material coming shall be segregated at site, with a safe manner

(Before construction, during construction and before removal for installation all material will be staging at site As per requirement)

6.12. Tolerance

6.12.1. The dimensional tolerance should be in accordance with Figure 2 attached.


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The alignment and fabrication tolerances for piping butt welds shall be in accordance with Figure 3 attached.

6.12.2. Flattening measured as the difference between maximum and minimum outside diameter at any cross section of bent pipe shall not exceed 8% of the nominal outside diameter.

The pipe wall thickness on the outside of the pipe bent shall remain within the specified pipe wall thickness schedule manufacturing tolerance as per applicable ASTM. The inside wall thickness shall not display any curling or cracks.

6.12.3. Linear tolerances are ±3/32” (3mm) for line sizes NPS 10” (DN250mm) and under, ±3/16” (5mm) for line size NPS 12” (DN300mm) through NPS 24” (DN 600 mm) and +1/4" (6.4 mm) for line sizes over NPS 24” (DN 600 mm)

Linear dimensional tolerances shall be applicable to dimensions measured from a common datum for the relative locations of branches, flanged or butt-weld ends and shall not be cumulative.

Before bolting up, flange faces shall be aligned to the design

Plane, measured across any diameter within: +1.5 mm

Flange bolt holes shall be aligned within: + 3 mm

Specified angles for bends or branches shall be within: + 0.25º


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Application of Pipe Fabrication Tolerances

Figure 3

Alignment and Fabrication Tolerances for Piping Butt Welds


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6.13. NDE and Repair of defects

6.13.1. Extent of welding test shall be examined in accordance with the approved NDE procedure for piping.

6.13.2. Root concavity shall be accordance with the ASME B 31.3 table 341.3.2.

6.13.3. Undercut shall be limited to 0.5 mm occasional, intermittent. No internal undercut is allowed.

6.13.4. NDE and visual inspection should be performed in accordance to ASME B 31.3 for piping.

6.13.5. All repairs and initial NDE will be completed prior to stress relieving of the pipe spools. When welding is carried out under a WPS which has been qualified with PWHT, the weld is not complete until the PWHT is complete. NDE for final acceptance shall only be accomplished after the weld is complete. (before finalizing we need confirmation fro Mr HHKim)

6.13.6. The surface of repair welding will be cleaned thoroughly before welding in accordance with applicable W.P.S. After gouging for removal of defects the area shall be ground smooth and shall be tested by MPI (carbon steel) or PT (non-ferrous steel)

6.14. STORAGE / STAGGING

6.14.1. Before delivery, checks will be made to ensure that all end covers are in place on piping spools to prevent ingress of dirt and moisture.

After final completion of carbon spool fabrication, carbon spools will be transferred to the painting area. Before transfer to painting area, spools should be blown thru or internally swabbed to remove contaminants.

6.14.2. After completion of painting, the spools shall be stored on pallets as per the pallet control system. For preservation, all flanges and gasket surfaces shall have all openings suitably sealed. Flanged openings shall be sealed with steel flanges at least 5 mm thick with oil resistant rubber gaskets and at least four full diameter bolts. Studded opening shall be secured with all nuts needed for the intended service and rubber gaskets. The threaded openings shall be sealed with solid-shank threaded plugs before moving the pallets.


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6.14.3. The Engineering Department will sort and select the spool as per the line system in order to install the spools on the equipment or part or equipment conveniently. The Piping Fabrication will fabricate the spools as per the line system

6.14.4. After completion of fabrication, stainless steel, high alloy & Non Ferrous spools are transferred to the pipe stock yard directly and segregated from carbon steel spool

6.14.5. Spools for yard installation and off-shore hook up and all pipe ends will be protected by caps, plywood or equivalent methods attached to flanges to prevent ingress of dirt etc.

6.14.6. All threaded nipples and bosses shall be protected using waterproof tape or equivalent material to prevent damage to the threads.

6.15. Painting

A protective coating will be applied in accordance with the COMPANY specification and approved painting procedure.

Procedure for Painting Doc. no. GD-100-A4Z-5-90xxx

After the installation of piping spools , touch up & insulation of the field welded joints can be carried out after the successful completion of hydro Test.

6.16. Inspection, Cleaning and Testing

Inspection will be done in accordance with the COMPANY specification (……………..) and Material Control Procedure (Doc No. …………………………..),

Cleaning shall be carried out in accordance with COMPANY specification (…………….) and testing shall be carried out in accordance with the COMPANY specification (…………………….).

6.17. Preparation for Shipment (Ship loose)


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Polythene sheet will be placed between the flange and the plywood to prevent the cover absorbing the grease.

6.17.1. Carbon steel & Low-alloy ferrite steel

6.17.1.1. Carbon steel flange face, including gasket grooves in ring joint flanges, shall be cleaned of all mill scale, rust etc and shall be coated with rust inhibitor to prevent rust formation. Each flange face shall be covered with a plywood cover held in place by hot dip plated bolts of at least 1/4" diameter. Up to 50% bolting may be used with a minimum of four bolts or tie-wraps.

6.17.1.2. Carbon steel spools with beveled or grooved ends shall be thoroughly cleaned and coated with rust inhibitor to prevent rust fabrication. Each end shall be protected by a closed type plastic protector securely held in place with a minimum of three layers of waterproof tape.

6.17.2. Stainless steel, High alloy & Non Ferrous material

All beveled and grooved ends shall be prepared as per the paragraph above, except that ends do not require the rust preventive coating.

6.18. INSTALLATION TOOLS AND EQUIPMENT


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6.18.1. All Construction Equipment shall be inspected and approved by ADGAS /IGD Third Party Inspection in accordance with Equipment Check List prior to work inside ADGAS / IGD Area.

6.18.2. The following equipment may need to be used for this work

A) Cranes

B) Compressors

C) Welding Generators

D) High Frequency sets for Welding

E) Welding Sets

F) Gas Cutting Sets

G) Grinding M/Cs

H) Hand Tools

I) Propane Heating Torches

J) Gas Cylinders (Argon, Oxygen, Acetylene, Propane)

K) Pick-Up

L) Trailers

ATTACHMENTS


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1. Job Hazard Analysis

JOB HAZARD ANALYSIS

Job / Task: Shop /Field Fabrication of Piping

JobStep No.

