AED PROJECT EPCC OF TRUNKLINE AND ASSOCIATED RECEPTION FACILITIES AND TIE-INS AT WAHA CPF

JT167/2013 MST
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AED PROJECT EPCC OF TRUNKLINE AND ASSOCIATED RECEPTION FACILITIES AND TIE-INS AT WAHA CPF

Field Joint Coating MST JT-167-MEC-MS-005-00

00

08/12/13

Preliminary for Bid

KT

MA

MA

Rev

Date

Object

Issued by

Cheked by

Approved by

CE DOCUMENT EST ETABLI PAR MEDCO ET NE PEUT ETRE EN AUCUN CAS UTILISE OU REPRODUIT SANS SON ACCORD PREALABLE ET ECRIT
THIS DOCUMENT IS ISSUED BY MEDCO ON THE INDERSTANDING THAT IT IS STRICTLY CONFIDENTIAL AND MAY NOT BE REPRODUCED OR UTILISED IN ANY WAY WITHOUT THE PRIOR WRITTEN PERMISSION OF THE COMPANY

Field Joint Coating MST

JT-167-MEC-MS-005-00

Rev : B

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AED PROJECT EPCC OF TRUNKLINE AND ASSOCIATED RECEPTION FACILITIES AND TIE-INS AT WAHA CPF
JT167/2013 MST
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TABLE OF CONTENTS 1.0 PURPOSE .............................................................................................................................................. 3 2.0 OBJECTIVE............................................................................................................................................ 3 3.0 SCOPE ................................................................................................................................................ 4 4.0 RESPONSIBILITIES ........................................................................................................................... 4 5.0 HEALTH, SAFETY & ENVIRONMENTAL ......................................................................................... 5 5.1 GENERAL .............................................................................................................................................. 5 5.2 ENVIRONMENTAL................................................................................................................................... 5 6.0 DESCRIPTION OF WORK ................................................................................................................. 6 6.1 PRELIMINARIES ..................................................................................................................................... 6 1. RAYCHEM SLEEVE HTLP60-1-15. .......................................................................................................... 6 6.2 JOINT COATING REPAIR. ......................................................................................................................... 7 6.3 POST WORK OPERATIONS ...................................................................................................................... 8 7.0 ANNEX 1 SAFETY AND ENVIRONMENTAL RISK ASSESSMENT RECORD ....................................................... 8 8.0 ANNEX 2 ENVIRONMENTAL IMPACTS AND MITIGATION REFERENCE .................................... 11

Field Joint Coating MST

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Rev : B

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AED PROJECT EPCC OF TRUNKLINE AND ASSOCIATED RECEPTION FACILITIES AND TIE-INS AT WAHA CPF
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1.0

Purpose
The purpose of this method statement is to provide a safe and secure working environment at all times for the employer, third party representatives, MEDCO personnel and subcontractors.

2.0

Objective
Ensure a safe working environment for all personnel. Ensure that there is the minimum risk of exposure to any harmful substances or hazard

encountered during construction activities. Promote a vigorous environmental culture within the project. Protect, and if possible, enhance, the environment. Protect the general public form any hazards or disturbance generated by construction

activities.

Field Joint Coating MST

JT-167-MEC-MS-005-00

Rev : B

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AED PROJECT EPCC OF TRUNKLINE AND ASSOCIATED RECEPTION FACILITIES AND TIE-INS AT WAHA CPF
JT167/2013 MST
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3.0

SCOPE
This document is to identify each operation that is required in the execution of the field joint coating of trunk line and associated reception facilities and tie-ins at WAHA and to ensure that they are carried out in a safe and efficient manner.

4.0

RESPONSIBILITIES
The project manager is responsible for ensuring distribution and implementation of this method statement. The Construction manager is responsible for the overall supervision and co-ordination of work activities including the provision of adequate supervision, labour and resources to complete the required activities. Discipline supervisors are responsible for specific elements of this method statement

The HSSE Manager or his deputy is responsible for safety inductions, visiting site activities and advising on safe working practices. The HSSE Manager is responsible for all environmental issues including environmental induction and for advising the project manager as appropriate.

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5.0 5.1

HEALTH, SAFETY & ENVIRONMENTAL General

Prior to commencing work all employees shall have attended and passed an appropriate Induction No work shall be undertaken by personnel who have not attended this induction. All works shall be carried out in a safe manner, using only certified equipment, and the work site maintained so that it functions safely and efficiently. The site manager will ensure a sufficient amount of cleansing wipes will be issued to all crews. All persons, except when in offices or similar accommodation will wear: safety boots safety helmet safety glasses high visibility jackets or waistcoats a coverall No one will enter any work site without the correct PPE

5.2

Environmental
The HSSE manager or his deputy will give a general environmental induction to all personnel with special emphasis on pollution prevention. All vehicles shall carry First Aid kit

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Rev : B

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AED PROJECT EPCC OF TRUNKLINE AND ASSOCIATED RECEPTION FACILITIES AND TIE-INS AT WAHA CPF
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6.0 6.1

DESCRIPTION OF WORK Preliminaries

The pipe should be placed on sand bags elevated from ground level not less than 40cm above ground level and easy accessible by coating working team. This is carried out ahead of lowering-in operation Application of field joint coating requires strict measures relating to safety and preservation of coating at all the work stages.

