qatar pin braze.pdfr1

CONTRACT REF: GC 08102800

PROJECT NO: 2678

EPIC OF GAS SUPPLY TO STATION V AND FACILITY C (GSVC)DOCUMENT TITLE:

METHOD STATEMENT FOR PIN BRAZING

MAIN CONTRACTOR:

CONSULTANT: CONTRACTOR: CP

23/ AMG 1 AMG BB Issued for Review/ Approval 11/09 25/ AMG 0 AMG BB Issued for Review/ comments 06/09 REV. PREPARED CHECKED DATE QP NO. REASON FOR BY BY ISSUE DOCUMEN REV6- 1 8 - 9 9 0 9 - 4 2 013 2 7 4 SHT 1 of

APPD BY.

APPD

T NUMBER :


CONTENTSSL. NO 1 2 3 4 5 6 7 8 PAGE NO. TITLE 3SCOPE 3 REFERENCES 4 RESPONSIBILITIES 5 HEALTH, SAFETY & ENVIRONMENT 9 METHODOLOGY 12 INSPECTION & TEST PLAN 13 SITE INSPECTION REPORT ENCLOSURE 1 CONNECTION SCHEME No: 2678-9909-4301

Contract No. PAGE GC 2 of 13 -08102800

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1.

SCOPEThe scope of this method statement is to describe in detail the performing methodology of Pin Brazing associated with connection of cable to pipeline pertaining to the Cathodic Protection system including identification of associated hazards and mitigation to be taken in order to execute all works safely, as per project requirement & specifications for the project EPIC for Gas Supply to Station V & Facility C (GSVC) in Ras laffan City.

2. REFERENCES:Project Specifications. QP-PHL-S-001 QP-REG-S-001 2678-8000 2468-9066 2468-9050 QP Corporate Philosophy for Fire & Safety. QP Safety Regulations for Contractors. HSE Plan CP system Design Drawings CP system Design Rev 1

2678-9909-4101 TCP Design Document


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3. 3.1

RESPONSIBILITIES The Construction Supervisor Construction Supervisor is required to ensure that all works are carried out as per approved drawings, project specifications & requirements & HSE requirements Construction Supervisor will ensure that the work is covered with valid work permits from RLC & QP, wherever applicable, and all permit/safety requirements are strictly followed. Conduct daily tool box talks explaining the hazards associated with the work and the mitigation measures.

3.2

The Civil QC Inspector (QCIC) QCIC will ensure that all activities that are required to be inspected have been inspected and approved by QP. Accompany the company representative while carrying out inspections and release of hold points. Issue CAR, when and where required, and ensure that construction provide & implement the approved corrective action.

3.3

The HSE Engineer HSE Engineer will ensure that the work is covered with valid work permits from Government agencies, RLC & QP, wherever applicable, and all permit & safety requirements strictly followed. HSE Engineer will ensure that daily tool box talks are carried at all work locations, as per HSE Plan. HSE Engineer will ensure that work locations are safe to work in & with safety signs. Any unsafe act or condition will be immediately stopped and reported to the HSE Engineer and Construction Supervisor.


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4.

HEALTH, SAFETY & ENVIRONMENT Prior to commencing with any work on site, work permits from Government agencies, RLC & QP, wherever applicable, will be obtained and available on site at all times. Vehicles to be maintained in road worthy & Licensed. Vehicles to be insured. Drivers must have the valid Qatari driving licenses Drivers must follow defensive driving skills. Vehicles must have backup alarms. No night travel other than approved deviations. Avoid set up of work behind equipment operator. Make available drinking water, fluids and insulated tents/shelters for the employees & appropriate ablution facilities commensurate with size of workforce. During the hours of darkness the working area must be clearly illuminated or have sufficient warning lights correctly positioned. Barricades, sign boards must be present at the work site/ ROW. Works shall be carried out according to Safe Construction Practices, QP's Safety Regulations. All personnel involved in works shall be aware of Safety requirements of the project the site shall be kept clean and in tidy conditions. All access / exit points to work areas shall be maintained free from obstacles, materials and equipment. Safety sign boards shall be placed all along the temporary access road. Physical barricading shall be placed at the work area to control the vehicles & traffic. Contractor shall maintain good house keeping at all the times. All worksite locations are to be well barricaded with sufficient safety signs indicating type of work being performed and only authorized personnel permitted to access worksite and the signs to indicate the danger of the worksite. HSE engineer shall monitor the site personnel during all construction activities. Permit conditions checklist to be attached to permit. According to the QP Regulations ail equipment shall have a Third Party certification. All operators shall have the certification by third party.