Description Hazard / Potential Incidents Control Recovery / Measures

1 Mobilize Men and Equipments

1.1 Engaging unskilled and in-Experience workers

1.2 Use of defective tools andEquipments

1.3 Injury accidents due to improper handling of tools and equipments

1.1.1. Engage skilled workers for the work1.1.2 All workers will be inducted by ADGAS /IGD for safety1.2.1. Implement equipment pass system1.2.2 All equipment will be certified by ADGAS /IGD with third party certificate for all lifting equipments1.3.1 First aider on site Emergency response plan in place1.3.2 Emergency communication telephone numbers issued to site staff

2 TSTI 2.1 People not familiar with the Job and Hazards involved.2.2 Poor understanding of workers2.3 Poor safety attitudes of workers2.4 Subject matter incomplete

2.1.1 Conduct tool box talks by line supervisor and safety offices (Confirm understanding)2.2.1 Use local language and to be simple and concise2.3.1 Safety Audits and Unsafe act auditing2.4.1 Counseling and Training Disciplinary action as last result

3 Loading /Unloading the Pipes

3.1 Unauthorized Lifting Cranes3.2 Failure of Lifting slings and dropping the materials3.3 Personal standing on the trailer while Loading/ Unloading3.4 Too many signal confusing the operator

3.1.1 Ensure Lifting crane is inspection and certified byADGAS / IGD

3.2.1 Ensure Lifting slings and tested / Inspected and correct color coded

3.2.2. Ensure by visual inspection lifting slings are in good condition and free from damage3.3.1 No personal are allowed to stand on trailer before the piping materials reaching to the trailer deck or while lifting the material from the trailer deck.3.4.1 Engaging trailer & Approved Rigging person as banks man for signaling

JobStep

Description Hazard / Potential Incidents

Control Recovery / Measures


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No.4 Welding of Carbon

Steel &LTCS Piping

4.1 Face injury / Skin burns while working

4.2 Electricity- Electric shock, Electrocution

4.3 Confined space working

4.4 Defective tools and machine

4.5 Due to sound

4.1.1 First aider in site Emergency response plan in place4.1.2 Welders gloves ,apron, leggings, long sleeve cotton coverall, welding mask, Dark glass, face shield, eye goggles to be used4.2.1 Earth welding generators4.2.2 Check Electric cable for damage and replace any defective material4.2.3 Use fire blanket to cover pipe coating4.2.4 Fire extinguisher to be provided near welding4.3.1 Check the permit to work4.3.2 Proper ventilation to be provided4.3.3 Cool drinking water to be provided at all times4.3.4 Emergency medical evacuation facility to be available4.4.1 All machinery will be certified by ADGAS / IGD4.5.1 Proper PPE will be ensured

5 Manual Handling 5.1 Handling with improper Posture may result to back injury

5.2 Work piece –Sharp edge on work piece may cause injuries or hot work piece may cause burn

5.3 Slippery surface or obstruction at walk ways may lead to falls or trips resulting to injury

5.1.1 Observe proper lifting posture, Minimize manuallifting , use lifting equipments Provide properaccess to work place and ensure constant supervision5.2.1 Report to dress up sharp edges on work piece , Use hand gloves5.3.1 Carry out housekeeping daily before shift end Inform supervision any obstruction in work area

6 Mechanical Lifting 6.1 Lifting equipment (Faulty slings & cranes defects)6.2 Untrained personnel unsafe crane positioning , ground condition, liftingload

6.1.1 To use certified , color coded lifting equipments regular maintenance and third party inspection to be carried out6.2.1 To deploy trained operator, signaler and bankman

7 Electrical Operated hand tools

7.1 Damaged wiring may cause shock or electrocution

7.2 Defective or incorrect use of handtools leading to personal injury

7.1.1 Inspect electrical tools prior to and during use7.1.2 Report defect to supervisor7.1.3 Use double insulation type tools7.1.4 Wear hand gloves7.1.5 Deficiencies shall be rectified immediately7.1.6 First aider on site Emergency


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7.3 Flying metal fragments, weldspatters, grinding

response plan in place7.2.1 Inspect electrical tools prior to and during use7.2.2. Report defect to supervisor7.2.3 Do not defective tools7.2.4 Deficiencies shall be rectified immediately7.2.5 Correct tool usage shall be supervised7.2.6 First aider on site Emergency response plan in place7.3.1 Wear safety goggles, protective cloth and face shield attached with helmet7.3.2 Inspect grinding disc for damage before use7.3.3 Install safety sign / protection coverFirst aider on site Emergency response plan in place

8 Emergencies 8.1 Inadequate ER Plan8.2 Poor emergency response forworkers8.3 Inadequate communicationEquipment8.4 Emergency contact numbers notavailable

8.1.1. Follow ADGAS /IGD Emergency response plan8.2.1 Scheduled for emergency exercise / Drills to be carried out8.3.1 Adequate communication equipment e.g. hand phone provided to essential field supervisor staff8.4.1 Readymade pocket sized card with emergency numbers to be provided


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B) INSTALLATION METHOD

8. PURPOSE

The purpose of this Method Statement is to ensure that define the general sequence of events, interfaces and responsibilities relating to Above Ground Piping Field Installation works for the ADGAS / IGD, DAS Island Project.

9. SCOPE

The scope of this Method Statement covers to the objective and requirement of steps to followed and applicable to Above Ground Piping Field Installation for the IGD DAS Island Project.

10. RESPONSIBILITIES

10.1. Construction Manager

Constructions Manager has the overall responsibility for this Method Statement and is responsible for supporting it and for ensuring that all entitles at the Worksite actively participate.

10.2. Piping Manager

Piping manager has the responsibility for compliance with this Method Statement and shall ensure that review contract documents and provide all resources necessary to effectively implement throughout the construction period.

Piping Manager shall review the construction details and specification with Piping Engineers and ensure they fully understand the requirements of the job.

Piping Manager shall ensure that all personnel involved in the project are fully aware of all quality control requirements.

Piping Manager shall monitor the quality and progress of the work plus ensure project schedule are achieved.


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Piping Manager shall identify any problem, which may affect completion or progress of the job and produce proposals for submission to Construction Director for resolving the problem.

10.3. Piping Engineer/Supervisor

Piping Supervisor shall obtain the required clearance from IGD regarding completion of above ground field installation in accordance to lines and levels within the permitted deviations stated in the Reference documents as described in Chapter 4.0.

Piping Supervisor shall ensure that relevant quality control check sheets / report formats are available and duly completed where identified on Inspection and Test Plans (ITP).

Piping Supervisor shall check that welders and fitters are working to the current approved editions of Drawings, MS ITP, Welding Procedure Specification (WPS) schedules, and that obsolete information is removed from the place of work.