1. RAYCHEM sleeve HTLP60-1-15.

This sleeve is: Good up to 60 degrees Celsius operating temperature of the line pipe. Suitable for the 6" diameter line pipe. It has 1mm backing and 1.5mm adhesive thickness. With a closure patch is pre-attached on the sleeve. Compatible with a 3-layer polyethylene factory coated pipeline.

All accessories and repair material needed for this application shall be provided on site. The mixing ratio for the epoxy primer for the sleeves is 3 parts of S1301-M-part-A and 1 part of S1301-M-part-B by volume. The pumps are already calibrated for this purpose. The amount of epoxy should be enough for the number of sleeves. Epoxy should be applied on the bear steel only.

During shrink sleeves application the works are carried out in the following sequence: Cleaning of the field joint by sand blasting to SA2.5 Inspection of the materials supplied as to their conformity to the design and standards; -free pulling of a sleeve together with wrap on the pipe; - heating of the weld zone after welding; Removal of the wrap and pulling of the sleeves on the joint with an overlap not less than 10 cm; Alignment heat shrinking and adjustment of a sleeve to the surface coated; Quality control of the coating in the weld joint zone. Heating of the weld zone is performed by hand burners. Heating temperature is defined by the technical specifications for this type of shrink sleeves and further controlled. Alignment of a shrink sleeve with the pipe base coating is done by adjusting wedges. Heat shirking of a sleeve starts from the middle. For this purpose the burner is held not closer than 15 cm from the sleeve and transferred by reciprocating motion along the perimeter of the sleeve until the latter is pressed by its middle part to the surface of the weld joint. After shrinking of the middle part of the sleeve this process continues from the middle to the edges of the sleeve to accelerate levelling of the surface improve adhesion silicon rollers are used.

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JT-167-MEC-MS-005-00

Rev : B

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Lowering of the pipe section into the trench is carried out by the pipe installation spread with the use of soft belts. Soft belt lowering is performed by the "taking-over" method. The pipe lowering into the trench is carried out to place weld joints in 10:00 and 2:00 oclock position. Prior to lowering in all pipe coating, both factory coating and field joints, will be holiday detected set at 15000V. 6.2

Joint coating repair.

In case of scratches (holidays and cracks up to 10mm x 10mm): Use a clean cloth to remove surface dirt, dust and debris from the damaged coating section. Application of Melt Stick, which may be used to fill the damaged area completely. In case of damage (small but deep damage up to 150mm x 150mm): Use a clean cloth to remove surface dirt, dust and debris from the damaged coating section. Use a sharp knife and/or file to remove all delaminated, damaged and unbounded coating from the damaged area. Use a knife to rot away any jagged edges and interfering materials that may impede the filling of the damaged region with repair materials. Using power brush and/or band wire brush abrade the exposed metal surface and damaged section to provide an anchor profile for the repair coating products. Typically, if the damaged area is less than 2" (50mm) in diameter a band wire brush is used for surface preparation to prevent additional damage to the coating section. Wipe clean or air-blast the prepared surface to remove debris and dust from the prepared surface Preheat the bare metal exposed region to a minimum temperature of 40C (104F) to remove all surface moisture and to provide surface heat for subsequent stage. Apply E-Primer epoxy to the bare metal using appropriate mixing instructions as shown above. The epoxy should be applied to cover all exposed bare metal to a thickness of minimum 4 mils (100 microns). Force cure the epoxy using a propane torch to a temperature of 90C tacking care not to damage the surrounding PE mainline coating or heat shrinkable sleeve. Using an emery cloth, hand wire brush or mechanical brush abrade the surrounding mainline coating to be covered by Repair Patch, with an additional 50mm around the entire perimeter of the patch also abraded. The abrasion acts as an anchor profile for the repair patch and removes surface dust, dirt and debris. The repair patch should be cut to size using the following guidelines: The minimum overlap of the repair patch should be 2" (50mm) beyond the edges of the entire repair zone. The corners of the repair patch should be trimmed 10mm at a 45 angle. Gently preheat the area to be covered by the repair patch with a low intensity flame to Remove the release liner from the cut to size repair patch and gently heat the adhesive gicle of the path until the adhesive becomes glossy and softens. Gently reheat the damaged area to en sure that is warm prior to repair patch placement. Apply the adhesive side of the patch to the damaged area and press down over the entire patch surfaces area firmly. Heat the patch with a low to moderate flame intensity, and using a roller or gloved band, part down or roll to remove wrinkles and promote adhesion. Roll any entrapped air pockets to the edge of the repair patch and remove. Continue heating and rolling the repair product until adhesive fiow is evident along the entire edge of the repair patch

