Method Statement

for Underground Piping

3 06.01.10 REVISED AS MARKED

2 03.12.09 REVISED AS MARKED I.S.K. C.G.J C.K.S J.D.J.

1 17.10.09 FOR CONSTRUCTION I.S.K. C.G.J C.K.S J.D.J. APP’D APP’D SECTION PROJECT TEAM

ORDER NO. OWNER

PROJECT TEAM AOFP

APPROVED J. D. Joh

QA / QC C. K. Seo PROJECT

SECTION Piping Team

APPROVED C. G. Joung

DWG. NO

DRAWN D. J. Lee . REV.

DRAWN DATE 27. Aug, 2009

 

D I S T R I .

CLIENT 4

-

MHI 1

DEC-

PROJECT

QA/QC

SAFETY

PROCURE

CIVIL

BILDING

MECHANIC

PIPING

ELECTRIC

INSTRU

PAINTING

SUBCON

TOTAL

20 Pages including Cover Sheet

This

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MHI-DEC Consortium

FOR CONSTRUCTION

RE

VIS

ION

REFERENCE DESCRIPTION DATE NO.

El-Djazairia El-Omania Lil Asmida Spa

Algeria Oman Fertilizer Project (AOFP)

3 6423DP420-00-00200 00

                                                                          

 1 / 19

 

 

 

TABLE OF CONTENTS  

 

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCE

4.0 DEFINITIONS

5.0 ROLES AND RESPONSIBILITIES

6.0 GENERAL

7.0 PROCEDURE

8.0 TESTING

9.0 SAFETY

10.0 ATTACHMENT

                                                                          

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1.0 PURPOSE

This document is to define the methods and processes to be adopted in order to ensure that all

underground piping system are installed in accordance with Algeria Oman Project (AOFP) specifications,

applicable code and standard.

2.0 SCOPE This method statement covers the excavation, installation, jointing and backfilling of underground coated

carbon steel piping.

Pressure testing of all piping systems will be conducted in accordance with Hydrostatic Test Procedure

(6423DP420-00-0130000).

3.0 REFERENCE 3.1 Codes & Standards

DPEM Circular No.2 Technical Control Regulation for Installation for the Treatment and

Storage of Hydrocarbons and Electric Power Generating Stations

Decree 90-245 Statutory Regulations of Gas Pressure Equipment.

Decree 90-246 Statutory Regulations for steam / Vapor Pressure Equipment.

ASME B 31.3 Chapter V Fabrication, Assembly and Erection

ASME B 31.3 Chapter VI Examination, Inspection and Testing

ASME BPVC Sec. II Part C Welding Rods, Electrodes and Filler Metals

ASME BPVC Sec. V Nondestructive Examination

ASME BPVC Sec. IX Welding and Blazing Qualifications

ANSI/AWWA C209 Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections

and Fittings for Steel Water Pipelines

Steel Structures Painting 1.Steel Structures Painting Manual

Council (SSPC) 2. SP-3 Power Tool Cleaning

3.SP-10 Near White Blast Cleaning

NACE RP-02-74 Recommended Practice, High Voltage Electrical Inspection of Pipeline

Coatings Prior to Installations

3.2 Technical Specifications / Documents

The following technical specification / documents shall be used in conjunction with this document

6423MS231-00-00100 00 Specification for Piping Fabrication by Each Service Class

6423MS230-00-00200 00 Specification for Inspection of Piping Work

6423MS285-00-00100 00 Specification for Flushing & Cleaning of Piping

6423MS286-00-00100 00 Specification for Hydrostatic & Pneumatic Pressure Test

6423MP201-00-01200 00 Specification for Field Joint Rubber Lining

6423MP201-00-01100 00 General Specification for Rubber Lining (Seawater Piping)

6423MP201-00-01101 00 Rubber Lining Materials For Site Lining Work

6423MP342-00-91100 00 Wrapping Procedure For Underground Piping

6423MP202-00-00100 00 Piping Material Specification

6423DA060-00-00500 00 Qualification of Welding Procedure Specification

6423DA060-00-00700 00 Welder Qualification Procedure

                                                                          

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6423DA060-00-00900 00 Welding Control Procedure

6423DA060-00-01200 00 Welding Material Control Procedure

6423DP420-00-00420 00 Method Statement of Painting

6423DS202-00-01300 00 Confined Space Procedure

6423DS202-00-01600 00 Excavation Work Safety Procedure

6423DC420-00-00700 00 Procedure for Earth Work

6423DP420-00-01300 00 Hydrostatic Test Procedure

Note : If there are any conflicting requirements between this specification and individual specification or

drawings, the requirement shall be governed in accordance with the following order.