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When excavating, warning signs and barricades must be provided at all times to all trenches, pits and wells. Prior to the start of work, excavations should be inspected by the competent site engineer. Employees working in excavations should be provided with valid excavation permit and the necessary protective equipment. Before the commencement of any excavation the entire route is to be scanned for under ground services and the scanning report to be attached to excavation permit. For excavation over one meter in depth an entry to Confined Space Permit shall be required in restricted areas. Before digging, check if under ground utilities are present, in location near to the utilities hand digging only permitted. If required excavation should be supported with shielding, shoring, sloping, step and bench to prevent collapse hazard. Use ladders to access structures. Barricades should be placed above 2m from the edge of the excavation. Excavated material should not be placed nearer than 1 m from the edge of the excavation at all times. Do not drive nearer than 3m around the excavation. Wear PPE at all times. Gas testing in regular intervals, placement of fire extinguisher should be present. All excavations in public places, regardless of depth should be provided with sufficient barriers/display boards. Stop blocks to be fitted when tipping in to excavation to prevent vehicles from falling in. Jumping across excavations is prohibited, use a bridge or walk around. Access across excavation shall be by appropriate walkways in sufficient numbers to prevent jumping across excavation. Ensure excavations do not undermine the footings of scaffolds or the foundations of near by buildings or walls. While excavating pay attention to possible buried services. If unexpectedly discovered, these must be checked by a competent person before excavation continues in the affected area. All areas to be scanned & scanning report provide start of any excavation. Contract No. PAGE GC 6 of 13 -08102800 Doc. No 2678-9909420 4 Rev. No 1


During the hours of darkness any excavations openings or obstructions near or on road ways and walk ways must be indicated by a sufficient number of warning lamps and whether day or night, barricaded and protected in accordance with the excavation procedure. Platforms, walkways and pedestrian crossovers must be of sufficient width as per HSE standards minimum with handrail and toe boards. All underground services are to be exposed by hand excavations & the pilot holes barricaded. Contractor shall obtain from the operator and owner of any existing pipelines a permit-to-work within 15m either side of existing pipelines. Provision of a permitto-work by QP does not release contractor by obligation of obtaining relevant permits to expose or near utilities/ facilities not under QP area or responsibility. Example, Q-TEL, KHARAMMA etc. Mitigation measures identified in the Job Hazard Analysis, will be in place, prior to commencing with installation works on site. Daily Safety toolbox talks will be carried out at all work locations, as per CONTRACTORs approved HSE Plan. WORK SITE SUPERVISOR will be available on site at all times. Qualified first aider will be available on site at all times. Appropriate PPE will be worn by all workers at all times. Communication on site will be provided by mobile phones. Mobile phones are not allowed within live stations. Plastic bags or food packets/cans will never be thrown around but will be contained in appropriate skips, placed at work locations. Required construction tools and materials will only be brought to site. No equipment with axle loads greater than 30 Tons shall cross through the existing track crossings. All excavations will be provided with barricades & warning signs. Daily check will be carried out for exposed trench sections and it will be ensured that proper barricade and warning signs are in place. Excavated trench will be protected by warning signs, barricades or excavated material at all times to prevent man, camel & machine from falling into the trench. Excavated material will be placed 1meter and safety barricades will be placed 2 meter away from the edge of the excavation. Contract No. PAGE GC 7 of 13 -08102800 Doc. No 2678-9909420 4 Rev. No 1


Any excavation at underground services location will be by hand digging only. Machine excavation will not be carried out within 3 meters of any such facility. Approved Ladders will be used for access into pipeline trenches or any other excavations. List of emergency contact telephone numbers will be provided to all key personnel associated with the pipeline civil works & displayed at work site. All work will be stopped in case of any incident and reported to the HSE Manager, Project Manager, Construction Manager and QP representative immediately. Work shall proceed only after investigation & corrective actions are in place and approved by QP to proceed further. HSE Manager will conduct periodical audit and report to the project manager for corrective actions. Prior approval will be obtained from QP, if works are to proceed beyond the normal working hours. Work permit to be displayed at work site in permit boxes at all times.


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5. METHODOLOGY5.1 Scope This procedure covers Pin Brazing for cable connection with pipeline for C type of Test Station Connection Scheme related to Cathodic Protection System.