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6.3

Post Work Operations

All areas will be left clean and tidy and secure, with all unnecessary equipment removed and returned to stores. 7.0

Annex 1 Safety And Environmental Risk Assessment record

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AED PROJECT EPCC OF TRUNKLINE AND ASSOCIATED RECEPTION FACILITIES AND TIE-INS AT WAHA CPF
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RA Ref. : JT167-RA-05; Subject : Field Joint Coating Location: Waha pipeline Responsible Person: Site Supervisor Date of RA : 08/12/2013

RR = Risk Rating 0-8 Trivia 12-24 Adequate control 32-48 Moderate risk 60+ Intolerable L= Likelihood Certain 10 Very Likely 8 Likely 6 May happen 4 Unlikely 2

S = Severity Slight injury / First Aid 2 20 16 12 8 4 Minor/ Serious Injury 4 40 32 24 16 8 Major Injury DAFWC > 1 days 6 60 48 36 24 12 Single Fatality/ Permanent Disability 8 80 64 48 32 16

Multiple Fatality 10 100 80 60 40 20

No.

Hazard

Effect

Risk Analysis (No Controls)

Risk Analysis (With Controls) Control Measures Evaluation

R Use a banks man with all plant works and ensure certified operators. Banks men trained & in possession of passport to confirm. Firm base for plant when excavating correct batter of trench. Machines and plant kept away from edge of trench. Trench sloping or stepped depending on soil type. Excavated soil minimum of one metre from trench. Check sides for slip. Ensure good stance. Do not over-reach. All excavations to have a barrier, by use of a fence at a distance of one meter from the edge of the excavation and warning signs to be clearly displayed.

kely

1.

Plant movement

Crushing, trapping, death

48

24

AC

2.

Trench collapse

Crushing, trapping, death

48

24

AC

3.

Falling in trench

Broken bones, cuts, crushing, death

48

24

AC

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AED PROJECT EPCC OF TRUNKLINE AND ASSOCIATED RECEPTION FACILITIES AND TIE-INS AT WAHA CPF
JT167/2013 MST Battered to correct angle. Inspection by a competent person at regular intervals. All plant and vehicles kept away from edge of excavation. Banksman to ensure a safe distance for vehicles to pass Traffic control. Traffic Management Plan to be adhered to. Ensure all tripping hazards are removed, site cleanliness. Trench inspections regularly to identify potential side wall instability. Suitable means of trench support as necessary. Suitable means of egress where appropriate. No plant within 1.5m of trench edge.
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4.

Trench collapse

Crushing, trapping, death

32

24

Other plant and 5. vehicles falling into trench 6. Road traffic accident

Crushing, trapping, broken bones, death

48

Adequate control

24

Physical injury, possible death

32

24

Adequate control

Falling into 7. trench with line pipe

Physical injury, possible death especially if trench collapses on top of worker.

Adequate control

48

24

Moving plant and equipment, 8. in particular screening plant

Crushing, trapping, death

48

Use a banksman with all plant undertaking works and ensure certified operations.

64

Adequate control

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8.0

Annex 2 ENVIRONMENTAL IMPACTS AND MITIGATION REFERENCE

REF NO: RA-PH-05 ISSUE A

SUBJECT: Field Joint Coating ENVIRONMENTAL IMPACT / CONSEQUENCE Damage Loss of natural habitat Large volumes of dust create a nuisance to residents and damage crops MITIGATION OR REQUIREMENT Heavy vehicles are to remain on the right of way. Areas of plant life are to be avoided. In dry weather, spray the spread with water Reduce vehicle speed Plant refueling operations to be carried out by trained and competent personnel. Any fuel spillage is to be cleaned immediately. Pipe hauling trucks are not to be fueled on the pipeline spread. Any discovery of archaeological items will be reported to the relevant authority for examination prior to works recommencing. Any waste material generated during the pipe hauling, stringing and bending operations will be immediately cleared and returned to the main storage area for correct disposal. All equipment to be maintained Induction and tool box talks Site presence of environmental personnel Daily, weekly, monthly system of checks

Flora & Fauna

Dust

Fuels / Oils

Spillage causes ground and water contamination

Archaeology

Damage to sites Loss of content of finds

Waste

Not classifying and segregating waste leads to uncontrolled waste on site

Exhaust Fumes Training Inspection / Auditing

Emission of noxious gases Lack of training does not promote best practice, increases potential for non-conformance Lack of inspection produces a fall in standards of best practice

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JT-167-MEC-MS-005-00

Rev : B

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