Piping Supervisor shall report any problem that may affect quality, completion or progress of the job to the Piping Manager.

Piping Supervisor shall give support to QA/QC Inspector for ensuring that required inspection and tests are attended and any defects noted are rectified to the satisfaction of the client

Piping Supervisor shall ensure that quality levels are maintained.

Piping Supervisor shall ensure that required daily check sheets are completely signed off and maintained.

Piping Supervisor shall coordinate receipt of materials with Material Controller and supervise lifting and offloading to the site.

Piping Supervisor shall ensure that the equipment and tools required for carrying out the job are available, maintained and used in safe manner.

Piping Supervisor shall produce all necessary records / diaries for the confirmation of works completed and pass to QA/QC inspector as required.


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10.4. Rigging Manager

Rigging Manager/Supervisor shall physically examine the job site and the equipment to be used prior to the lift. He shall be physically present to supervise all lifts that requires his expertise. He shall assume full responsibilities for the rigging works.

10.5. QC Manager

QC Manager has overall responsibility for all QC activities of the project. He shall be interacting with related to all Piping QC activities. He shall be responsible for Non conformance management and Quality Audit.

10.6. QC Engineer

QC Engineer shall be responsible for the QC activities, material controller and traceability, non conformance management and compilation of test packs for Hydro / Pneumatic Test.

10.7. QC Inspectors

QC Inspectors shall be responsible for Site QC activities, coordination with HSSE authorities for NDE works, Piping/Welding Department for inspection activities and NDT work at site.

10.8. HSSE Coordinator

HSSE Coordinator shall be responsible for monitoring all site activities and ensuring compliance to safe work procedures and best practices.

10.9. Rigging Foreman

The Lifting Foreman is responsible for lifting and ensures the lifting procedures for pipe launching is followed to the fullest directives of ADGAS / IGD regulations. He will be responsible for checking the lifting tools such as slings, shack, shackles, and chain blocks. He will conduct tool box meeting to riggers and discuss launching plan before any launching commences.

10.10. Piping Foreman

The Pipefitters’ assigned will follow the procedures for fitting random pipes on the pipe rack.


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10.11. Welding Foreman

Welding Foreman is responsible for all welding works base on Welding Procedure Specification and conducts daily TSTI for all welders.

10.12. Pipe Fitter

The Pipe Fitters groups including Helper helps the riggers in hauling or moving the pipe, raising or lowering chain blocks and monitoring every aspect of pipe installation.

10.13. Riggers

The Riggers will follow the lifting procedures as planned by the lifting foreman. He will conduct tool box meeting to the pipe fitters and discuss proper fit-up for random pipes.

10.14. Banksman

- Controls the movements of equipment by giving signals to the operator.

- Assists operator to safety maneuver the equipment in congested areas where people are working.

- Controls the movement of people while the equipment is in operation.

- Erects necessary barricades to control access of vehicles and to clear out all people from the equipment.

- Banksman is the eyes and ears of the operator of the machine wherein he sees nothing (blind spots).

- Checks the area for any obstacles like other equipments, excavations, trenches, people, etc.

- Must stop operator by using whistle and hand signals if there is any danger which concerns people or other machine.

- Always stay behind the operator’s view or otherwise machines can be dangerous to Banksman as well as to the workers.


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11. CONSTRUCTION PLAN

11.1. Introduction

The successful completion of construction in accordance with the approved schedule and contract requirements will be dependent upon a through, logical and practical construction plan. This plan details the guidelines to be utilized for carrying out all field activities directly related to construction of the permanent facilities.

The plan will commence during mobilization and will continue in effect until permanent facility construction is completed and demobilization well in advance.

The activities coming under the construction plan are interrelated. This construction plan must be compatible with the associated plans such as piping installation, welding and testing: that comes under the overall execution plan for the project.

11.2. Construction Operation Support

Detailed planning will begin for all temporary facilities, construction utilities, construction Equipment, tools, consumables and miscellaneous services required to support construction operations.

All such requirements will be frequently reviewed throughout the course of the work to ensure that all items of construction operations support are adequately provided as required to properly maintain the construction efforts.

Preliminary plans regarding the various construction operation support requirements, arranged alphabetically by subject, are as follows;

11.2.1. Construction consumables

Construction consumables such as welding rod, grinding wheel, cutting wheel, etc., shall be correctly stored at site and stock records will be provided at site.

Issuance of construction consumables will be closely controlled to ensure that wastage is minimized and that adequate quantities are always available to provide proper and continuous support of construction operations.

Specially, welding rods will be controlled by QC Inspector welding rod control procedures.

11.2.2. Construction Equipment


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All construction equipment will be brought on board and when required and will be available on site for the estimated periods indicated in the construction equipment schedule.

Rigorous initial inspections will be performed to ensure that all arriving equipment are in good condition and suitable and safe for the intended use.

It is intended to establish facilities at site for performing of normal serving, maintenance and minor repairs of construction equipment. However, equipments requiring major repairs or overhaul will be sent off from the site and will be replaced, if required, with ones in good condition.

11.2.3. House Keeping

Construction areas will be kept in a neat orderly and clean manner so as to maintain good, efficient working conditions and reduce safety hazards and sanitation problems.

Trash will not be permitted to accumulate throughout the work areas but will be continually removed to designated temporary trash storage areas.

Before Installation (Erection) & after Installation the area where to be installation carried out should be kept clean & clear.

The supervisor will frequently monitor job site cleanliness activities in his assigned construction area to ensure that accumulations of waste materials and rubbish are minimized.

11.2.4. Tools

To maintain high efficiency, all craftsmen will be outfitted with suitable tools. It is intended that adequate warehouse stocks of tools will be maintained on site. Frequent HSSE inspections of individual tools will be made to ensure that all tools are in safe working condition.

11.3. Construction Personnel Support

At an early arrangement will be finalized for the provision of all job site support required ensuring the efficient and safe performance of all personnel.


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Preliminary plans regarding the various construction personnel support requirements, arranged alphabetically by subject, as follows. As a part of the construction temporary facilities an equipped first-aid box will be provided.

11.4. Quality Control

To obtain the maximum advantage from an effective Quality Control Plan, contractor shall embrace the whole range of the project activities. To this effect, it is essential to maintain the continuity of responsibility between the various phases of the project.

The criteria to be followed in order to ensure the compliance of construction works with the established quality requirements will be indicated in proper procedures to be prepared during the engineering stage.

Technical supervision, inspection and testing at site are the responsibility of each supervision and his team.