5.2 Materials Required

S.No 1

Application Material/Tool Pin BrazingPin Brazing& Igniting Equipment Brazing Connection to pipe For Encapsulation of

2 Pins 3 Cables 4 5

Intergard 821 or Equivalent exposed portions Sand Paper Surface cleaning

5.3 Pre-requisite i. ii. iii. Demonstration of Pin Brazing shall be performed by the Technician before starting the job at site. Pin Brazing Equipment / materials approval shall be done by QP / TPI Test reports of live pipeline shall be approved by owner before starting pin brazing activities.


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5.4 Procedure i. Pin Brazing is for the live pipeline crossing the GSVC pipeline and Permission should be taken from the foreign pipeline owner before carrying out the pin brazing ii. Excavate a pit over the pipeline to expose the pipeline top surface at location of Pin Braze where cable to pipe connection is to be done as per design document. Care should be taken not to damage the coating of buried pipeline. Only manual excavation shall be carried out over pipeline. iii. Mark where connection is to be carried out. If there are more than one connection as per design document, consecutive marking shall be minimum 300 mm apart. Connection location shall be minimum 300mm apart from other connection and Welding joint, Seam or Circumferential Weld Joint of the pipeline. The location for cable to pipe connection shall be selected such that the pipe joints and field-coated areas are avoided. iv. Cut open the coating on the pipeline with care and without damaging the pipe for a size of approximately 50 mm x 50 mm v. vi. vii. viii. Clean the surface of the pipeline to white metal finish using sand paper and cleaning with fine file as required. Carefully braze the Pin over the exposed pipeline using the pin brazing machine Wait for 1 min after brazing and remove the gun Clean the braze with brush and conceal the exposed pipeline and cable with suitable coating repair material / Epoxy encapsulation like Intergard 821 or equivalent. ix. Cable shall be laid in accordance with cable laying drawings. Cable route shall be carefully measured and cable cut to be required length from test station to pipe. A loop of approx 0.5mtr.of cable shall be kept at both pipe and Test Station end.


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5.5 Precautions i. ii. iii. iv. Only Manual excavation to be done after nearing the pipe surface without damaging the coating. All cables are to be appropriately tagged. Location of cable to pipe connection shall be minimum 300mm apart from other connection and from Pipe weld joint, Seam or Circumferential Weld Joint Check hardness of encapsulation by applying pressure with thumb/Wooden Stick.

5.6 Health, Safety & Environment Hazard Identification and risk assessment will be carried out and Operational Control measures shall be adopted for the said activity. i. ii. Necessary PPE to be utilized Only trained personnel to be deployed for this activity.


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FOR PIN BRAZINGS. No Responsibility Remark Activity Description Acceptance Criteria

INSPECTION & TEST PLANReference Document

Method of Inspection

TTC / L&T

TPI QP

2 3 4 5 6

Check the Location SS Check the Cables S Check the Braze S Check the WW S Continuity Check S Encapsulation

Check as per Design Check as per Design Visual Perfectness Continuity Visual Perfectness

TCP Design Document / Drawings TCP Design Document / Drawings Method Statement Method Statement Method Statement

Visual Visual Check Visual Check Visual Measurement Visual Check

W W W S S

W

S

Inspection Report Reference No: 2678-9909-420401 Reference Document No: 2678-9909-4104 Legend W Witness check RFI to be issued to client. Work Shall proceed if client representative does not attend H Hold point RFI to be issued. Work may proceed subject to Hold point approval / clearance from responsible party. S Surveillance Notification not required. Client / Client representative may carryout surveillance work without advance information. R Review Review of Documents

QPSignature Name Date

TYCO / L & T

TPI


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SITE INSPECTION REPORT FOR PIN BRAZINGPROJECT CATHODIC PROTECTION SYSTEM FOR GSVC PIPELINE PROJECTCP CONTRACTOR: REPORT NO: FORMAT NO. : 2678-9909-4204-01 TYCO THERMAL CONTROLS. DATE

Location ( Chainage in Km) Test Station Type Size of Cable, Sq.mm. Length of Cable, Mtrs Pin Brazing to Pipe /Not Acceptable Acceptable Check the Continuity Acceptable/Not Acceptable Check the Encapsulation OK / Not OK Coating repair / Not Reqd. Done If Any Restoration Check OK OK / Not

NOTES:

QPSignature Name Date

TYCO / L &T

TPI


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qatar pin braze.pdfr1

Documents

valid work

corrective

existing pipelines

hse engineer

minimum 300mm

tyco

design document

safety amp