Grp Procedure

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Orp1c SI. No. 1

Contractor Comments on Rev.04 Construction/ Engieering Comments at Page No. 6, 7 & 17.

Comments Resonse Sheet (120476/Jl-02022/27-06-01/MMS-04 AHEC Response

,

Rev. 5) AHEC

'

Method Statement revised as per Construction/ Engieering Comments at Page No. 6, 7 & 17.

M s.

DAU trofac 1 DPJV

Signature

d •••

=- "

al Hassan

Remarks

2

3 4

5

6 7

CRS Page 1

DAELIM Petrofac CONTRACT NO. - 21297

DAELIM-Petrofac SRIP JV

.:, ,,, -. II al Hassan

JOB NO :120476 / Jl-2022

AHEC JOB NO.:B-212

SOHAR REFINERY IMPROVEMENT PROJECT

METHOD STATEMENT FOR UNDER GROUND GRP PIPING PACKAGE - 3 & 4 -

A

Revised as per comments As per comme.nts JHA Revised & MHDS I attached

5

07-July-2015

4

27-May-2015

3

14-May-2015

2

03-Jan-2015

1

09-Nov-2014

0

8-0ct-2014

For Review

Rev.

Date

Descriptior

As per HSE' comments JHA Revised FPI Documents Attached for Approval Comments incorporated & re issued for Approval

AHEC JOB NO.:B-212

Owais Kareem

Deepak Pawar

Kameshwar Rao

Prepared

Checked by

Approved by

by

PROJ. ENG.

SIGN

DP - JV APPROVAL

DOCUMENT TYPE :

DOCUMENT NO.

Page

Mechanical Method Statement

120476 / JI -02022 / 27-06-01 / MMS - 04

1of 27

,).,Jq i Orp1c Section No: 1

Method Statement For Under Ground GRP Piping

-

rol&: 1 1. al Hassan

INDEX CONTENTS PURPOSE

Page No. 3

2

SCOPE

3

3

REFERENCES

3

4

DEFINITIONS / ABBREVIATIONS

4

5

MANPOWER

5

6

RESPONSIBILITIES

5

7

EQUIPMENTS &INTRUMENTS

6

8

HANDLING & STORAGE

6

8.1

LOADING & UNLOADING

6

8.2

STORAGE OF MATERIAL

7

9

I NSTALLATION OF UNDERGROUND PIPE SYSTEM

8

9.1

THE TRENCH CONSTRUCTION

8

9.2

SPOOLS LAYING

9

9.3

BACKFILLING

9

ADHESIVE BONDED JOINT

10

10.1

SURFACE PREPARATION PRIOR TO ADHESIVE BONDING

11

10.2

SEQUENCE OF WORK

13

10.3

REPAIR

19

LAMINATION JOINT

19

REPAIR

22

12

FLANGED JOINT

23

13

FLANGE TIGHTENING

23

14

TIE-IN JOINTING, FITTINGS, BENDS

24

15

REPAIRS

25

16

HYDRO TESTING

26

17

HSE REQUIREMENTS

26

17.1

SUPERVISION

26

17.2

HSE REQUIREMENTS

26

17.3

PTW REQUIREMENTS

27

18

DOCUMENTS

27

19

ATIACHMENTS

27

10

11

11.1

l Doc. No: 120476 / Jl-02022 / 27-06-01 I MMS-04 j Rev. No: 5 j Date: 07-July-2015

Page 2 of 27

,) .,JQi Method Statement For Under Ground GRP Piping

Orp1c 1

1111-1 1 .

PURPOSE

.

The purpose of this Method Statement is to define the Scope of Work and sequence of performing Bell & Spigot Jointing

(Adhesive Bonded Joints), Lamination jointing

and

Flange Joints of various diameters for the installation of underground GRP piping work for Sohar RefineryImprovement Project. This Method Statement is as complete as possible, it is not possible to describe all circumstances that may be encountered in the field. For this reason FPI experienced supervisor may vary the described procedure in order to achieve an optimum solution using the latest techniques and processing method. 2

SCOPE This Method Statement

covers the

minimum requirement for the installation of GRP

underground piping work for Sohar RefineryImprovement Project 3

REFERENCES

GRP nstallation Manual S-000-5360-106

Issued by GRP Supplier. Technical specification components.

for

FRP

piping

and

ISO 14692 - 4

Petroleum and natural gas industries GRP piping - Fabrication,installation and maintenance.

ISO 14692 - 2

Petroleum and natural gas industries GRP piping - Qualification & manufacture.

ISO 14692 - 1

Petroleum and natural gas industries GRP piping - Vocabulary, symbols, applications & materials.

D-000-5311-003

Geotechnical nvestigation (soil report).

ASTM D 1599

Standard Test Method for Resistance to Short Time Hydraulic Pressure of Plastic Pipe, Tubing, and Fittings.

ASME B 31.3

Process Piping.

Applicable "Approved For Construction" Drawings.

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Page 3 of 27

"' .,JQI Method Statement For Under Ground

Orp1c 4

DIEIIHetrolac

GRP Piping

DEFINITIONS / ABBREVIATIONS The word shall indicate a requirement. The word should indicate a recommendation. The word may indicate a possible course of action.