(1) Drawing and individual specifications

(2) This specification

(3) Codes and standards

4.0 DEFINITIONS For the purposes of the document the following definitions shall hold.

4.1 Owner

This shall mean EL-Djazaria El-Omania Lil Asmida Spa (A joint venture of SBGH & Sonatrach) who

initiated the project and ultimately specifies the technical requirements.

The Owner may also include an agent or consultant authorized to act for on be-half of Owner.

4.2 Contractor

This shall mean MHI & DEC who carries out all or parts of the engineering, procurement, supply,

construction and commissioning.

4.3 Media

The technical document may be prepared, submitted and reproduced using any of the following media.

- Hard copy

- Reproducible (transparencies, tracings…). Photocopies and electronic copies

- Photographs

- Electronic media including compact diskettes / floppy diskettes.

4.4 Shall

This shall mean mandatory requirement.

4.5 Should

This shall mean desired requirement.

4.6 Document

This shall include output in the form of hard copy, drawing, tracing, reproducible, floppy diskette, compact

diskette and field inspection reports.

5.0 ROLES & RESPONSIBILITES 5.1 Project Manager

Project Manager shall responsible for overall management and HSE of all Construction activities at site

including installation and testing of underground piping.

5.2 Piping Manager Piping Manager shall be responsible for overall management of piping activities.

He shall be responsible for implementation of this procedure and shall pass the instruction down the line to

                                                                          

 4 / 19

maintain the required quality level.

5.3 Piping Engineer

Piping Engineers shall be responsible for planning and executing installation activities of underground

piping at site and implementation of quality and HSE plans during construction.

5.4 Piping Supervisor

Piping Supervisors shall be responsible for requisitioning the materials required for installation, ensuring

the installation as per approved drawings and implementation of good piping work and HSE work

practices in their areas of operation.

5.5 Civil Manager

Civil construction manager is responsible for the excavation and back filling of piping trenches,

construction of concrete pits and all associated survey work.

5.6 QA/QC Manager

QA/QC Manager shall be responsible for overall management of QA/QC activities.

He shall be responsible for non conformance management quality audits both internal and external.

5.7 QC Engineer

QC Engineers shall be responsible for QA/QC activities, material control and traceability, and review of

test packages for hydro tests.

He shall also be responsible for non conformance management and internal quality audits.

5.8 QC Inspector

QC Inspectors shall be responsible for carrying out inspection activities and witnessing NDE during the

installation processes and coordinating with the owner’s QA/QC personnel for inspection and certification,

as per approved ITP.

5.9 Safety Officer

Safety officer shall be responsible for coordination with HSE authorities of owner safety officer shall

monitor all the works to ensure that they are carried out correctly and in safe manner and advise

supervisors for corrective measure, if required.

He shall ensure that toolbox talks are held which shall cover details of specific tasks to the personnel and

specific job risks involved are explained to the work force involved.

6.0 GENERAL 6.1 When welder is welding, he shall wear the appropriate safety equipment and clothing to prevent him from

getting an electric shock or burns.

6.2 A confined space entry permit is required before entry to confined space.

When welding in confined space, an extractor must be installed to remove hazardous / toxic fumes and to

ventilate the area, if necessary a mask shall be worn and an assistant will be posted at the entrance to the

work area in case of emergency.

6.3 When welding, inflammable materials must be removed from work area to avoid causing a fire.

7.0 PROCEDURE 7.1 Sequence of work

(1) Pipe transportation

(2) Excavation

(3) Wrapping (External)

                                                                          

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(4) Pin hole test & Inspection

(5) Fabrication for spool and double joint pipe

(6) Internal cleaning and arrangement

(7) Fit-up and welding

(8) Hydrostatic test (for WF line)

(9) Rubber Lining (Welded Joints)

(10) Line leveling and supporting by sand bag

(11) Wrapping (Welded Joints)

(12) Pin hole test & Inspection

(13) Backfilling

(14) Service test (for WCM, WCR, WCS, WW, WSM, WSR & WSS line)

7.2 Material control

(1) Rubber coated carbon steel pipe shall be provided by the contractor (MHI).

