ms for installation of gre piping

ADCO CONTRACT NO. 6798.01/ EC 10678

WASH WATER WELLS HEADER REPLACEMENT AND PRODUCED WATER

RE-INJECTION PILOT

METHOD STATEMENT FORINSTALLATION OF GRE PIPES

Rev No

DATE DESCRIPTION PREPARED REVIEWEDAPPROVED

(ADCO)

METHOD STATEMENT FOR INSTALLATION OF GRE PIPES

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CONTENTS

1. SCOPE

2. RESPONSIBILITIES

3. REFERENCES

4. DOCUMENTS (DRAWINGS, SKETCHES ETC.)

5. SEQUENCE OF WORK

6. RESOURSES (MANPOWER, MATERIAL, EQUIPMENT)

7. RISK RATING

7.1 SUPERVISION7.2 HSE REQUIREMENT

8. QA/QC REQUIREMENT

9. TIME DURATION

10. APPROVALS

11. ATTACHMENT


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1. SCOPE

This document is intended to briefly describe general procedure to be adopted for the installation of GRE pipes under the scope of this project.

2. RESPONSIBILITIES

ADCO - Abu Dhabi Company for Onshore Oil Operations.

All technical support and guidance / assistance for safe and smooth execution of the activities under the contract in ADCO restricted areas such as, issue of required permits (including conducting gas tests etc), approval of drawings / Documents, Safety / Quality surveillance, deputation of relevant personnel for inspection & testing as per QA/QC plans, commissioning of the new installations with the assistance of the contractor etc.

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Complete execution of the work with proper workmanship and supervision as per AFC Drawings, specifications / procedures / standards as applicable, strictly abiding by ADCO PTW system and safety regulations as laid down in ADCO HSE manual Volume 10.

3. REFERENCES

Construction Package - 11-01-91-0602Specification for Piping Fabrication and - ADCO Doc. 11.99.12.604 &

Installation - ADCO DOC No. 11.99.12.606

ADCO HSE Procedure Manual - No.10ADCO Procedure Manual - No. 10 / 3XXXXX HSE & LP Manual - Doc. No. HSE/GAD/001The Project HSE Plan - HSE MSP-7037-026 Rev BPQP - PQP-7037-026 Rev B

4. DOCUMENTS

- 11/ 20/ 15/ 0601 (8 Sheets)


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5. SEQUENCE OF WORK

5.5 Calibration

5.5.1 Mark the required spigot length.5.5.2 Assemble the desired mandrel to the shaft and insert the same into the pipe.

Keep the mandrel in position and rotate the handle clockwise until the mandrel tightened against the inside of the pipe. Ensure the whole length of mandrel is inserted inside the pipe.

5.5.3 Position the shaver main frame, power drive and collect nut over the shaft. Rotate the collect nut anti-clock wise to disengage the feed and pull back the main frame against the collect nut.

5.5.4 Adjust the cutting tool as per the required dimension. 5.5.5 Start the power drive for calibration. The tool post should be rotate in a clock

wise direction 5.5.6 As soon as the spigot end has been machined to the required length, stop the

power drive. Loosen the collect nut clock wise to disengage and pull out the collect nut, power drive and main shaver frame.

5.5.7 Use PI tape to measure the OD of the machined end. If more machining is required, repeat steps.

5.5.8 Rotate the shaft anti clockwise to loosen the mandrel, after which it can be removed.

The following two sections apply only in the cases where the pipe has to be cut to suit site conditions.Ensure the machined ends are according to the required measurement and with in the specified tolerance. Clean the calibrated spigot with a clean and dry cloth or use a dust brush.

5.6 Factory shaved spigot

The factory-shaved spigot are in accordance with the required measurements

With in the specified tolerance. The spigot shall be abraded using an emery paper of grade 40 or 60.