OWNER

Oman Oil Refineries Company SAOC

MAIN CONTRACTOR

Daelim and Petrofac

DPJV

Daelim - Petrofac Joint Venture

SUB CONTRACTOR (AHEC)

Al Hassan Engineering Company SAOG

QP GRP SUPPLIER AFC ASTM BPS BPQR

cs CSR GRP I GRE HSE ISO

ITP MEK MIBK BA SA TS TB QA QC ID OD FLG BOP STD STHP

and

Petroleum Industries

Sub Contractors Quality Plan Future PipeIndustries (FPI) Approved For Construction American Standard for Testing Materials Bonding Procedure Specification Bonding Procedure Qualification Record Carbon Steel Company Site Representative Glass Reinforced Polyester

I Glass Reinforced Epoxy

Health, Safety and Environment International Organization for Standardization Inspection and Test Plan Methyl Ethyl Ketone Methyl sobutyl Ketone Bell Area Spigot Area Tapered Spigot Tapered Bell Quality Assurance Quality Control Inside Diameter Outside Diameter Finished Level Ground Bottom of Pipe Standard Short-Time Hydraulic Pressure

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015

.

al Hassan

Page 4 of 27

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Orp1c

S

Method Statement For Under Ground GRP Piping

- ac 1 1

MANPOWER Allocation of Manpower shall be in line with the Site Organization Chart appended as Annexure to QP. As a minimum the following personnel shall be available Depending on the

activity:

• Construction Manager. • QA/QC Manager. • HSE Manager. • QCInspector. • Discipline Supervisor / Foreman. • GRP Supervisor. • Bonder / Lamination Technician • Riggers and Helpers. • Crane Operators. Personnel involved in these activities shall follow the necessary safety precautions during preparation, assembly, erection, installation and jointing of GRP piping work. 6

RESPONSIBILITIES • Construction Manager Responsible for all site GRE activities and provides assurance that all related activities like preparation, execution, testing of joints in site fabrication yard as well as job site are performed in accordance with project specifications, safety and quality requirements.

• QA/ QC Manager Responsible for a ll quality activities during installation and fina l inspection. •

HSE Manager Responsible for safety matters and safety monitoring of all activities relating to the transportation, placement and installation of the unit.

• QC inspector Shall ensure and monitor the implementation of this Method statement during installation works.

• Discipline Supervisor / Foreman Responsible for overall implementation of this Method statement. Responsible for coordination of lifting activities and communication with others. Responsible for all installation works including the GRE jointing with qualified technicians.

! Doc. No: 120476 / Jl-02022 / 27-06-01 I MMS-04

! Rev. No: 5 ! Date: 07-July-2015 !

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al Hassan

Page 5 of 27

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Orp1c

Method Statement For Under Ground GRP Piping

Dllll ac l I

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al Hassan

• GRP Supervisor Shall be responsible for implementation of this Method statement during jointing

works.

• Bonder / Lamination Technician shall have qualification certificate Issued by Vendor for jointing of GRP Pipe / Fitting. • Riggers & Helpers

directly

Lifting plan is coordinated and communicated to all involved and to communicate with crane operator during lift.

Ensures the area being barricaded before commencement of any lifting activity with crane. Identifies the type of lifting arrangement with respect to material. Ensures tools & tackles used for lifting are inspected and have valid certification. Helpers shall be equipped with mandatory and work related PPE'S. Helpers shall follow the instruction of the respective discipline

rigger/foremen/engineer.

• Crane Operators Shall follow the instructions & signals given by Rigger and Banks man. Shall have Valid Third Party Certification for the respective crane. 7

EQUIPMENTS & INSTRUMENTS • Appropriate tools & equipment in safe working condition shall be used. The same shall be monitored by the Discipline Foreman and QCInspector. All inspection instruments shall have valid calibration at the time of use. • Equipment shall be handled and operated by the trained or authorized personnel as instructed by Discipline Foreman and Supervisor only. • All the equipment shall have valid Third PartyInspection Certificates (Wherever required).

8

HANDUNG & STORAGE

8.1 LOADING & UNLOADING The GRP pipes, spools, fittings and jointing materials (stored in controlled temperature), etc. received will be off loaded and stored in suitable designated location. End protection of piping components shall remain in place during handling & transport. Chains, wire ropes or clamps will not be used during lifting. For loading / unloading Suitable Third party certified Nylon or Canvas hoisting belts with a width of 10cm & 20 cm shall be used.

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Page 6 of 27

,..,,_ , Jqi

Method Statement For Under Ground GRP Piping

DIEUI "'ac

al Hassan

.

Orp1c Standard pipe lengths shall be picked up at two or more supporting points. Hoisting belts shall always be placed around the widest part. During transportation, all components shall be firmly secured to prevent excessive

8.2

STORAGE OF

movement.

MATERIAL

In order to avoid damage to the stocked pipes, fittings and bends the following rules must be observed: a) Do not lay the pipes directly on the ground, onto rails or concrete floors. Provide a flat surface, i.e. compacted sand. b) Pipes shall be stacked in heights up to 1.5 meters with side supports provided. c) Suitable supports / Spacer stripping shall be used for example Plastic or wooden, (approximately 10 x 5 cm), as supports for the pipes and as separators between pipe layers. d) Pipes of small diameter may be stored inside pipe of large diameter and spacers provided to prevent contact between pipes. e) Manufacturer instruction should also be followed for storage of pipe, fittings, etc. f)

The distance between supports shall not be more than 3 m. To avoid damage to pipe ends, stocking shall be undertaken with care. (See Figure below).

g) Pipe stacks shall have side supports or blocks to prevent rolling or slipping of the stack. h) Unprotected flange-faces shall never be placed directly on the ground or on concrete floors. i)

All pipe ends to be covered.

j)

All pipes / flanges / elbows etc. shall be properly covered (if required as per manufacturer instruction) with suitable / applicable covering.

k) The site storage of cement kits should be maintained under an ambient temperature of 20=25 C under a shaded area or as per manufacturer recommendation, to achieve the optimum performance of the product.

·-·-·- -·-·-·-·-·-·-·-·-·----- L._ - ' :r

mcx.