All delivery inspections and certifications are done by contractor (MHI/DEC).

All pipes shall be inspected for conformity by QC inspector.

(2) Welding consumables shall be controlled in accordance with Welding Material Control Procedure

(6423DA060-00-012000 00).

7.3 Handling and Transportation

(1) All coated pipes will be handled by means of wide sling bands or belts to avoid damaging the coating

material.

(2) Coated pipe shall be handled with wide nonabrasive canvas, leather belts and or other.

(3) All equipment designed to prevent damage to the coating.

(4) The use of tongs, bare pinch bars, chain slings, rope slings without canvas or composition belt slings

with protruding rivets, pipe hooks without proper padding or any other handing equipment found to be

damaging to the coating shall not be permitted.

(5) All skid used to support coated pipe shall be padded.

(6) Walking on the pipe shall not be permitted.

7.4 Excavation

(1) Excavation by machine shall be carrying out if the working space is within the safe limit against the

existing facilities.

(2) Manual excavation shall be performed if the working area is to close to the existing underground

facilities.

(3) Shuttering or sheet piling (if required) should be done initially to ensure proper protection and stability

of the existing facilities before commencing the excavation work.

7.5 Wrapping

(1) Surface Preparation

Surface Preparation shall be according to Steel Structure Painting Council Specification SSPC-SP-3

(or equivalent), Power Tool Cleaning. SSPC-SP-2 (or equivalent), Hand Tool Cleaning may be used

for narrow sections. Bare pipe shall be free from mud, mill scale, mill lacquer, wax coal tar, asphalt, oil,

grease, or any other foreign materials. All prepared surface shall be coated on the same day it was

cleaned.

No pipe shall be allowed to flash rust before coating.

(2) Liquid Adhesive (Primer) Application

                                                                          

 6 / 19

Prior to any liquid Adhesive application, the pipe shall be cleaned to remove any wetness or other

contamination. Liquid Adhesive shall be thoroughly agitated in its container before application to the

pipe. Liquid adhesive shall be either brush or spray applied to the cleaned pipe surface in a uniform

thin film at a minimum coverage of approximately 7.4 square meter per liter or Liquid Adhesive. Prime

coat shall be dry to tacky at the time the anti-corrosion tape is applied.

(3) Tape Installation

All irregular shaped items with voids and field welded butt joints shall be pre-coated with filler tape

(mastic) such that smooth, rounded shapes are formed prior to application of anti-corrosion tape.

The seam of the welded area of pipe from vendor shall be pre-coated with anti-corrosion-layer tape

along its length.

The anti-corrosion tape shall be applied directly onto the primed pipe surface approved by the tape

manufacturer in compliance with the applicable standard. The anti-corrosion tape shall be spirally

applied with minimum overlap of 55% of the tape width being used. The application tension on the

tape shall be approximately 1% of tape width in width drawdown (approximately 5 to 10 lbs per inch

width of tape). Hand application is permitted only for tape width no wider than 6 inches. A tight,

smooth, wrinkle-free coating should be observed throughout the application.

The end of each new roll of tape shall overlap the end of the preceding roll by a minimum of 6 inches.

This end lap splice shall be hand applied for a wrinkle free splice to maintain the continuity of the

anti-corrosion tape. The spiral angle of the new roll should parallel the previous roll’s spiral angle.

The outer-layer tape shall be applied over the anti-corrosion tape using the same method used to

apply the anti-corrosion tape. The seam for the outer-layer tape shall overlap the exposed seam of

the anti-corrosion tape by a distance of half the tape width so that they do not coincide. The overlap

width shall be 1”. The application tension and the minimum end lap of two rolls shall be the same as

the anti-corrosion tape. The total thickness shall be kept in accordance with Wrapping Procedure

for Underground Piping (6423MP342-00-91100 00).

Pipe size ≤ 50” : Manual, Turning roller or machine wrapping application is permitted.

Pipe size > 50” : Turning roller or machine wrapping application.