5.7 Socket Preparetion

The bell end shall be abraded using an emery cup of grade 40 or 60 inserted in a rubber mandrel and fixed to a drilling machine

5.8 Precautions.


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The prepared bond surface area must not have any greese, oil, dust, moisture, water etc.If any greese or oil is noticed on the bonding surface, soak a piece of cloth with acetone MEK (methyl ethyl ketone) or MIBK and clean the surface. If the bond surfaces is cleaned with solvents re- sanding shall be carried out to refresh the surface. Do not use paint thinner, petrol etc, for cleaning purpose

5.9 Cement application

5.9.1 Prior to the application of cement on the spigot and bell fix the latch belts on both sides of pipes. Leave enough working space between the pipes to be jointed. Use wooden blocks to prevent damage from come along jack. Ensure the pipe supports are adaquately supported and aligned properly. Check if the prepared bonding surface is clean and free from dust, oil etc. sand it with an emery clothAnd made it fresh before applying the adhesive mixture. Mark the required length to be inserted to the bell. The prepared bonding surface should not be touched with a bare hand or with dirty hand gloves.

5.9.2 Add the hardner from the small container to the resin in the large container and mix with the supplied spatula for about 3 minutes untill the mixture has auniform colour. Adhesive components should not be mixed parially from the container to avoid propotional mixing variations. The expiary date of the adhesive components shall be checked before using the prodect at all times

5.9.3 Once the adhesive is mixed properly, apply a thin, uniform layer of adhesive mixture to the freshly preparated bond surface of the bond end(approximat 0.5 mm thick). Do not apply excess quantity of adhesive mixture to the bell end to avoid excessive formation inside the joint.

5.9.4 Apply the adhesive mixture to the freshly prepared spigot. The initial layer should be a thin and uniform to ensure the surface area is properly wet with the mixture. Once the entire spigot area is wet with the mixture apply enough quantity of the adhesive to the spigot (approx. 1.0 mm of thick). It is important to ensure that no dust/ sand or any other particles are mixed with the adhesive or on the mixture spread of the bonding surface.

5.10 Precautions


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In humid environment the prepared joint may need to be warmed up to avoid moisture contents on the bonding surfaces. Use a heating blanket to warm up the joint. Once the warming process completed the joint shall be re- sanded before applying the adhesive mixture.

The bonding process shall be performed within one hour after preparing the bond surface, if not re-sanding should be carried out.

Never use the adhesive, which has started curing or turened tacky.

The adhesive mixture will cure too fast if it is mixed above 40 degree C and the work shall be carried out within the pot life after mixing the two components.

A qualified technician shall perform the joining of all adhesive bonded joints.

5.11 AssemblyPull the pipe sections together with the aid of the come-along-jack,

ensuring the required length of the spigot is entered in to the bell end. Ensure that the vertical 7 the horizondal alighnment of the two sections during the insertion of spigot end in to the bell. Clean the excess quantity of adhesivformed around the joint. The bonded joint should not be distributed under any circumstances during the curing period

5.12 Curing

5.12.1. Ensure the bonded joint is self cured by ascertaining the applied cement is tack free. Wrap the appropriate heating blanket around the joint ensuring the bond area is fully covered (Tie up the heating blanket with a securing wire ). Close all the open end of the pipe section to avoid any air breezing into the section. Connect the power cord in to a power socket. Switch on the temperature controller supplied with heating blanket to the required temperature of 90 C ensure the heatng devise is functioning throughout the process of heating.

5.12.2. The required curing time for Wavistrong Easy–Fit is 1.5 hourstheCuring the time starts when the cement reaches 90 C. Once the heating process is completed allow the joint to cool down and remove all fasteners and materials from the joint.

5.12.3 Once all the process is completed the joint is for use

5.12.4 Backfilling will start immediately after laying jointing curing of the


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pipe leaving joint locations exposed. It will be laid in loose lifts not exceeding 150 mm up to the crown level of the pipe, flooded with water & compacted by hand tamping. Backfill will place symmetrically to prevent centric loading and displacement of pipe.

