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PROCEDURE
(METHOD STATEMENT)
FOR
PROCEDURE (METHOD
STATEMENT) DETAILS FOR
INSTALLATION OF
FLEXPIPE (FCP)
SHELL PETROLEUM DEVELOPMENT COMPANY
Revision: A Rev Date: 27/02/17.
SIGN
SHELL PETROLEUM DEVELOPMENT COMPANY
Revision: A Rev Date: 27/02/17.
TABLE OFCONTENT
Introduction 4
Purpose 4
Scope 4
Responsibilities 6
Emergency Response
Collection/Mobilization to site 8
1.0 Introduction
PETRA Services Limited has been awarded a contract to undertake the Installation of Flexpipe
(FCP) at different SPDC locations.
2.0 Purpose
This document is for the purpose of developing work procedure for all the activities that will be
carried out during modification of the Installation of Flexpipe (FCP).
3.0 Scope
This document shall apply for Installation of Flexpipe (FCP) at different SPDC locations. It must be
appreciated, that the methods as detailed herein may be subject to revision or modification
depending upon prevailing conditions and circumstances encountered on site; however major
changes shall be approved by the SPDC prior to implementation.
6.0 Responsibilities
The organization that shall be responsible for the execution of this document shall be as
described below:
• The Project Manager shall have overall responsibility for the successful and safe execution of all
activities on the Project.
• The Construction Manager shall be responsible for the successful and safe execution of this
document. He shall delegate as may be necessary, all or part of this function to the Field Project
Engineer.
• The HSE Manager shall be responsible for the monitoring of the HSE aspects of this document
and shall delegate all or part of this function to the Site HSE Officer.
• The Field Project Engineer shall in addition to undertaking as directed by the Construction
Manager, have direct Site Management responsibility for a safe and successful execution of this
document.
• The HSE Officer shall undertake as directed by the HSE Manager and shall carry out Site HSE
surveillance and ensure HSE compliance
• The Construction Supervisor shall have direct responsibility for the successful and safe
execution of all the excavation, thrust boring, installations, tie-in, NDT, pressure testing,
backfilling and site restoration activities.
• The entire crew shall be responsible for safe and successful execution of the tie-in modification
activities.
7.1
SPECIFIC SAFETY REQUIREMENTS
There must be daily toolbox meeting every morning prior to commencement of work to
be delivered by PETRA Services in the presence of client representatives.
SHELL PETROLEUM DEVELOPMENT COMPANY
Revision: A Rev Date: 27/02/17.
All key personnel on this section of the works are to be experienced in construction and
shall be inducted into this method statement. Records of attendance at the toolbox
meeting shall be kept and filed on site.
Work procedures shall be in accordance with this Work Method Statement. These shall be
presented at a toolbox talk, prior to commencement of the works. Records of attendance
at the toolbox meeting shall be kept and filed on site. All lifting equipment are to be
inspected and approved as prior to use.
All equipment, together with the working areas, are to be regularly inspected.
SPDC PTW is required for all works within the Pipeline vicinity.
A sign indicating their location shall mark the muster points. The location will be
communicated to the workers at the daily start/toolbox meetings and advertised on
message boards.
In any case where there is an incident directly related to the pipeline, emergency
response team of SPDC focal points shall be contacted:
7.2
EMERGENCY RESPONSE
Petra Services shall procure all project materials and mobilize all the necessary equipment and
personnel for the execution of the works at SPDC site. The equipment includes specific and
general tools for the installation of the Flexpipe Systems FCP and tools for the installation
Permeation Barrier. (remove?etc shall be certified by SPDC representatives and certified fit for
the execution of the works.) Before commencement of the work, a meeting will be held with the
project Engineer, the asset owners and Petra Services site representative to harmonize activities.
I. Prior to performing the survey, access permission and other required permit will be
obtained from the Shell Representative.
II. The survey crew will locate the pipeline traces cut during the original survey using the
pipeline, the survey Drawing, supplied by Shell.
III. On verification that the traces located are those for the Reinforced Thermoplastic system
Pipeline, the survey team will flag pillars in to identify the ROW to be cleared.
IV. The contractor will commence clearing the vegetation from the traces that may have
grown and obstructed sight line since the original survey. This vegetation will be cut by
hand using machetes and chainsaws.
V. A record will be kept of any survey pillars that are missing or have been damaged. The list
of damaged or missing pillars will be forwarded to Shell.
VI. Any missing pillars will be replaced by temporary stakes. The purpose of these stakes is to
delineate the right of way limits for use in subsequent clearance operation. The temporary
stakes used will be cut from trees in the right of way and will be marked with flagging tape.