They verify and document that welding, piping installation works done comply with the approved WPS, procedures and established quality requirements, conducting the inspections as per the ITP,

He also carries out his own inspections to verify compliance with Specifications, Drawings and ITP’s as follows;

11.4.1. Conform that the ITP for piping prefabrication work is in place.

11.4.2. Conform availability of the latest revision of drawings.

11.4.3. All piping material & welding consumables shall be conforming to specifications, construction drawings and WPS.

11.4.3. All measuring Instruments shall have valid Calibration Certificates.

11.4.4. Area to be welded shall be cleaned of paint, grease, dirt, etc.

11.4.5. Enclosure shall be used for welding works when there is wind or dust of unacceptable nature.


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11.5. Drawings

Document controller will distribute all relevant Company approved drawings (Approved for Construction) such as Isometrics, Plot Plan drawings and P & ID to the Piping Manager and Piping supervisor.

11.6. Materials

The materials to be used will comply with Contract Requirement & applicable Standards/ specifications. Materials will be inspected by QA/QC engineers to ensure that they are not defective and are incorporated with Contract Requirements.

All material test certificates will be verified by Material Controller QA/ QC Engineer prior to issue for construction. All materials used for fabrication and installation shall be prior inspected and released by QC Inspector as per the requirements of related Standard and as per Codes described.

12. Welding Procedure and Welders Qualification

QA/QC engineer will ensure that all welding procedures are approved by Company in accordance with the Contract requirements, prior to commencing any welding works. Welders will be qualified as per Welding Procedure Specification (WPS)

12.1. Welding Consumables

All welding consumables will be controlled as per WPS. (GD-100-A4Z-5-90511)

13. Installations

13.1. Preparation

Bevel end/edges on pipes and fittings shall be prepared by means of the thermal cutting and grinding to provide a reasonably smooth true weld surface.

Preheat may be applied during bevel edge preparation and while thermal cutting, if required. Whenever cutting is employed, all oxides and traces of previously melted and notches will be removed from edges by grinding or machining.

Cutting will be made considering suitable allowance taken into account for shape of connections and shrinkage due to cutting and welding.


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Special care will be taken to remove internal burrs resulting from cutting, especially on Pipes ≤ 2” Diameter.

Surface and end preparation for welding will be as defined in the applicable qualified WPS (Welding Procedure Specifications).

Bevelling and welding end preparation will be in accordance with specifications and approved welding procedures.

13.2. Handling, Storage and Transportation

All spools will be handled by means of wide sling bands or belts to prevent damage to the painted piping. Wherever possible spools fabricated in the piping shop will be transported from storage area to the site area and installed.

Pipe spools will be stocked in designated areas as possible to the installation area. All fabricated spools shall be protected properly from the damage of material, painting and spool tags.

During installation pipe should be warped rubber tape on the section of pipe passing through sleeve.

All the transported spools will be covered by polyethylene papers/plywood pieces on both sides of the spool and also any other opening like vent, drain, instrument tapping, branches, etc., during resting.

Pulling/Dragging activities of spools are prohibited to avoid the damage of painting, material damages.

13.3. Cleaning Requirement

The external and internal surface at the cutting edge of the pipe joint will be cleaned by a hand brush and or mechanical wire brush (buffing wheel) for a minimum distance of 2” (50mm) from the fusion face to prevent contamination in Heat affected Zone(HAZ) of the weld area.

Bevel face to be welded and HAZ will be smooth, uniform, and free from fins, tears, cracks, lamination, or other defects which could adversely affect the quality and strength off weld.


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Also bevel face and HAZ will be prepared free from loose or thick scale, rust, grease oil paint, moisture and any other materials that would prevent proper welding.

13.4. Tagging / Marking

Pipe racks/tracks/equipment and routing shall be tagged or marked with respect to piping GA drawings, ISO-drawings and or other related drawings prior to installation of piping components. After rectification and instruction from QA/QC Engineer for released for piping, piping installation shall be started.

The straight lengths of pipes, which do not require any prefabrication in the shop, will be shifted from the paint shop after the painting, the site location where it will be directly installed with the mention area.

In case of prefabricated spools from lay down area a Spool Request Form shall be used for the request and intimated to piping spool coordinator at the spool lay down area.

Piping foreman shall make arrangements of transportation of the pipe spools to field as per the requests received by the field piping supervisors.

Where possible, supports to be welded on the pipe shall be completed prior to installation work at the fabrication shop. All necessary NDT shall be completed as per the specification.

If supports are to be welded at the field for the purpose of any field adjustments the supports may be tack welded at the fabrication shop and forwarded to the field.

All permanent supports as per piping isometric drawing shall be installed along with piping installation. (Temporary supports shall be provided and shall be removed when permanent supports are in place)

13.5. Accuracy and Tolerances

Accuracy and dimensional tolerances of pipe spool shall be checked and assured as per the detailed drawings and applicable to Field Fabrication of Piping specification and ASME B31.4.

The dimensional tolerance for finished piping will confirm to the followings:


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- All linear dimensional involves in the relative position of branch connections, Flanges, ends and changes in direction will be maintained within ±1/8”(±3mm)

- The availability of a pipe bends as a measured difference between the maximum and the minimum diameters at any cross-sectional area of a bend will not exceed 8% of the nominal outside diameter of the straight portion of the pipe.

- Lateral transition of branch connection will be ± 1/8”(± 3mm)

- Rotation of flanges from the indicated position measured as shown will be within 1/16” (±1.5 mm)

- Alignment of flanges and branch-welded ends measured across any diameter will not deviate from the indicated position more than 0.75mm (1/32”)

- All angular dimensions of bends and branch will be maintained so that out of alignment will be within the tolerance.

13.6. Flange face alignment

Flanges connecting to rotating equipment (pump, compressors, etc)

The flange face alignment check shall be performed with bolting inserted loosely, and the acceptance criteria shall be as given below

Flange Diameter at OD Maximum misalignment at OD of flange<300 0.2 mm

300 to 600 0.3 mm≥ 600 0.5 mm

13.7. Tie -In

13.7.1. Piping connections to equipment shall be properly aligned without imposing any stress on equipment nozzles.

13.7.2. Following pre-alignment of the equipment to the required elevations as per relevant drawings the pipe work shall be connected to the equipment nozzles within the manufacture's tolerances or within the following.