Mechanical compaction (plate compactors) will only be used 300 mm on top of pipe crown. Sand material will constitute the first layer of fill on top of pipe crown followed by 300 mm layers.

. RESOURCE (Manpower and Equipment)

6.1 Man Power :

Services of following category of manpower is envisaged:

1. Supervisor/Job Performer - 1 No.2. Safety Officer - 1 No3. Fitter - 2 No.4. Riggers - 2 Nos.5. Labourers - 4 Nos.6. Crane Operator - 1 No.7. Trailer (H.D.) Driver - 1 No.8. Hiab Truck Operator - 1 No.9. Welder - 2 Nos.10. Sk. Helper - 2 Nos.

6.2 Equipment:

Measuring Tape Marker pen Pipe fitters wrap-a-round Measuring gauge Pipe clamp Bench Rubber strip (for use underneath the chain clamp) Angle grinder with diagrit or carborundum cutting dise (grain 64) Flapper sander Sanding bobbin Hand hacksaw with 24 teeth / inch blade

Jig saw with a 14 teeth / inch blade Shaver Cleaning rag Adhesive, spatula (=rubber scraper plate ),


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Emery cloth Heating blanket Hot air gun (paint stripper gun ) Digital temperature gauge Variable energy condrol (rheostat) Insulation blanket Generator Cleaning fluid / gloves / dust mask / safety glasses. Shelter ( depending on the weadher conditions ) Hiab Truck Traior Crane

7. RISK RATING

All required Safety pre-cautions identified by "risk analysis" shall be implemented, so that the residual risk becomes "LOW".

7.1 SUPERVISION

A full time Supervisor / Job Performer shall be available at the Workshop / Site to supervise the activities.

Contractor's Safety Officer shall oversee the safety precautions.

7.2 HSE REQUIREMENTS

1. All members of the team shall undergo safety induction relevant for the job. This shall include "Emergency Response Procedure".

2. All workmen shall have PPE (of approved brand) determined for the job (Viz: coverall, helmet, Safety shoes, hand gloves, goggles etc.).

3. Conduct "Toolbox Talk" to brief all concerned about nature of job, risk involved, contingency plan, course of action in case of emergency etc.

4. Only experienced / skilled personnel shall be deployed for the job.

5. Obtain required Work Permit along with relevant certificate, if any, one day prior to commencement of the job.

6. Insist on Good House Keeping at all times.


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7. A stand-by vehicle shall be available during erection at Site.

8. No work shall commence before obtaining the required Permit to Work / Certificate.

9. Wind socks shall be installed at Cluster site.10. No vehicle shall park within 30 M of the Cluster.11. The Crane / Hiab shall have valid Test Certificate from

an ADCO approved third party.12. All machinery will be safeguarded.13. All lifting tackles shall have valid Test Certificates and

be colour coded.14. Fire Extinguishers (Dry Powder) of approved brand shall

be available as per ADCO requirements.15. Welding machines shall be provided with ELCBs and auto-

lock safety device as per ADCO requirements.16. Approved Project Safety Plan will be strictly followed.17. Lighting shall be sufficient in accordance with ADCO

requirements.18. Spark Arrestors shall be fixed to all machinery / vehicles.19. Sufficient drinking water will be available for all the

workforce at all times.20. Temporary shelters (tent) shall be provided on site to

safeguard workmen against high temperature.21. Journey Management Plan shall be implemented for all

vehicles on site.

8. QA/QC REQUIREMENTS

As per relevant construction procedure / inspection and test plants.

9. TIME DURATION

Time duration is depending upon the project work shedule

10. APPROVALS

All relevant drawings pertaining to the job shall be approved by ADCO. (Ensure "AFC" Status).

A general Inspection shall be carried out after completion of the activity and relevant inspection report shall be signed off by ADCO.

11. ATTACHMENT


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Risk Assessment


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