VIII. After the ROW has been cleared of any vegetation by the contractor, the surveyors will
stake out the ditch line in accordance with the pipeline route survey at intervals not
exceeding 100 meters, unless this is not possible due to the ground conditions.
IX. In addition to the staking out of the pipeline center line, the precise location and depth of
all facilities in the construction area, in addition to the location of facilities provided by
Shell, will be recorded in the survey Record Book by the senior surveyor.
SHELL PETROLEUM DEVELOPMENT COMPANY
Revision: A Rev Date: 27/02/17.
X. Where the proposed flow line route crossed another flowline, the exact depth of the
flowline to be crossed will be veryfied by using probes to identify the location of existing
line.
7.4.2 EXCAVATION
Purpose
The primary object for excavation is to bury the pipeline for protection from adverse weather,
protection from tampering by unknown persons and to minimize the outflow of damage that will
lead to leakages.
I. Provide a ditch that could accommodate the pipeline during installation. The scope of this
Procedure comprises the excavation methods, which will be employed in the land and
swamp to produce the ditch in which the pipeline will be installed.
II. To ensure that the process is done in a safe manner taking into consideration the technical
requirement approved.
III. Prior to commencement of the excavation and trenching activity, a detailed Job Hazard
Analysis will be carried out. After all known, suspected or potential hazards and risks have
been identified, the workforce shall be informed of the hazards and control measures that
must be in place to eliminate or control the hazards and potential risks surrounding the
excavation and trenching activity. The JHA for this activity is attached here as a part of the
procedure. (JHA is to be made and does not need to be much different from installing steel
pipe)
IV. All personnel involved in excavation and trenching operations will have received Safety
induction, trenching and the job-specific training required for the particular operations in
which they will participate.
V. All the work force shall wear the appropriate Personal Protective Equipment (PPE)
reference to job specific JHA. All the work force shall comply with Contractor’s Health,
Safety, and Environmental Requirements as per the HSE Plan.
VI. Only authorized personnel shall be allowed in the work area. All necessary measures as
per Client’s requirements or manufacturer’s recommendations or specification shall be
followed.
7.4.3 Preparation
Before manual excavations for the pipeline begin, the Foreman shall confirm that the ditch
line has been staked out by the survey crew and that presence of any underground
facilities has been determined.
No excavation shall proceed until the Site Manager/Engineer has obtained all relevant
grants, licenses, authorizations and work permits pertaining to construction of the ROW
and has authorized the Foreman to proceed.
SHELL PETROLEUM DEVELOPMENT COMPANY
Revision: A Rev Date: 27/02/17.
A valid copy of the ‘Fitness Certificate’ for all personnel must be at the site at all times and a copy
of these certificates must be submitted to the Shell CSR (Company Site Representative) prior to
commencement of the works.
Excavation and Ditching is carried out manually utilizing machetes, shovel. The Foreman shall
supervise the excavation and ditching.
Areas around underground services shall be exposed by hand digging to positively locate the
service.
The Foreman shall ensure that excavations 1.0m by 1.6m depths are completed as shown on the
construction drawings and in accordance with the client specifications.
Any excavated material that is unsuitable for backfilling operations shall not be reused.
The Foreman shall complete the Daily Ditching and Backfilling Report, and forward this to Site
manager.
Road crossing with FCP shall be carried out following the SPDC standard drawing for open cut
crossing as shown in the design drawing. Road crossing shall be installed with a minimum cover
of 1.5 meters between road surface and the top of the pipeline.The FCP pipe shall be placed on
a sand bedding not less than 15 cms thick and shall then be surrounded with similar compacted
material to at least 15cms above the top of the pipe. A 20cms thick compacted layer of, assorted
sand shall then be placed in the trench and on top of this layer, a reinforced concrete slab shall
be constructed over the entire length of the road crossing. The slab shall be not less than 10cms
thick and the width shall not be less than the overall diameter of the pipe plus 30cms above the
concrete slab, the road bed and road surfacing shall be back filled and fully reinstated.In-line
coupler connections should be at least 20 meters away from the road crossing.
FS pipes can be connected with flanged end fittings (150, 300, 600 and 900 ANSI flanges),
coupling fittings to interconnect FS pipes and weld neck fittings.
Select the appropriate die sets by verifying that the color on the crimper dies correspond to
the product size.
Make sure the dies are clean and free of defects. A wire brush can be used to clean them.
Select the length of bolts that correspond to the dies used.
Bolt all six (6) dies into place using a 5/16” Allen wrench. Make sure the bolts are firmly
tightened and the faces of the bolts are recessed so that they do not extend past the
surface of the dies.
6.4.2 Crimper hose set up
Only one hose from the 4-way valve should be connected to the crimper: the supply line.