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DescriptionNPS

< 12” (300mm) < 22” (560mm) < 24” (600mm)

Vertical bolt hole

offset

1/8” (3mm) 1/16” (1.5mm) 1/64” (0.4mm)

Horizontal bolt hole

offset

1/8” 1/16” 1/64”

Rotational offset 1/8” 1/16” 1/64”

Flange face

parallelism

1/64” 1/64” 1/64”

Flange face

separation, plus

space for gasket

±1/8” ±1/16” ±1/64”

13.7.3. Final bolting of the flanges shall be carried out after completion of coupling alignments.

13.7.4. Flanged connections shall be tightened diagonally in counter clockwise direction to obtain an even gasket contact on the flange faces.

13.7.5. Flange bolting shall be carried out using a calibrated torque wrench to bolt manufacture’s recommendation. The bolting torque shall be per ASME B 16.5.Once the nuts are tightened per the required torque, a minimum of three (3) threads shall protrude from each nut.

13.7.6. Except as noted, for all piping system fastening shall be with stud bolts. The length of the stud bolt shall be as per ASME B16.5.


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13.8. Pipe Fit-up and Alignment

Pipe fit-ups shall be prepared by tack welding. Qualified welder will carry out before welding of joints.

Piping components will be adequately supported and aligned through the use of jig clamps, or other suitable devices as required in order to avoid deformation and to minimize strains during tacking. Also temporary stoppers/restraints will be provided before starting of welding to avoid distortion/cambering during welding.

Welders will be instructed to weld both sides of pipe alternatively so that welding shrinkage is made most minimum.

Welder will be advised to get help of fitter to check the right angle/parallelism of flange etc. in between different passes to minimize the bulking effect.

Ends of pipe-to-pipe or pipe-to-fitting joints will be aligned accurately.

Special care will be taken regarding internal misalignment which must not exceed 1/16” (±1.5mm) in order to facilities welding of the root pass.

On joining pipes or fittings of different wall thickness, the internal surface of the thicker part will be tapered and chamfered to meet the wall thickness of the difference in wall thickness of the two parts in accordance with ASME B31.4

Special care will be taken in order to avoid a reduction of all thickness in the part having the lowest yield strength.

Prior to pipe alignment, each pipe or fitting will be inspected to ensure that the outside and/or inside surfaces and bevels are free from foreign materials.

Piping connecting to the nozzles of the equipment such as pumps, vessels will be aligned so that no stress is induced on the equipment.

Qualified fitters have to take care for proper alignment of flanges to pipes and connecting equipments including connection to relief and control valves is of great importance to keep equipments stress free for trouble free operation of the system.


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13.9. Supports

Pipe supports for shop-fabricated spools will be installed based on the construction drawings.

13.10. Pipe Spool Installation

Piping spools shall be positioned in the location & slope (if any) to be maintained as shown on the approved construction drawings.

Temporary support can be used during installation so that no bowing/sagging/ overhanging deficiencies, or other unbalanced displacement exists.

Rigging of piping spools shall be performed in a manner that will not cause any damage to the surface of the material.

If needed to install piping components (valve or other inline components) later, the temporary pipe pieces or spools with the same length as the piping component shall be installed instead of piping components.

During installation of piping all openings (small bores) for pipe connections, all access openings, and all ended pipe (small bores) shall be covered with weather proof covers whenever work is not actually in progress. Temporary covers made of plywood or metal sheet will be used to cover manholes and flanged connections.

Excess pipe lengths shall be cut as per site requirement and checked as per isometric drawings.

Prior to installation, bolts, nuts and gaskets shall be visually exanimate to verify that they are undamaged and corrosion free.

Flange face must be square with the pipe.

All flanged joints shall be made with proper sized bolts(as per drawings/ specification)for that flanged end with uniform bolts stress and the gasket properly compressed in accordance with the design principles applicable to the type of gaskets used.

During installation we will warp rubber tape on the section of pipe passing thru’ sleeve.


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13.10.1. Installation of pipe spools on the Pipe racks

Lifting study shall be carried out by rigging foreman and piping supervisors for the spools to place on pipe racks of higher and lower elevations.

Consider the weight of the spools, geometry of the spool, elevation and location. Accordingly select the capacity of crane, boom length and radius and study the load charts.

Scaffolding shall be erected as required by Scaffolding procedure the others as per v requirements.

Check the dimensions as per QA/QC ISO drawings and cut the excessive length and prepare weld edges of the spools to be joined. Weld edge preparation on the pipe spools, fittings, and flange and valves shall be done as per the requirements of related WPS.

No colour is applied on Tools used for Carbon steel or Low temperature carbon steel materials.

Tools used for Stainless steel shall be identified with red paint markings and blue paint marking for alloy materials.

Permanent and temporary supports as required will be installed on the rack. Place the pipe spool on the rack and ensure proper supporting. The next spool is placed in the similar way.

13.10.2. Installation of piping Components

Lifting and access studies shall be carried out when component to be lifted is more than 15 tone in weight and or when free access is not available.

Piping components shall be lifted and placed in a safe way with the least damage to painting and no damage to nearby components.

Care shall be taken to avoid any undue strain on the piping components during installation works.

Before installing the pipe spools it shall be ensured that there is no foreign material (debris, dust, etc.,) inside the pipe material.


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All necessary measures shall be taken to prevent stainless steel piping components getting into contact with carbon steel and alloy material.

13.11. Installation of Critical Valves

Critical valves such as Control valves, tight shut off valves, emergency shutdown valves, motorised valves relief valves etc. shall be installed to confirm pipe fit up configuration, then removed and replaced by piping spool pieces (Dummy or Pup spools). The spool pieces may be fabricated using temporary piping materials, but must be sufficiently strong to maintain the piping geometry around the valves.

Special attention has to be paid to reinstall all internals of non return valves or any other valve, if any. Dedicated trained crew shall be deployed for reinstalling process. Qualified fitters with correct tools will carry out repacking of valves if damaged/worn out any other components e.g. strainers, sight glasses, level glasses/gauges etc to be checked properly for its location, tag no etc with the drawings to prevent installation on the wrong equipment. Also ensure its bolts, gaskets, glass, plugs etc for proper seating, tightening and have no damage.

13.12. Installation of Stainless Steel, Alloy Piping

13.12.1. Pipe fit up / Alignment.

For stainless steel piping and Alloy Piping without back welding of the internal side, the root pass shall be carried out by the GTAW process (GD-100-A4Z-5-90511)

The fit up of the assembly shall be as per WPS & Drawing requirements. Separate tools like grinding machines, grinding wheels, cutting wheels, wire brush etc. shall be used for Stainless Steel and other alloy piping material with suitable colour markings.