3;r.

max. 3m.

m.

-l

..I

-·-·-·-·-·-·-·-·-·-·-·-·-·-·-i - -

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Page 7 of 27

,) . ,JQi

Method Statement For Under Ground GRP Piping

Orp1c 9

-

al Hassan

INSTALLATION OF UNDERGROUND PIPE SYSTEM Special attention needs to be given to

the

bedding

(minimum

backfilling of the trench, this provides the necessary support of

150mm), side the

pipe,

filling and

and hence

manufacturer instruction shall be followed. It also prevents settlement and possible damage by the soil and / or traffic. Resistance to horizontal movement of the pipe depends on the soil type, its density and moisture content. The greater the soil resistance, the less the pipe will deform or move, when fully buried

and

compacted. 9.1

THE TRENCH CONSTRUCTION The Civil Contractor will open the trenches as per the approved issued for construction drawings. Depth of trench should be 3.800 Mtrs as per approved drawing. Proper side slopes protection must to be maintained due to deeper excavation of trench . The trench dimensions should comply with the requirements specified in pipe manufacturer's installation manual and those mentioned in the procedure. Details of local soil conditions and water table should be obtained from Geotechnical Investigation (soil report) prior to trench excavation. The minimum width of the bottom of the trench for a single pipe should be at least 1.5 times the pipe diameter or as per GRP supplier instruction manual or as suitable space required for Lamination joint. For multiple pipes, the distance between pipes should be at least 0.5 times the

larger pipe

diameter and the gap between the outer pipe and the trench wall should be at least the same width as for a single pipe. The pipe trench shall be smooth, regular and free from stones or any other hard objects, which may damage the pipe or cause stress concentrations. The surface of the bedding layer should be at the same elevation as the pipe invert

level.

The trench should be over-excavated under the joints as mentioned in "Requirements from Civil Contractor" to allow for space required for the jointing activity, as well

as

inspection

for

monitoring leaks during hydro test. Pipe laying will be started only after the Trench is accepted.

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Page 8 of 27

,.., .,JQi Method Statement For Under Ground

Orp1c

GRP Piping

1111 dac & . .

9.2 spools Lavina The spools will be laid in the trench by Mechanical Contractor under according to the coordinates and the elevations specified in the approved isometrics, or otherwise as directed by Client. Ideally water should be removed from the trench prior to pipe laying & backfilling. All pipes shall be carefully inspected for damage during loading, unloading and or laying before installation.

Each pipe/spool shall be cleaned inside and maintain cleanliness. Open ends of the installed line shall be covered with caps at end of each day to avoid contamination and entry of animals. Pipes can be double-jointed beside the trench in order to reduce the installation time. The pipes can be lowered into the trench after curing of the joint. This must be done with reasonable care in order to prevent overstressing of the pipe. Do not move the joint during curing. Following are the methods, which will be used for the installation and adjusting of pipe systems in the field: a) Adhesive Bonded Joint ( Bell & Spigot ). b) Lamination Joint. c) Flanged Joint. 9.3 BACKFILLING After the spools are jointed and inspected and if the "Line and Elevation" is approved i.e. (BOP, survey report verified by Construction & QA/QC prior to backfill), only then

will

the

Civil

Contractor start the backfilling. The Backfill material should be worked into the underside of the pipe before backfilling the trench. The lines will first be released for partial backfilling. The spools will be covered with the compacted backfill soil up to minimum one diameter above the crown level with a minimum of 300mm and a maximum of m. At this stage, the joints will be kept exposed to allow a proper inspection during the hydro test. t is important that partial backfilling follows closely the pipe installation as covered pipes will not expand due to thermal variations.

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Page 9 of 27

"' - ,JQI Method Statement For Under Ground GRP Piping Orp1c

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al Hassan

In the same form, the Civil Contractor will be also given the approval to pour concrete around the installed pipes as specified in the approved isometrics, e.g. at wall insert in the valve/discharge pits. After the successful hydro test, Mechanical Contractor will release the tested lines for complete backfill up to the grade level. The same release note used for the partial backfill release will be used at this stage. Backfilling shall be carried out in accordance with the procedures mentioned in manufacturer's installation manual. During Backfilling care should be taken

regarding

pipe top

elevation (FLG) with respect to above ground piping.

10

ADH ESIVE BONDED JOINTS Before adhesive bonding, all safety precautions shall be checked. Ensuring that all necessary tools and materials are available. No person may produce an adhesive-bonded connection unless that person has passed the bonding qualification test as per FPI Training procedure. The adhesive-bonded joint consists of a tapered socket end and a tapered spigot end bonded with an adhesive/hardener mixture. See figures 1and 2 below.

Tapered Spigot End - Figure 1.

,

O•.S x4

Taper Angle

• rt

59 r

-\

. I

(SA)

..... ...

• • •I

!

I

.

I

-·-·-·-·-·-·-·-·-·-·-·-1 •f l . . 0-/.-.././. / . . . . . .

0

0

.

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Page 10 of 27

,··) .,JQi

Orp1c

Method Statement For Under Ground GRP Piping

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1111 ac 1b1

Tapered Bell End - Figure 2.

,i i

·-·- -·-·

spigot funit

I

Before forming the joint every precaution shall be taken to ensure that all the moisture has been removed. f necessary, moisture, absorbed by glass fiber or subsisting on surface of the socket and spigot, must be removed by thoroughly drying with hot air gun or Suitable localized preheating as recommended by manufacturer. Contamination of the spigot should be avoided. It is essential that precautions shall be taken to avoid moisture on jointing surface when weather is highly humid, or having high density

fog. It is also recommended not to carry out bonding activities during sand storms and sand blown conditions. Temperatures and Relative Humidity Requirements: • The bonded assemblies may be performed only if the temperature of the pieces to be assembled is 3° C above the dew point and, •If the relative humidity is lower than 75%. Alternatively, • Temperature of the jointing surface is not more than 40° C.