(4) Inspection and Testing

All coating shall be subject to 100% visual inspection and 100% inspection with an electrical holiday

detector. The holiday detector shall be as per NACE RP-02-74 during the inspection of the

anti-corrosion tape coating. Holiday detector shall not be permitted to remain stationary around

coated pipeline with the operating voltage switched on. All defects shall be clearly marked.

(5) Repairs to Coating

All the defects in coating should be fixed immediately after the detection.

In case of inner/outer tape damage/defects:

1. Peel back and remove the outer-layer tape complete around from the damaged/defect area.

                                                                          

 7 / 19

2. Peel back and remove the anti-corrosion layers with minimum 3 inch apart from the

damaged/defect edge

3. The exposed area shall then be coated with liquid adhesive(primer).

4. Apply the anti-corrosion tape in strips with minimum of 55% from the edges of the exposed area.

5. Outer layer tape should then be wrapped over the anti-corrosion tape with wrap-around method.

6. The repaired area shall be tested with a holiday detector after the repair is complete.

In case of outer layer tape damage/defects only:

1) Remove the outer layer tape complete around from the damage/defect area with minimum 6 inch

apart from the damage/defect edge.

2) Holiday test shall be done over the anti-corrosion tape where the portion of the damaged/defect

of the outer layer is detected to make sure it is not also damaged.

3) Wrap the outer layer tape with wrap-around method.

7.6 String out the pipes into trench

(1) Prior pipe string out, civil work for trench shall be completed.

(2) Before putting the pipes into the sand bags, the circumferential area of the pipe with the contact

points to the sandbags shall be tested using brush type holiday detector.

(3) Pipe joints will be laid individually in the trench on sand bags, suitable spaced to support the length of

pipe being installed.

(4) On long pipe lengths, sand bags will be spaced on five meter centers.

(5) To avoid damage to coating and following accepted construction practices.

(6) Pipe will be installed in the trenches using wide sling belts and / or hands.

(7) Tolerance of pipe laying shall be as follows :

The level of the pipe at any point along its length is to within ±15mm of the level stated on the

drawings.

The center line of the pipe at any point along its length is to be within ±50mm of the location stated on

the drawings.

(8) Pipe lowering into trench, pipe shall be inspected internally for dust / debris which, shall be cleaned

(air blowing, brushing etc…)

7.7 Welding

(1) Welding preparation, fit up, inspection and testing shall be carried out in accordance with

Specification for Piping Fabrication by Each Service Class (6423MS231-00-00100 00).

All surfaces to be welded shall be free from oxides, scale, oil or other foreign matter.

Production joints shall be made using qualified welding procedures and welders.

Visual inspection shall be done by welding inspector during and after welding.

(2) The daily welding report shall be generated by construction team in accordance with Welding Control

Procedure (6423DA060-00-00900 00).

7.8 NDE

Required NDE shall be requested and carried out in accordance with method statement for NDE control.

All NDE requests shall be transmitted to subcontractor by QA/QC manager.

Contractor will transmit hard copies of NDE information to the owner.

Matrix operator will input NDE date to the data base.

7.9 Repair of welding

                                                                          

 8 / 19

Welding repair shall be carried out in accordance with method statement for Welding Control Procedure

(6423DA060-00-00900 00).

7.10 Rubber lining

(1) Inspection for steel substrate

Size, appearance, welded parts and so on shall be checked and confirmed whether there are no

defects, which may influence on lining work.

If there are such defects, repair shall be performed.

(2) Surface preparation

Surface preparation shall be carried out by grinder on welding area, so that rust and scale on a steel

surface are completely removed.

In this process, welding areas shall be rechecked and if any defects, such as pinholes are found,

repair shall be performed.

(3) Bonding treatment

After grinded, first primer shall be immediately applied.

After dried, rubber cement shall be applied and dried sufficiently.

(4) Application of rubber sheet

Pre-cure rubber sheet (vulcanized rubber sheet : B-5S) shall be applied to steel substrate, so that no

air bubbles are locked between rubber sheet and the surface of steel substrate.

Please refer to “Rubber Lining Procedure” below.

Rubber Lining Procedure (Pipe Joint Welding Area) : Example

(5) Inspection

After lining application, following inspection shall be performed for whole rubber lined area.