In addition to the welding requirements of ASME B31.3

13.12.2. Inert Gas Purging.

Root run of all welds on process pipe line to be made by TIG welding to avoid internal slag generation unless access to back weld is possible. Paper dams with sticky taps shall not be used, if used at all; it shall be minimum to ensure internal cleanliness of pipe following proper procedure to remove weld dams.


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Low Chloride Masking tapes shall be used for sealing the root gap, end caps and hardboard dams. Soluble dams will be held in place with soluble adhesives. Inert Gas Purging shall be controlled by both the welder and piping supervisor.

13.13. Connection

13.13.1. Ends Connections

End connections of fabricated spool pieces will be in accordance with the following criteria:

Before preparing the fit-up of any field weld of two pre-fabricated pipe spools or pipe with fitting/flange, it is the responsibility of the fabricated to ensure that both adjacent ends are bevelled for field welding and are installed to the drawing dimensions.

Before carrying out any welding, Piping supervisor shall instruct to welder to be aware of nearby/adjacent instruments, cables etc. which are to be protected properly by means of suitable coverings or any other means.

Where a field fit-up is required, one spool piece will have a plain end. The adjacent spool piece will have a bevelled end and will be installed to the dimension indicated.

13.13.2. Branch Connections

All welded branch connections will be joined to the header with full penetration welds as per approved WPS.

Branch connections will comply with the requirements of ASME B31.4

13.13.3. Connection between Underground and above ground piping (If Required)

The connection between the A/Ground piping and U/Ground piping will be flanged connections as shown on the piping drawings (Using Insulation Kit Assembly).

Before the installation of Insulation Kit Assembly, flange parallels’ will be checked test lugs will be welded on either side of the Insulation flange joint.


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The connection flange connecting the underground and above ground piping will be protected against possible damage.

Care will be taken that minimum of 300 mm of above ground piping is wrapped and coated above the finished floor level (FFL) of that specific location where there is a connection between Underground and above ground piping works.

13.13.4. Threaded Connections

Unless otherwise indicated on the drawings, all threads will be tapered on Nominal Pipe Thread (NPT) and concentric to the outside of the pipe.

Normally, all threading of pipe will be carried out after bending, forging, or Heat treatment. When this is not possible, thread must be protected.

Threaded ends of pipe will be clean out without burrs or stripping of threads. Ends will be reamed to remove burrs. The last three threads of the joint shall not be gauged.

During storage, transportation and field assembly, the threaded ends of piping will be protected by threaded caps or plugs to avoid any damage to threads. Teflon tapes to be used for making all threaded connection to ensure leak proof joints.

Where seal welding is required, it shall be performed after the approval of the Company

13.13.5. Alloy and Stainless Steel Piping:

It is to be ensured that minimum 2mm gap is maintained between the pipes a fitting. The socket/seal welding will be of minimum 2 runs.

Sealant approved by the Company will be applied on the outside of male thread and inner side of the female thread before tightening the pipe/fittings, valves, etc.


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13.14. Pipe end preparation

Immediately prior to alignment pipe for welding, the bevelled ends of joint of pipe for minimum distance of 50mm shall be thoroughly cleaned of coating paint, rust adhesions, dirt and any other foreign matter by use power brush or disc wheel.

All damaged pipe ends shall be re-cut and bevelled. When the re-cut is located at a distance of more than 25mm from the original bevel, then the re-cut ends shall be ultrasonically inspected for lamination over a zone extending 100 mm from the newly prepared bevel end.

All required bevels on the piping and tie-ins shall be done by automatic flame bevelling devise.

13.15. Line-up and Clamping

External line-up clamp shall be used for line-up all bore pipe, except at other piping, tie-in, and elbow and others.

Root gap shall be maintained by taper wedge at six locations and same shall be removed on aligning pipe with the clamps. The root gap shall be checked accurately and shall be as per WPS.

Long seams of the straight pipe shall be positioned such that weld is located in the upper half of the pipe circumference and not matching one another but having minimum offset of 50mm.

14. Welding

Where preheat is required for the root run, this shall be applied prior to tack welding and maintained until the joint is completed Ach welding incorporated into the final weld shall be ground to a feather edge at each and to ensure adequate fusion on the root pass.

Welding shall be carried out with single pipes lowered in and joined one after the other.

Prior to fit-up and welding, the groove face and adjacent face shall be cleaned to remove all grease, oil, rust, paint by use of brush, grinding or approved solvents.


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The welding joints surface shall be visually checked for the presence of moisture before Welding. If moisture is present, the joints surface shall be dried by a flame torch or by other approved methods.

The root gap shall be accurately checked and shall be as per approved WPS.

Welding shall not be interrupted during a pass and shall be completed with a speed as mentioned in the approved WPS. Any kind of movement of components, shocks, vibration, bumping stress and other stresses are prohibited while welding is in progress.

While carrying out welding of valves care has to be taken to keep its closure in open condition to prevent damage to the internals, Also to check inside surface of valves remain clean (free from dirt, rust, burrs and any foreign materials)

Distance between welds shall not be less than 2” (50mm) or 5 times the thickness of the thicker component which ever more is unless otherwise.

14.1. Welding Repair

Welding repair shall be performed as per approved WPS.

The cut of the pipe in case of cut-out weld joints shall be re-bevelled

Only two attempts per repair shall be permitted.

Preheating (if required) and inter-pass temperature shall be maintained during all weld repairs.

Final NDE for repair welding shall be performed in accordance with NDE requirements for the original welding.

14.2. Welding Joint Numbering

All welds shall be identified with the welder’s number, weld joint number using a paint marker. Welds made by more than one welder shall be marked by each welder in a similar manner and daily welding report will be maintained.


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15. Inspection

After welding is completed, welding spatter will be removed by chipping and wire brushing. Also, dirt, rust, slug shall be removed to provide clean weld bead for inspection and NDE.

Radiographic testing percentage required and PWHT requirements will be indicated in the isometric drawings.

15.1. Assemble of flange to piping.

Foreign material and protective grease shall be removed from flange face prior to assembly.

After cleaning the flanges for make-up, dry gaskets shall be cantered by the flanged bolts. Cantering of spiral wound type gaskets shall be properly centred.

All bolts and nuts shall be thoroughly cleaned before assembling joints. Bolts shall be long enough to show one to three full threads after proper tightening.

When are aligned, both horizontally and vertically, and faces are parallel, bolts shall be installed with the exception of one or two, and nuts hand tightened. In one of the holes left open, a pin wrench may be inserted to rise or lower either flange as required to ensure proper alignment.