10.1 Surface Preparation Prior to Adhesive

Bonding I nspection Before proceeding it is important to inspect all the pipes and fittings or any components, which are to be used in system prior to assembly of the joints. All pipes and fittings shall be visually inspected for damages that may have occurred during shipment. One hundred percent (100%) of the interior and exterior surfaces shall be inspected visually. Damaged pipe/fittings shall not be used in the system. Remove the end protectors and check these areas carefully for any possible damage. The male end is the more fragile of the two parts of the joint, i.e., if the male of the pipe is chipped, the edge shall be made square by cutting and re-formed taper end by machining.

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Page 11 of

,) .,JQi Method Statement For Under Ground

Orp1c

GRP Piping

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ac 1 1 . al Hassan

Visual inspection of all pipes and fittings including corrective actions shall be in accordance with Annexure-D of 150-14692-4. Each pipe spool shall be internally blown out with air or otherwise, cleaned to ensure that it is free from dust, dirt, sand, etc. prior to lowering into the trench/support. Adhesive bond kits shall be inspected prior to use to ensure that the expiration date has not elapsed. If any doubts or any clarifications are needed before the use of pipe, the subcontractor's personnel shall contact FPI and Contractor Site Supervisor.

Roughening and Cleaning of the Surfaces The grade of roughening and cleaning of the surfaces are directly proportional to the high quality strength of the joint. Roughening is by the use of flapper wheel or emery to remove the smooth shiny finish from the surface of either the spigot or socket, which subsequently make the adhesive bond between the two roughen structures. Cleaning Is essential to remove any contamination of the spigot & socket and any created dust during the roughening process.

Preparation of the socket & Spigot Each bonding surface shall be checked visually and cleaned using acetone to remove any grease or dust. Factory-formed spigot & socket ends have to be roughened using a flapper wheel or Emery Caps (40:60 grit) mounted on a 13 mm hand drill, at 2500-3000 rpm and by hand with emery sheet/ paper (40:60 grit). Also the control of roughening of the spigot end surfaces is very important. Over abrading of the spigot and socket will cause a loose fit of the joint during trial fit (dry fit). After roughening, the surfaces to be bonded should show a dull fresh finish, not a polished appearance. Dust removal from ends to be jointed shall be carried out using a clean dry brush or compressed air that is dry and free from oil. The surface of the spigot & socket shall be cleaned by swabbing with acetone or Methylene or other suitable solvent prior to the bonding using clean cloth. The cleaned surfaces shall not be touched or contaminated by oil, moisture or bare hands prior to bonding.If surfaces become wet or contaminated they must be cleaned / dried, re roughened made dust free using brush or clean cloth. Note that the bonding shall be executed immediately (Within 1 hour) after the surface preparation to avoid any dust and humidity that will contaminate the spigot and socket.

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Page 12 of 27

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Orp1c

Method Statement For Under Ground GRP Piping

DIUl ac l 1

al Hassan

.

Trial Assembly A trial assembly is required for each joint prior to bonding, to check the machining of the pipes and to determine the length of spigot penetration. There must be a gap between the stub of the socket and the spigot end that shall not be more than the dimensions as recommended by manufacturer. Measure and note the length of socket prior to trial fit. Align and engage the end of the spigot into the socket without turning the pipe, push it until the tapered surfaces are touching. 10.2

SEQUENCE OF WORK CONSTRUCTION FLOW CHART I - ----- - --- -- ---- ---..,

:

Pipe CUtting

:

I - - - - - - - - - - - r - - - - - - -

_1

I I I

------------ -----------'

calibration cl Pipe Ends :

I------------, -------------I

'

I

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _tI _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ I

Preparation of Factory Shaved Spigot

I I

I

•-----------------------L -------------------

I

I I I

______________y ________________ I I I

Preparation of Socket

I---------------, - - - - - -I '

I I

1---------------------t -------I

:

Joint Bonding / Curing

I

l

---------------------T----------------

I

1 I

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _tI _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ I

:

QA/QCInspections

I

:

·----------------------------------- · PREPARATORYWORKS The preparatory work shall be completed as per the agreed project specification and requirements shall be confirmed to all Method Statements, ITP and Job Hazard Analysis. Following are the completion of the related works shall be detailed below. Pipe Cutting The pipe section to be cut shall be marked using a marker pen and a pipe fitter's wrap-a-round guide. Ensure that the cut end is completely square as the reliability of the joint depends on

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it.

Page 13 of 27

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Method Statement For Under Ground GRP Piping

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al Hassan

Cut the pipe using an electric grinder attached with an abrasive cutting disc or other suitable tool. Ensure the cut ends are square and if any adjustment is to be made, use an electric grinder with abrasive disc. Pipe of nominal diameter up to lOOmm should have squareness up to 1.Smm or as per manufacturer recommendation. Cuts on larger pipes should be up to 3.0mm or as per manufacturer recommendation.

CALIBRATION Calibrate the pipe ends using the FPI supplied GRP shaving machine. Make sure to Reach the spigot dimensions as specified by manufacturer specially 51. The taper angle is achieved by using the cutting drum of the shaver machine that corresponds to the required taper angle.