(a) Appearance inspection

(b) Dimension inspection

(c) Thickness inspection

(d) Hardness inspection

(e) Pinhole inspection

(f) Adhesion inspection

7.11 Backfilling

(1) Backfilling work shall be carried out in accordance with Procedure for Earth Work (to be prepared by

Civil Department).

(2) Before the pipes are subjected for backfill, holiday test using the ring type holiday detector shall be

done onto the remaining pipe’s surfaces that is not yet holiday tested except for the branch & fittings

which is to be tested using brush type holiday detector.

(3) Pipe padding should go after pipe bedding by filling with suitable materials 300mm thick from top of

pipe.

(4) Subsequently after completing the pipe padding backfilling of suitable excavated earth material shall

                                                                          

 9 / 19

be placed 300mm in layers and compacted in accordance with project specification requirements.

7.12 Hydro test line (for WF line)

(1) Epoxy coating shall be done at site.

(2) Pipe surface shall be prepared by mechanical power tool cleaning.

(3) Fit up and welding shall be carried out as per WPS.

(4) Hydro test shall be carried out after completion of all NDE (if required) and spool clearance activities.

(5) After completion of hydro test and its acceptance by owner, the epoxy coating of welded joints shall

be done.

(6) If any repair, modification occurs in the site during installation to the fabricated spool then the same

spool shall be recoated and re-hydro tested in the site with the above same procedures.

(7) The epoxy coating application shall be done in accordance with manufacturer’s instructions.

Coating inspection shall be made and recorded on attachment #1.

7.13 Service test line (for WCM, WCR, WCS, WW, WSM, WSR & WSS line)

(1) Before fit up and welding coating shall be removed from pipe in the range of 10cm over and the cut

back area surface should be cleaned properly.

(2) Pipe surface shall be prepared by mechanical power tool cleaning.

(3) Fit up and welding shall be carried out as per approved WPS.

(4) After completion of all NDE activities(if required), spool clearance shall be carried out epoxy and

rubber coating.

(5) Epoxy coating shall be done to all fabricated spools joints in the work shop.

(6) The epoxy coating application shall be done in accordance with manufacturer’s instructions.

(7) Field welding joints shall be coated at site as per manufacturer’s instructions.

Coating inspection shall be made and recorded on attachment #1.

(8) After installation of all spools at site and mechanical clearance of above lines by owner, the service

test shall be done.

7.14 Holiday Test

The following voltages shall be impressed in electrical inspection, based upon the calculation instructed in

the Section 3 of NACE Standard RP-02-74.

1. Summary of recommendation

Minimum 10,000V shall be impressed to all sizes of pipe surface wrapped with POLYKEN tapes.

2. Calculation

1) Straight pipe (50” or below)

Total tape thickness: 20x2+20 = 60mil → 9,682V

9,682V → +20% =11,618V

9,682V → -20% =7,746V

2) Straight pipe (50” or above)

Total tape thickness: 20x2+20x2 = 80mil → 11,180V

11,180V → +20% =13,416V

11,180V → -20% =8,944V

3) Fitting, flange (50” or below)

Total tape thickness: 35x2+15 = 85mil → 11,524V

11,524V → +20% =13,829V

11,524V → -20% =9,219V

                                                                          

 10 / 19

4) Fitting, flange (50” or above)

Total tape thickness: 35x2+15x2 = 100mil → 12500V

12,500V → +20% =15,000V

12,500V → -20% =10,000V

Holiday detection checks shall be carried out and recorded on attachment #2.

7.15 Drawings

As-built drawings must be drawn before leak test (As-built drawing shall be checked during punch check).

8.0 TESTING 8.1 Preparation for testing

(1) A punch list(will be attached in the Hydrostatic test procedure) shall be prepared by construction

team to verify that the piping system are installed to the extent necessary for testing.

(2) A test punch list shall be made through line check and punch list will be to verify that all piping

components requiring post test actions are documented.

(3) After all punch items are completed satisfactorily, both contractor and owner shall sign all necessary

documents.

(4) Pipe lines (FW line) shall be thoroughly blown out by air compressor.

(5) Lines shall be free from all debris such as trash, welding rods, rags, tools, etc.

8.2 Test pack preparation and control

(1) Preparation and control of test package shall be done in accordance with Hydrostatic Test Procedure

(6423DP420-00-01300 00)

(2) All test package shall be approved by owner prior to the start of pressure testing.