One bolt shall then be tightened sufficiently to keep the gasket seated. The pin wrench shall then be removed and remaining bolt tightened by gradually working around the flange until all bolts are tight with equal tension on each bolt.

The spiral wound type gasket joints, the bolting sequence shall consist of a series of uniform loadings starting with the flange bolt in the 12 o’ clock position, then transferring successively to the 6 o’ clock, 9 o’ clock, etc. bolt positions, increasing the load uniformly each time until the sequence is completed. Bolts shall be tightened until the flanges are uniformly seated on the gasket centring.


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15.2. Temporary Gaskets

All permanent gaskets will be installed during the work where the flange assembly need not opened. Gasket will be protected from damage until final installation is completed.

Blinds made of thin aluminium sheet with blind neoprene gaskets between pump suction and discharge flanges and piping counter flanges to be provided at the time of pipe welding for isolation of pump casing to prevent damage to bearings. Suitable temporary gaskets are also to be provided during testing of lines to isolate pumps and any connecting equipments. Temporary gaskets shall be replaced with permanent gasket during reinstatement phase, prior to Commissioning.

16. Completion Checks

16.1. Punch Clear

After installation of the piping, system shall be inspected for Punch Clearing prior to hydro testing.

The line will be checked by the Piping Supervisor/QC Inspector for any missing supports, inline instruments, instrument tapping etc. Also, it will be ensured that the line is completed in all aspects as per the approval drawings. P & IDs / Isometric.

16.2. Inspection Clearance

QA/QC Engineer will ensure that all NDT and destructive testing are completed.

Pressure testing of piping systems (ISO 14692)

Inspection clearance will be documented in the Punch list and reviewed by the QC Inspector prior to hydro testing.

Category of Punch

Punch “A”: As per site Condition

Punch “B”: As per site condition


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17. HYDROTEST

Hydro test will be carried out as per the project specification and Method statement for the Hydro & Pneumatic Testing. (Doc No GZ-100-A4Z-5-90xxx)

17.1. REINSTATEMENT

After hydro testing, the piping will be flushed and dried Doc No.GZ-100-A4Z-5-90xxx) as per contract specifications Pressure testing of piping systems.

The system will be boxed up with proper size bolts, gaskets, etc., after draining.

All gauges and instruments will be re-installed to original position.

9. HSSE

Piping installation procedure shall be executed in conjunction (but not limited) with the rules and precautions mentioned in HSSE plan.

Contractor will evaluate and prepare Risk Assessment / Job Hazard Analysis of each and every activity involved in the job. It will be approved by HSSE Officer.

The approved Risk assessment will be issued to contractor and the HSSE Officer will ensure that contractor explain every risks involved during the job execution to each and every workman through the daily tool box talks. The risk assessment will also have the details of emergency services like hospital, ambulance, fire services, etc.

Fire fighting equipment: Fire fighting equipment will be provided as per requirement following the CHC HSSE standards throughout the construction areas and temporary facilities areas as follows;

Temporary facilities areas: Fire extinguishers will be located in areas which are easily accessible in case of emergencies.

Construction areas: Fire points will be established where fire extinguishers will be stored and kept ready for use. Additional fire extinguishers will be provided for immediate work areas during certain phase of work that are particularly susceptible to fire.

Equipment: Fire extinguishers shall be provided for each working equipment at site such as welding machines, generators, compressors, cranes etc.


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All the fire extinguishers will be inspected on a monthly basis, maintained in good working order and recharges when necessary to ensure continue serviceability.

RESTRICTIONS:

1. Never put your hands in between pipe ends while pipe launching to prevent entrapment.

2. Never to allow pipe launching at a distant level. The proximity of distance or height in between the load and the structure should be in minimum to prevent swinging of the pipe.

3. Minimum piping/fitting crew consists of pipe fitter, semi skilled pipe fitter and helpers.

10. FORMATS AND REPORTS

All the formats and reports will be utilized from approved ITP and Procedures.

Records of all testing will be kept by the QA/QC Inspector for inclusion in the Construction

Certificate of the materials shall be reviewed and included in the Dossier Records.

- Approved WPS and PQR

- Welder Certificates and cards

- Pre-Fabrication Daily welding reports

- RT and MPI Reports (If available)

- Pressure Test Certificate.

- PWHT Report & Hardness Test

ATTACHMENT

Job Hazard Analysis


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Job / Task: Pipe Launching / Installation

Job Safety Analysis: A/G Piping Field Installation

Supplier Location:

Date:

Job Step No.

Description Hazard / Potential Incidents

Control &Recovery

1 Arrival of Personnel on Site Unfamiliar with local situation

Site Induction cause. All personnel to fully understand to tasks & responsibilities with the use of PPE

2 Check Work Location for space & Obstacle

Insufficient Space Cordon Off Area

Obstacle Present Have Obstacle Removed

3 Enter Work Location Collide with the equipment Follow the approved lope

4 Rig Crane of Lifting Location In adequate ground Follow Approved Procedure

Incorrect Crane Configuration

Follow Rigging Study

Incorrect Position Approved Procedure &Independent Check

Collide With Equipment Clear Instruction & Communication

Unauthorized People in Work Area

Cordon-Off Area & Remove Unauthorized People

5 Load Position Beneath Crane Hooks

See Transport Risk Analysis

6 Attach Lifting gears with Hand Lines to Head Trunions & Tailing Attachments ( Sling & Shackles)

Wrong Lifting Gear

Danger Crush

Follow Approved Lifting Study.Use Only Certified & Tested Lifting Gears

Work at Elevation Approved Procedure & Independent ChecksClear Instruction & Communication and Use of Stairs/ Scaffold or Sky Lift, Man Basket With Safety

ATTACHMENTSJob Hazard Analysis


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Job / Task: Pipe Launching / Installation

Job Safety Analysis: Piping Field Installation

Job Step No.