This hose connects to the tee fitting, which directs the pressure into both halves of the
crimper. The other hose from the 3 position remote valve that doesn’t attach to the crimper
should be capped.
6.4.3 Operating the crimper
Place the bottom half of the crimper under the pipe. Do not position the bottom half under
the crimp fitting.
Slide the upper half of the crimper onto the bottom half and pin the halves together.
Ensure that the pressure relief valve is set correctly.
Start the hydraulic pump unit and close the dies (not on the fitting at this point) to ensure
that all dies close evenly. Open the dies back up and position the crimper to line up the
crimper dies..
Pressurize the crimper by turning the 3 position remote valve into the ‘close’ position.
Once the unit has reached the required crimping pressure, hold the pressure for 20
seconds.
Follow the further procedure as per the instruction manual
The purpose of the Permeation Barrier System (PBS) is to prevent Hydro Carbons(HC)
permeating through the Poly Ethylene (PE) pipe into the soil. FCP is made of PE with a
reinforcement layer of aramid. A known phenomena of pipes made of PE is that light HC’s
permeate through the wall. For the application it is estimated that about 30kg per km of pipe
permeates through the wall per year. The HC’s range roughly from C1 to C12. The lighter the
molecule, the easier it permeates. The lighter HC’s evaporates at ambient conditions but the
heavier ones pollute the soil and water table when the pipe is buried. In case of above ground
installations, abundantly done in the Middle East countries, all the HC’s evaporate. Governing in
this matter is the opinion that in particular aromatic components such as Benzene, Toluene and
Xylenes are to be avoided to be dissipated in the soil and water table at measurable quantities as
they have carsinogenic properties.
Before installing the foil, the FCP pipe will have to be wrapped with a net structured material to
prevent transport blockage by soil pressure and to enable transportation alongside the pipe into
the collection drum.
The FCP pipe-on-reel will be transported to site on a low bed trailer. At site a crane will lift the
pipe into a stationary A-frame. FS pipe can be un-spooled from a stationary A-frame by attaching
the free end of the pipe to a truck or track hoe. Ensure that the FS pipe is un-spooled in a
controlled manner at average walking speed of 5 km/hr,
Excessive pulling force is to be avoided and the instruction manual is to be followed to minimize
this force.
The pipe can be lowered into the trench by 4 to 6 people walking along the trench and lifting and
bringing the pipe into the trench
A job Hazard Analysis (JHA) of the job to be done is prepared, identifying the hazards
involved,assessing them,put in place control measures and recovery measures should the
control measures fails.
Raise and validate a permit to work (PTW) before the commencement of any work.
A tool box talk is carried out with workers to discuss the activities for the day and the hazard
involves and their controls.
Load the pig in the pipe-end on the lowest pipe level.
Connect the test equipment at the pipe-end on the lowest pipe level.
Fill the pipe with water at the pipe-end on the lowest level.
Connect the test equipment at the end where the pig emerges after filling.
SHELL PETROLEUM DEVELOPMENT COMPANY
Revision: A Rev Date: 27/02/17.
10.0 HOOK-UP
Since there will be a connection of stainless steel to carbon steel the flanges will be electrically
isolated. This will be done by using an isolation set, consisting of isolation washers, stud bolts
sleeves and gasket. In this case standard stud bolts will be used. Isolation of both parts protects
the parts against corrosion due to material potentials differences.
If possible move the pipe by hand rather than make use of vehicle
Make sure the pipe is not damaged by moving action
Make sure moving the pipes does not change the run of the pipe in other sections, for
instance pulling the pipe into a too small bend or putting unnecessary tensions on the pipe
body or other couplers.
Make sure the pipe length is long enough to reach hook-up, and have enough length to form a
small bend (lazy S-curve) even in the maximum excursion of the hook-up point.
Make sure no unnecessary stress is introduced during bolting up the connection.
The procedure for bolting up FS pipe to existing pipe work is the same as for bolting up
existing pipe work.
Do not use the fixing of the stud bolts for locating the FS pipe flange in the right direction. Just
make sure enough pipe length is available and position by hand.Small corrections are no
problem.
11.0 COMMISSIONING
The commissioning activities shall be done using established work procedures and instructions
indicated in applicable codes and standards in the documentation reference.
30cms above the concrete slab, the road bed and road surfacing shall be back filled and fully
reinstated.In-line coupler connections should be at least 20 meters away from the road crossing.
13.0 DEMOBILIZATION
The Project Engineer informs asset owner of the completion of installation and requests for line
opening and commissioning handover notes signed by asset owner.
Petra servicesshall clean up and restore the site to its original state and then demobilize all its
equipment and personnel.