8.3 Main pressure testing

(1) Every part that has to be tested should be vented until free of air.

(2) Be aware that there is always a possibility of the presence of entrapped air in a system.

(3) A hydrostatic pressure has to be built up gradually and, in doing so, no fast closing valves and

booster pumps should be used.

8.4 All final inspection and documentation after pressure testing shall be done in accordance with method

statement for pressure test of piping.

8.5 Service test line (Seawater, CCW and etc) shall be back filled after lapping & testing.

8.6 Records of pressure test and leak test shall include the following items.

(1) Date of test (2) Identification of piping tested(line number and service) (3) Test fluid (4) Test pressure (5) Certification by examiner (6) Design pressure (7) Photograph of pressure gauges and indication board showing the test sequence (time and pressure,

etc.) 8.7 Repairing of defects

(1) When the defective material found during construction, a repairing method and extent shall be

prepared.

                                                                          

 11 / 19

(2) Imperfections in welds exceeding specified limitations shall be considered as defects, removed and

repaired in accordance with the followings.

(a) Defects shall be removed completely under the careful examination.

(b) Repair welding shall be also done in accordance with welding procedure specification(WPS)

(3) Repaired welds shall be examined and inspected in accordance with Specification for Piping

Fabrication by Each Service Class(6423MS231-00-00100 00)

8.8 Inspection and testing

(1) All the work shall be inspected or examined as per approved ITP and inspection records shall be

prepared as per ITP (6423DA424-00-00200 00).

(2) Before starting the job the drawings shall be checked for the latest revision.

(3) All piping material & welding consumables shall be checked for conformity to specifications,

construction drawings and approved WPS.

(4) All measuring instruments shall be checked for valid calibration.

(5) Area to be welded shall be checked for the cleanliness, free of paint, grease, dirt etc.

(6) Each piping installation, including it’s components and workmanship, shall be examined to ensure

compliance with applicable examination requirement.

9.0 SAFETY 9.1 The unsafe work practices and conditions in the work place shall be immediately identified and eliminated

through the use of analytical techniques such as risk assessment. 9.2 Build a team safety mentality where each worker contributes to the effort and each superintendent is fully

aware of the capabilities and limitations of their team. 9.3 All tools and equipments shall be used in accordance with the manufacturer’s recommendations, required

tool guards in place, and maintained in good working order. 9.4 Where appropriate shall require employees to wear eye, ear, head and face, foot protection outfit. 9.5 Special care shall be taken for the erection of scaffolding and ladders at height. 10.0 ATTACHEMENT

1) Attachment #1 : 6423DP420-002-01 Inspection and Testing Coat of Joint & Repairs (Inner-layer

tape application)

2) Attachment #2 : 6423DP420-002-02 Inspection and Testing Coat of Joint & Repairs (Outer-layer

tape application)

3) Attachment #3 : 6423DP420-002-03 Holiday Detector Test Report (HTR)

4) Attachment #4 : 6423DP420-002-04 Rubber Lining Inspection Records

5) Attachment #5 : 6423DA060-009-01 Daily Welding and Inspection Record (DWIR)

6) Attachment #6 : Job Safety Analysis (JSA)

Attachment #1

Inspection and Testing Coat of Joint & Repair Report ( Inner-layer tape application)

                                                                          

 12 / 19

Algeria Oman Fertilizer Report No. : Date :

PCWBS Drawing No. Sheet No.

Rev. No.

Pipe No.

Spool No.

Weld No. Remarks

Component Description Construction QC Owner

Preparation of substrate

Time duration between surface preparation and coating of primer

Application of filler tape (mastic) (for irregular shape only)

Application of primer

Application of tape wrap

Wrap overlap

Prepared by : (Construction) Name Signature Date

Inspected by: (QC Inspector) Name Signature Date

Inspected by:

(Owner) Name Signature Date

6423DP420-002-01(3) Attachment #2

Inspection and Testing Coat of Joint & Repair Report (Outer-layer tape application)

                                                                          

 13 / 19

Algeria Oman Fertilizer Report No. : Date :

PCWBS Drawing No. Sheet No.

Rev. No.

Pipe No.

Spool No.