Hazard / Potential Incidents

Hazard / Potential Incidents Control Recovery / Measures

1 Mobilize Menand Equipments

1.1 Engaging unskilled and in-Experience workers

1.2 Use of defective tools andEquipments

1.3 Injury accidents due toimproper handling of toolsand equipments

1.1 Engage skilled workers for the work1.2 All workers will be inducted forSafety by ADGAS2.1. Implement equipment pass system2.2 All equipment will be certified by ADGASwith third party certificate for all liftingequipments3.1 First aider on site Emergency responseplan in place3.2 Emergency communication telephonenumbers issued to site staff

2 Tool Box Meeting 2.1 People not familiar with the Job and Hazards involved.

2.2 Poor understanding of workers

2.3 Poor safety attitudes of workers

2.4 Subject matter incomplete

2.1.1 Conduct tool box talks by line supervisor and safety offices (Confirmunderstanding)2.2.1 Use local language by selectingforeman of same nationality of theworkers or by using interpreters2.3.1 Safety Audits and Unsafe act auditing2.4.1 Counseling and Training Disciplinary action as last result

3 Loading/Unloading thePipes

3.1 Unauthorized Lifting Cranes

3.2 Failure of Lifting slings anddropping the materials

3.3 Personal standing on the trailer while Loading/ Unloading

3.4 Too many signal confusing the operator

3.1.1 Ensure Lifting crane is inspection and certified by ADGAS3.2.1 Ensure Lifting slings and tested /Inspected and correct color coded3.2.2. Ensure by visual inspection lifting slings are in good condition and free fromdamage3.3.1 No personal are allowed to stand on trailer before the piping materials reaching to the trailer deck or whileLifting the material from the trailer deck.

3.4.1 Engaging trailer & Approved Rigging person as banks man for signaling

4 Welding of Piping

4.1 Face injury / Skin burns whileworking barricades on gradeunder the area where welders

4.1.1 First aider in site Emergency response plan in place4.1.2 Welders gloves ,apron, leggings,


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are welding

4.2 Electricity- Electric shock,Electrocution

4.3 Engine oil- leak

4.4 Lifting Load

4..5 Confined space working

4.6 Heat-Heat stroke

4.7 Defective tools and machineDue to sound

long sleeve cotton coverall, welding mask, Dark glass, face shield, eye goggles to be used4.2.1 Earth welding generators4.2.2. Check Electric cable for damage and replace any defective material4.2.3 Use fire blanket to cover pipe coating4.2.4 Fire extinguisher to be provided near welding4.3.1 Inspection /Maintenance of equipment4.3.2 Report any oil leakage and authorized disposal4.4.1 Certified lifting equipment to be used4.4.2 Full-line supervision by experienced personnel and a trained firewatcher to be present4.4.3 Fire aider on site Emergencyresponse plan in place4.5.1 Check the permit to work4.5.2 Proper ventilation to be provided4.5.3 Cool drinking water to be provided at all times4.6.1 Fire-retardant sheets to be provided for sun shade4.6.2 Emergency medical evacuationfacility to be available4.7.1 All machinery will be certified by ADGAS Proper PPE will be ensured

5 Working atheight

5.1 Incorrect use of defectiveScaffolding

5.2 Vertigo

5.1.1 Use proper scaffolding materials, Use trained & experience personnelinspect and ensure5.1.2 Constant supervisionInduction and Refresher Trainingmust be provided to train them on theproper method of wearing and safe use.5.1.3 100% Tie-off policyEvery personnel must be providedFull Body Safety Harness with Double Lanyard attached to separate pieces of Shock absorbers;5.1.4 Safety nets will be utilized in the pipe racks5.1.5 Overload Secure ladders at max. 15 deg to vertical and one meter5.1.6 Projected at upper step off point5.1.7 First aider on site Emergency response plan in place.


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5.2.1 Check for the fitness of persons working at height. Those with phobia or afraid of height must not be used

6 ManualHandling

6.1 Handling with improper Posture may result to back injury6.2 Work piece –Sharp edge onwork piece may cause injuriesor hot work piece may cause burn6.3 Slippery surface or obstruction at walk ways may lead to falls or trips resulting to injury

6.1.1 Observe proper lifting posture,Minimize manual lifting , use liftingequipments Provide proper access towork place and ensure constantsupervision6.2.1 Report to dress up sharp edges onwork piece , Use hand gloves6.3.1 Carry out housekeeping daily before shift end Inform supervision any obstruction in work area

7 MechanicalLifting

7.1 Lifting equipment (Faultyslings & cranes defects)

7.2 Untrained personnel unsafecrane positioning , groundcondition, lifting load

7.3 Above SWL of crane(wrongprocedure)

7.1.1 To use certified , color coded lifting equipments regular maintenance and third party inspection to be carried out7.1.2 Hazard falling objects: calls for barricading of crane flight area.7.2.1 To deploy trained operator, signaler and bankman7.3.1 Limit lifting to SWL of crane , boomangle and follow approved liftingprocedure and apply lifting plan all jobsabove 15t weight

8 ElectricalOperated handtools

8.1 Damaged wiring may causeshock or electrocution

8.2 Defective or incorrect use ofhand tools leading to personalinjury

8.3 Flying metal fragments, weldspatters, grinding disc maycaused injury

8.1.1 Inspect electrical tools prior to andduring use8.1.2 Report defect to supervisor8.1.3 Use double insulation type tools8.1.4 Wear hand gloves8.1.5 Deficiencies shall be rectifiedimmediately8.1.6 First aider on site Emergency responseplan in place8.2.1 Inspect electrical tools prior to andduring use8.2.2 Report defect to supervisor8.2.3 Do not defective tools8.2.4 Deficiencies shall be rectifiedimmediately8.2.5 Correct tool usage shall besupervised8.2.6 First aider on site Emergencyresponse plan in place8.3.1 Wear safety goggles, protective cloth and face shield attached with helmet8.3.2 Inspect grinding disc for damage before use8.3.3 Install safety sign / protection cover


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First aider on site Emergencyresponse plan in place

9 Environment 9.1 Continuous exposure to sun/Heat stress

9.1.1 Provide shed where ever possible9.1.2 Use coveralls of 100% cotton with long sleeves9.1.3 Wear sun glasses9.1.4 Ensure adequate drinking water at site9.1.5 Discuss tips on heat stress with subcontractors..9.1.6 Take intermittent rest during hard work, do not get exhausted

10 Confined space 10.1 Oxygen deficiency /Asphyxiation

10.2 Poor visibility / Injury

10.3 Fire burn / Injury

10.4 Trench / fall injury

10.1.1 Provide air circulation , standbyperson, gas testing10.2.1 Provide lighting (24W explosion proof cable)10.3.1 Provide fire watcher / Extinguisher10.4.1 Provide access ladder / scaffolding or platform

11 Emergencies 11.1 Inadequate ER Plan11.2 Poor emergency response forworkers11.3 Inadequate communicationEquipment11.4 Emergency contact numbersnot available

11.1.1 Follow ADGAS Emergency response plan11.2.1 Scheduled for emergency exercise / Drills to be carried out11.3.1 Adequate communication equipment e.g. hand phone provided to essentialfield supervisor staff11.4.1 Readymade pocket sized card with emergency numbers to be provided