Important Notes: a) Taking 51 as the controlling dimension, shave the spigot length SA at the required taper angle. b) The shaving length (SA) specified by the manufacturer is the minimum required cementing length. Actual shaved length is always longer therefore, application of cement should be maintained throughout the extent of the shaved length. c) Once the required 51 dimension specified by manufacturer is achieved, a joint geometry should be obtained or observed that allows a specified gap for different taper angle between the nose tip and bell stopper, provided by manufacturer. These gaps depicted in figure 2 should be maintained as much as possible. However, the installer shall rely on his judgment to determine the right position at which to stop pulling during joint Clean the calibrated spigot with a clean and dry cloth or use a dust

assembly.

brush.

FACTORY SHAVED SPIGOT {TS) The factory shaved spigots are in accordance with the required measurements within the specified tolerance. The spigot (TS) shall be sanded off using emery paper of suitable grade.

SOCKET {BELL END -TB} PREPARATION The top coat inside the bell end shall be sanded using an emery cup of suitable grade inserted In a rubber mandrel and fixed to the drilling machine. The sanding depth should not exceed more than that as specified by manufacturer which can be measured using a thickness gauge.

calibrated

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Method Statement For Under Ground GRP Piping

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Precautions: The prepared bond surface area should not have an influence of grease, oil, dust, moisture, water, etc. Clean the surface with a clean and dry cotton or dust brush. If any oil or grease is noticed on the bonding surface, soak the cloth in acetone or Methylene or other suitable solvent and clean the surface. Ensure that the bond surface is dry. Do not use water, paint thinners, petrol, etc., for cleaning purpose. Adequate precaution shall be taken in case of adverse weather conditions around the work place. Such as high humidity, mist, rain, sandstorms, etc. If the weather condition around the work area contain high humidity, mist, rain fall and sandstorm, etc., a) Arrange makeshift tents to protect the pipe assembly directly exposed to the atmosphere. b) The prepared assembly shall be heated up to avoid moisture content

on

the

bonding

surface. Use the heating blanket or hot air blower to warm up the joint. Once the warming process is completed, the joint shall be re-sanded before the cement mixture application. JOINT BONDING Fix the latch belts with side hooks, on both sides of the pipes. Use wooden blocks to prevent contacts between the come along jack and the pipe. After ensuring the pipe sections are adequately supported and aligned properly, check if the prepared bonding surface is clean, dry and free from dust, oil, etc., if not, sand it with an emery paper and make it fresh prior to application of the adhesive mixture. The prepared bonding surface should not be touched with a bare hand or dirty hand gloves. Mark a reference point on the spigot side at a length in excess of BA, as mentioned by manufacturer. BA is the bell length up to stopper. The BA dimension will be as per manufacturer recommendation. Mix the adhesive containers until mixture has a uniform color. Adhesive components should not be mixed partially.

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The expiry date of the adhesive components shall be checked before using the product at all times. Expired cement kits are not allowed to be used. Using a spatula or putty knife, apply a thin uniform layer of adhesive, to the inner surface of the socket. A thick uniform layer of adhesive has to be applied to the outer surface of the

Spigot.

It is important to ensure that no dust/sand or any other particles are mixed with adhesive or on the mixture spread of the bonding surface. The bonding process shall be completed before the setting time of the Adhesive Mixture detailed in Table below. Table Temperature of adhesive Setting Time

20°C

25°C

30°C

35°C

40-55°C

30 min.

25 min.

20 min.

15 min.

10 min.

The adhesive mixer will cure too fast if it is mixed above 40° C and the work shall be carried out within the pot life after mixing the two components. An important thing to be noted is that the adhesive mix should be spread on the pipe as fast as possible. A qualified technician shall perform the joining of adhesive bonded joints. Pull the pipe sections together by pullers, Secure the alignment of the joint during the insertion of spigot end in to the bell end. The spigot shall be inserted until the bell end is away from the reference marked to a specified distance as mentioned by the manufacturer. The installer shall rely on his experienced judgment to determine the right position at which to stop pulling. Clean the excess quantities of adhesive formed around the joint and if possible clean it out from inside. Do not release the lever hoist until the bonded joints is self-cured. The bonded joint should not be disturbed under any circumstances while the joint is curing.

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Method Statement For Under Ground GRP Piping

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at

Once the cement joint is self-cured, the puller can be released (Heating blanket required before release). The temporary supports provided for assembly or alignment proposes shall remain in place until the joint is fully cured. The adhesive bonded joints shall be considered accepted only after passing the hydrostatic test.

CURING Proper curing method and curing time depends on type of adhesive used, temperature of the pipe and conditions of the service. Ensure the bonded joint is self-cured by ascertaining the applied cement is tack free to touch. If additional heating is required to cure the joint, heating blankets are used as per GRP manufacturer's instruction. Apply the heating blanket around the joint with the required temperature as specified by the manufacturer. Close the ends of the pipe to prevent any air blowing into the

section.

The duration of heating starts after surface of the pipe has reached the required temperature underneath the blanket or as mentioned by manufacturer. Once the heating process is completed allow the joint to cool down naturally and remove all fasteners and materials from the joint. Mark the cured joint with permanent marker to identify the uncured joint. Each field joint shall be marked with a unique number, the joiner's identification, date of jointing and the date and time that heat curing started and finished. Once the process is completed the joint is ready for hydro test.

SITE STORAGE OF ADHESIVE KITS The site storage of cement kits should be maintained under an ambient temperature

of

20-25°C & under a shaded area or as per manufacturer recommendation, to achieve the optimum performance of the product.

f INAL CLEANING AND INSPECTION Once the bonding process has completed, the general area shall be cleaned and prepared for inspection. Contractor shall carryout an initial inspection to confirm the installation and general safety. Contractor / Sub Contractor shall at all time work together to ensure a smooth and safe working

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 I Page 17 of 27 !

,"") _ , JQi

Orp1c

Method Statement For Under Ground GRP Piping

DIELl oc . . al Hassan

environment. The processed joint will be subject to one final inspection prior to being fully operational for the Sohar Refinery mprovement Project.