Weld No. Remarks

Component Description Construction QC

Preparation of substrate

Time duration between surface preparation and coating of primer

Application of filler tape (mastic) (for irregular shape only)

Application of primer

Application of tape wrap

Wrap overlap

Prepared by : (Construction) Name Signature Date

Inspected by (QC Inspector) Name Signature Date

6423DP420-002-02(3) Attachment #3

Holiday Detector Test Report (HTR) Algeria Oman Fertilizer Project

                                                                          

 14 / 19

Report No. : Date :

Drawing Number :

Line Number :

Test Pack Number :

Type of coating :

Test Equipment used :

Test setting value :

Test carried out by :

Repairs required :

Repairs complete :

The testing of the above coating has been satisfactorily completed in accordance with the drawings and

specifications.

Prepared by : (Construction) Name Signature Date

Inspected by : (QC Inspector) Name Signature Date

Inspected by : (Owner) Name Signature Date

All underground pipe coating shall be checked for pinholes and holidays by contractor.

Testing shall be performed using a contractor approved holiday detector

Piping is to be backfilled immediately after being checked for holidays.

This form shall be retained with the appropriate piping field test report (underground piping).

6423DP420-002-03(3)

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ATE :

s

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b

c 

※ "Ａ" View

mm

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mm

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Judgement

b 

                                                                                                                                                                                          

 16 / 19

Attachment #5

Daily Welding and Inspection Report (DWIR) Report No. : Date : Algeria Oman Fertilizer Project Page :

Area System Isometric Drawing No. Sheet No.

Rev. No.

Spool No.

Weld No. Material Piping

Class Size Sch. Welder No.

WPS No. PWHT Req’d

NDE Inspected Result Remarks

Root Cap Req’d % Fit-up / Root Final

Prepared by : Inspected by :

Name : Name :

Date : Date :

(Construction) (QC Inspector)

6423DA060-009-01(0)

                                                                    

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Attachment #6

JOB SAFETY ANALYSIS

Date of Issue JSA No.

Work Group Preparing JSA Piping Prepared by

Job Description Underground Piping Approved by

Sequence of Task Potential Hazards Recommendations / Control Measures

Mark out exact location of proposed excavation site, plus erection of barricades and safety signs.

Minor works only, no major hazards associated with this task.

►All works to be fully supervised at all times. ►If the supervisor has to leave the area, for any reason, then

the job will be temporarily suspended until such time he returns to site.

►The excavation areas are to be identified on attached plot plan, highlighting the areas which can be excavated using machinery and the critical areas which must only be excavated by hand dig only.

Obtain excavation certificate including a hot work permit For information only. ►Hot work permit to be issued by AOFP safety department.

Carry out excavation work using 360° mechanical excavator and hand digging operations as per attached plan.

Contact with moving machinery. Heat source from diesel powered equipment is a potential for explosion in the event of gas escape from live plant Earth sliding, cave-ins and collapse.

►Physical barricades shall be erected to prevent access by unauthorized personnel.

►Warning signs to be erected also to advise personnel of ongoing excavation work.

►Take all necessary precaution as required in confined space procedure when working in excavation or trench 1.5m or above.

►All excavated area should be barricaded by safety barrier and alerted by warning light at night.

►Proper slope should be maintained in all trench excavations (45deg slope is required or as per actual soil condition).

►Ladders, steps, ramps or other suitable means of access and aggress shall be provided as per procedure.

►Excavator operator and other related personals should be properly trained.

Pipe laying in the trench and fit-up

Tear of slings / belts Fall of materials

►All rigging area should be properly barricaded by suitable means.

►All riggers should be trained. ►Know the weight and C.G of the material to be lifted and use

proper tools and equipments. ►All rigging tools and tackles should be checked before using.►No one should stand beneath the load. ►Do not allow unauthorized persons in rigging premises.

Pressure testing

Equipment Failure Bursting, Leakage of test medium Damage to ear drum Heat stress and dehydration

►Ensure well maintained and periodic inspection of equipment & tools’

►Only trained personnel is required to handle the pressure testing equipment / tools.

►Ensure equipment is pre-mobbed and certified for use ►Prior to testing, ensure proper check on hose connections,

blind points, bolting and on-line piping components and certified for test

►Ensure barriers / warning signs are in place around test areas and specify distance.

►Ear muffs must be worn at test area all time ►Ensure weather condition is conducive for work. ►Ensure availability of potable drinking water at work site and

short break for workers.  

                                                                    

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Sequence of Task Potential Hazards Recommendations / Control Measures

Welding and Cutting works Fire, explosion, damage to lives and properties

►Wearing of PPE shall be mandatory in all aspects of welding and cutting works.

►This shall include face shield and welding goggles. ►Hot work permit shall be secured prior to start of any welding

and cutting works. ►Fire extinguishers shall be available near the work site at any

time. ►Proper use of fire extinguishers shall be disseminated to all

personnel involve in the job. ►All welding, grinding and cutting equipment shall be inspected

prior to start. ►This shall also include inspection of electrical sources and

cables. ►Damage cables shall be immediately replaced. ►Only properly trained personnel shall be permitted to do

welding and cutting works. ►Work area shall be properly barricaded. ▶STAART required prior to start of task. ►Always check areas around and below prior to commencing

welding or cutting operations. ►Ali combustible materials under or near welding or burning

operations must be moved to a safe distance away or covered with a fire retardant material.

►Welding leads and gas hoses shall not be placed where they will present tripping hazards.

►Proper spark containment method such as fire blanket shall be used when doing welding and cutting.

►The welding machine shall be properly grounded and as close to the work as possible.

►Never leave a welding rod in the electric holder when not in use.

►Never use a torch as hammer to remove slag or scale. Use the proper tool.

►Never use lighters, matches or cigarettes to light a torch. Use only approved spark lighter.

►Welding machine shall be turned off at the end of the shift. ►Fire Blanket shall be used for welding habitat. ►All galvanized pipe shall be cleaned in areas to be welded

prior to welding.

Grinding work

Injuries by grinding machine Fire burn and eye injuries

►Only skilled worker can carry out the job. ►Avoid water contact and keep grinding machine always dry. ►Continuous training and remained hazard of grinding ►Damage of electric wire to be checked continuously. ►Grinding machine and grinding wheel should be checked

before use ►Wear adequate PPE

NDE Exposure to X-ray

►Working area should protected by installing warning tape and x-ray hazard symbol.

►Only skilled worker can carry out the job ►Wear radioactive absorption batch when working to

neutralized radioactive emission.

Housekeeping and area cleaning Slip, Trip, Fall

►Proper housekeeping to be maintained at all times ►Material should never obstruct walkways / staircase / ladders

and access to emergency equipments. ►Area to be cleaned and barricades and warning tapes to be

removed  

                                                                    

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Sequence of Task Potential Hazards Recommendations / Control Measures

Handling of pressurize tanks (Oxygen, Acetylene, Argon)

Fire explosion damage lives and properties

►Hose and fittings of gas cylinders shall be checked for leak by soapy water.

►Oxygen and fuel gas cylinders in storage shall be separated by a minimum of 6 meters.

►Gas cylinders shall be handled carefully. Avoid bumping or dropping them.

►Always secure in an upright position and properly supported.►Valve protection caps shall be on cylinders when not in use

and when being transported. ►Be sure protective caps are adequately screwed down. ►Use a holding cage when lifting cylinders with a crane. ►Choking around cylinder shall not be allowed. ►Smoking is not allowed on the project site except in properly

designated areas. ►Discard butts approved containers, not on the floor/ground or

in trash cans.

General

All risks to be happened during working Expected risks during night shift

►Every day before start of work tool box meeting to be between supervisor and worker.

►Supervisor should give information regarding hazards indulged to daily work activities.

►Always keep clean working area. ►Close supervision shall be done during late night hours. ►Supervisor should give information regarding hazards

indulged to daily night work activities. ►Adequate drinking water facilities should be provided. ►Every night before start of work tool box meeting to be

between supervisor and worker Comments

1. JSA should be used in conducting Tool Box Talks(TBT) with all concerned workers 2. Provide that all the necessary PPE are used, relevant PTW requirements are followed and all the control

measures stated above are adhered to, the activity can proceed.

PPE & Safety Equipment Required to Perform Task (Tick as Appropriate)

Safety Helmet Face Shield Goggle Barricade Harness Hand Gloves Safety Shoes

Ear Plug Coverall Safety Glasses Work Permit Fire Extinguisher Dust Mask Others