Tools for Adhesive Bonded Joints • • • • • • • • • • • • • • • • • • • • • •

Crane or Side boom or boom truck. TS Shaver for various diameter as required. Heating Blankets. Temperature Control. Pi-tapes covering all pipe diameter. Chain Block. Wrap-Around tape & guide. Angle Grinder. Spirit Level. Latch Belt. Come along jack. Grinding disc. Cutting disc. Emery disc. Emery cup. Backing disc pad. Rubber mandrel. Brush. Sanding paper. Marker pen. Generator. Shelter / Shade.

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015

Page 18 of 27

- ac & .

,..).,JQI Method Statement For Under Ground GRP Piping

Orp1c

10.3

REPAIR

al

Hassan

All the repairs shall be as per manufacturer recommendation and shall be approved by manufacturer (its representative). 1) If any TB / TS joint is found to be leaking, cut the joint out and replace it with a pipe piece length as specified by manufacturer. Connect this piece by two (2) lamination joint. The repair works are illustrated below. 1....

l.

E

-E-·...,

{i '·.. . Laakage

l l

E E

l

E

II ... l I Insert

E

_ ...,

Cut

....

x

·-----·

x

neT,

Perform 2.11eld

tomlnallun Joints

l 2. The same shall be done if the leak occurs on the pipe wall due to impact damage. 3. In case of a superficial damage on the pipe, the following steps to be followed. A superficial damage is a scratch within the resin rich outer layer of the pipe. a) Abrade the damaged area by using emery paper. b) Use a brush to clean the area from dust. c) Mix the Epoxy resin according to the recipe. d)If it is necessary apply 1or 2 layers of G-glass. e) Apply the mixed resin on the damaged surface.

Note: All joints found to be leaking and/or damaged shall be reported to the end user (Owner) in order to give them an opportunity to inspect prior tp the repairs being made.

11

LAMINATION JOINT Before starting a lamination joint, all safety precautions will need to be checked. Ensure that all necessary tools and materials are available.

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Page 19 of 27

, ;· ) _ ,JQi

Method Statement For Under Ground GRP Piping

Orp1c

- ac

al Hassan

Following notes should be taken care of:

• Lamination should be avoided in foggy conditions . • The length of exposed pipe should be kept minimum especially during summer to avoid effect of expansion/contraction of the pipe on the new lamination joints. This can be done either partially backfilling the jointed section or by covering at least 2 lengths of pipe with tarpaulins. • Fiber glass will be kept covered till used to prevent contamination by sand, dust or gravel. • In case of long lines, it is preferable to do erection and jointing in sections on either side of the manhole spool, manhole spool erected and jointed last to connect the jointed sections.

Cutting and Sanding Mark off the pipes to be joined using a pipe fitter's wrap-a-round guide & marker pen. Cut the pipe (sections) to the right length, with a straight cut perpendicular to the pipe axis. The pipe can be cut using abrasive cutting disc or other suitable tool or diagrit, carborundum-slitting disc or with a diamond edged disc. Use a sander (Angle grinder) to remove the topcoat of the pipes when cut to the right length, in order to give a clean and rough surface for adhesion. Clean the sanded part with a clean cloth or brush. The pipe sections must now be clean and free of dust. In case of oily contamination, wash with methylene or acetone or suitable solvent. The ends of the pipes to be connected should be chamfered back to a minimum taper of 1:6. Lamination

should

be carried

within

one

hour of

grinding

or as

per

manufacturer

recommendation / instruction.

Temperature and Relative Humidity Requirement. The temperature of the pipe bond area should be 3° C above the dew point prior to application of resin and, The relative humidity should be lower than 75%. Alternatively, No lamination should be done at site if the surface temperature of the pipe bond area is more than 40° c.

Mixing The hardener must be added to the container with the resin and carefully mixed. The resin and hardener shall be mixed as per the quantities mentioned in the pipe manufacturer's lamination recipe to maintain the right mixing ratio. Mixing should continue until the resin mixture has a uniform colour & consistency.

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Page 20 of 27

•t ) .

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Orp1c

Method Statement For Under Ground GRP Piping

DIEll ac &

al Hassan

.

The Mixing will be carried out as close as possible to lamination location. After mixing as per the recipe, Lamination will be started immediately and the mixed quantity will be used within the time specified as per manufacturer recommendation.

Fit Layer The functions of the fit layer are, firstly to ensure proper positioning and secondly, to create a seal (See Figure below).

Figura 2 No Lcrrillllm' moisture shall be present on the pipe bond area. The pipe bond area shall be dry prior to application of resin. Measure fit layer bond length (mentioned in recipe) from the end of each pipe. The surface should be uniform and free of sharp edges. Grind the above area to remove the surface layer of the pipe and remove the dust using clean dry cloth or brush. Clean this area and ensure that it is fully dry. The allowance of miss-alignment for pipe shall be as per manufacturer instruction. Cab-o-sil can be used to fill minor misalignment. The gap between the two pipes to be laminated shall be as per manufacturer's guidelines. The gap (if any) shall be filled using CAB-0-SIL mixture. Impregnate the roughened area with the resin & catalyst mixture as per the ratio specified in the recipe. Apply woven roving (type as per recipe) with 50% overlap between each two consecutive windings as specified in manufacturer recipe. Ensure that the layers are tensioned, wrinkle free, sag-free by continuously pulling the W/R layers. Impregnate the above layers with the resin/catalyst mixture. Ensure the layers are bubble free, if required remove with suitable roller. Repeat the above steps till the required number of layers is applied. Wait one hour till the lamination is cured under ambient

temperature.

l Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015

Page 21 of 27

,t) .,JQi Method Statement For Under Ground GRP Piping Orp1c

IEUI

ac 1 1

. al Hassan

External Lamination {Main Laminate} Measure the bond length (mentioned in recipe) on each pipe from the middle of the fit layer. Grind the above area to remove the surface layer of the pipe and remove the dust using clean dry cloth or brush & Ensure this area is fully dry. Impregnate the above area with the resin/catalyst/delayer mixture as specified in recipe. Apply two (2) layers of woven Roving (type as per recipe) with 50% overlap between each two consecutive windings as specified in manufacturer recipe. Ensure that the layers are tensioned, wrinkle free, sag-free by continuously pulling the W/R layers. Impregnate the above layers with the resin/catalyst/delayer mixture. Ensure the layers are bubble free, if required remove with suitable roller. Repeat above two steps till the required number of layers is applied. Every two layers should be impregnated before applying the second two layers of the same type or different type. After application of required layers of woven roving as per recipe, wind 2 layers of top tape glass around the laminate to extract the excess lamination quantity of resin and to provide smooth surface. Wait two (2) hours for curing to complete at ambient

temperature.

The Strength of laminate should be checked by Barcol Hardness on ground flat spot in 3 evenly spaced points (at 120 degrees) around the circumference.

Internal Lamination For diameters up to 600mm, internal lamination will not be done. If requiredInternal lamination be done for pipes of bigger diameter, if access is possible. Measure a length as specified by manufacturer from the end of each pipe. Grind the above area to remove the internal liner of the pipe and remove the dust using clean dry cloth or brush. Cut several pieces of roving (type as per recipe) with equal length and impregnate with the mixed resin (as per manufacturer recipe) on a flat surface. Wet the grinded surface with mixed resin and place the above impregnated roving on the joint . Evenly press the surface to flush air traps and blisters using suitable roller. The number of layers of roving is applied as mentioned in the recipe. Cover the laminate with two layers of surface MAT to provide a smooth resin-rich laminate surface.

Curing

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Page 22 of 27

,.., _ ,Jql

Method Statement For Under Ground GRP Piping

Orp1c The Lamination will harden at ambient

IEUl at . . al Hassan

temperatures.

The curing method shall be same as per Adhesive joint or as per GRP manufacturer instructions. The joint is ready and can be tested next day.

1. Inspection Report. 11.1REPAIR All the repairs shall be as per manufacturer recommendation and shall be approved by manufacturer (its representative) and shall be carried as above mentioned for Adhesive bonded joints.

Tools for Lamination joi nt • Measuring tape, pipe fitter's wrap-around, marker pen. • Cleaning rags. • Angle grinder. • Angle grinder + sanding disc

+ flexible support disc.

• Pair of scissors. • Gloves, brushes, rollers, buckets, dust masks, safety glasses. • Weighing scale. • Heating blanket/hot blower/halogen light. • Shelter / Shade. • Scaffolding depending on size. • Generator. 12

FLANGED JOINT All The fiberglass flanges shall be joined to the fiberglass pipes with Lamination joint

as

described above as per manufacturer recommendation with respect to lamination recipe for the respective diameter. The fiberglass flanges must always be installed tension free, therefore flanges must be accurately aligned. f possible, flanges should be jointed to pipe only after bolting the flange to the required torque value. Before assembling flanges, inside surface of the flange will be cleaned and checked for any defects or irregularities on the flange's gasket face. Steel blind flanges to be used during the hydro test and/or if connected to the fiberglass manufacturer or

Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04Rev. No: 5

Page 23 of 27

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Method Statement For Under Ground GRP Piping

IIUl ac &

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alternatively should have adequate steel reinforcement bracing for blind flanges of lower plate thickness.

Gasket shall be checked for any defects and will be cleaned on both sides. Permanent gaskets used should be as per the project specification or as recommended by pipe manufacturer. Gasket will then be fixed in position using masking tape. Make sure that the mating flange is properly supported to avoid load being transmitted to the fiberglass flange. Insert flange bolts, washers and apply nut until it is hand tight. Number each bolt starting at the top in a clock-wise direction as per the torque sequence. Once all the bolts are hand tight, bolts will then be tightened in sequence using a calibrated torque wrench up to the 30% of the max. torque value provided for that particular gasket, diameter and pressure rating {Torque values to be provided by Pipe manufacturer).In case of leak, bolts will be again tightened in sequence using the torque wrench up to the 60% of the max. torque value Tightening will be done as per the torque sequence provided in the Pipe manufacturer manual. After all bolts have been tightened to recommended torque, recheck the torque on each bolt in the same torque sequence.

1. Inspection Report. 13

FLANGE TIGHTENING For tightening GRP flanges with a flat-faced surface, the flange will be provided with kroll

&

Ziller gasket to seal the connection. The flange faces, holes, gaskets shall be properly cleaned with acetone, MIBK or MEK. Inspect the gasket for any defect prior to installation. Place the gasket in position and make sure that the holes of gasket and flanges are aligned. Position the other flange to be assembled to the GRP flange in the right place. Make sure the holes of the two flanges are aligned and leveled. Insert the stud bolts in the holes. Bolt threads shall be cleaned and lubricated to attain the proper torque.

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Page 24 of 27

,"' . , JQi

Orp1c

Method Statement For Under Ground GRP Piping

- .

al Hassan

Number each thread bolt starting from the top and following a clock wise sequence. Hand tight all the nuts. Tighten all the nuts using torque wrench. The nuts shall be tightened as per the sequence describe in the drawing. The torque wrench setting in Nm shall be 4 times of the Design pressure. After completing one round of tightening repeat the tightening sequence one more time. The bolts on the one side tend to get loose while tightening the bolts on the opposite

side.

Tools for Flanged joint •

Spirit level, Square angle, Marker pen, measuring tape.

•

Cleaning rags, Masking Tape

14

•

Combination spanner of required size.

•

Calibrated Torque Wrench of required capacity with wrench sockets.

•

PPE.

TIE-IN JOINTING, FITTINGS, BENDS The trench width for tie-in inside trench shall be as AFC drawings or as per manufacturer recommendation. Tie-ins of spools shall take by means of Lamination Joint. All tie-in connections to metallic systems shall be by means of flanged connections. Tie-ins to other GRP pipe systems may be made by flanged connections or by means of bonded couplings as stated in the AFC drawings or as per manufacturer recommendation. The Jointing of GRP Pipe to GRP fitting and GRP fitting to GRP fitting as required shall be carried out as per the same procedures as that of pipe to pipe.

15

REPAIRS Minor repairs to pipe & fittings may be repaired on site. Any damaged outer layer shall be ground and cleaned and resin / hardener mix applied as recommended by the manufacturer. Minor cracks in flanges can be repaired by grinding & filling with resin. All The Repair Methods shall be approved by the client and confirmed by the Manufacturer.

I Doc. No: 120476 / Jl-02022 / 27-06-01 I MMS-04 ! Rev. No: 5 ! Date: 07-July-2015 27

!

Page 25 of

•tl _ , JQI Orp1c 16

Method Statement For Under Ground GRP Piping

-

rolac l I . al Hassan

Hydro-testing Sectional / Final hydro testing shall be carried out as per approved hydro testing

17

procedure.

HSE REQUIREMENTS

17.1 Supervision Site Representative shall be responsible for execution of all activities at site. Supervisor shall be responsible for execution of the job and present at site according to the activity. 11.2

HSE Requirements • Proper communications are available during working in remote area. • All personnel shall complete safety induction and receive training as required by Contractor / Owner. • Prior to start of any work activity special attention shall be given to identifying the work area and providing fit for purpose barriers and applicable signboards. • Refueling of any equipment

is strictly forbidden while the equipment

is running.

• Refueling of vehicles must be planned in safe manner and carried out in a designated area. • Adequate quantity of water available at site. • Smoking, eating & drinking prohibited during handling & storage of resin, paste, adhesives or other chemicals. • Use of rubber gloves, barrier creams, dust mask, protective clothing etc., as per MSDS. • Use of oxygen or fresh air masks in confined spaces such as in trench depth below 1.2 meter or inside pipe of bigger diameter. • All involving employees are wearing proper P.P.E as per manufacturer MSDS. • All lifting operations must be carried out by competent trained personnel. • All equipment are fit and third party certified and safe to use. • Lifting will be done by properly tested, approved and third party certified equipment only. • Lifting gears are functional and third party certified suitable for hoisting operations. • Transportation and lifting activities will only be carried out during day light hours. • Transportation and lifting activities to be carried during night shall have valid permits. • Pipes are located on support and secured properly. • Fire extinguisher available at workplace. • All electrical tools & equipment are in good conditions.

! Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 ! Rev. No: 5 ! Date: 07-July-2015

Page 26 of 27

, tl . , JQI

Method Statement For Under Ground GRP Piping

llll aw

Orp1c

.

al Hassan

• Safe distance is maintained between the machine & overhead lines & above/underground services. • MSDS available with this Method Statement and understood. • Chemical/Hazardous Material Storage to be provided separately according with the HSE compliance and with Coolant/Exhaust system installed. • Good housekeeping is to be implemented after job completed. • Environmental policy adhered. • Site kept clean & tidy after completion the work. • An approved Job Hazard Analysis for this operation will be attached to the Method Statement. • All accidents

will be reported immediately to the Site Engineer and then as soon as possible

to Senior Project Engineer and/or appointed

Health and Safety Officer.

• Any First Aid treatment will be provided by the trained First Aider. • Tool Box Talks will be carried out daily before start of work and shall be Activity specific. • All electrical & power tools are to be in good condition inspected prior to use. • Color coding system to be implemented and shall be inspected by DPJV HSSE representative.

17.3 PJW Requirements Hot Work Permit. 18

DOCUMENTS

1) GRP instruction manupl. 2)Incoming MaterialInspection report. 3)Inspection report. 4)Release note. 19

Attachments

1) JHA - JOB HAZARD ANALYSIS. 2) Handling & Storage Procedure (V-616G-462-J01-A01-N01-001) 3) MS Lamination Procedure (V-616G-462-J01-B01-H99-001) 4) FPI Doc. No. 010054-MPI-GRP-DPJV 5) FPI Doc. No. 010054-RP-GRP-DPJV 6) FPI Doc. No. 010054-ABJ-GRE-DPJV 7) FPI Doc. No. 010054-MFJ-GRP-DPJV

l Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 Page 27 of 27

IIAE•• t1etr otac GI

PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022

JOB HAZAR

D ANALYSI S I RISK ASSESSMEN T

Sohar, Sultanate of Oman

Jqi

Orp1c

Sohar Refinery Improvement Project JV Job No. 120476

JHA Title:

Work Location: SRIP Site 1.0 Permit(s) Required: ./ Confined • Space N. CAING lHV IHat _....U .J os ,,, ./Hard rnav.ire Name PPE Required:

REV 2.0

. Please t1ck 3.0

c

.

Potential Environmental Hazards

6.0

Hazardous Materials (attach SHOC Cards) Other Potential Hazards

7.0

Additional Instructions

5.0

Risk Rating Matrix

0 1 Severity

Date ./Ear Plugs

2 3 4

5

Entry

I

- ,

09

D,

r'\ I O Energy Isolation ./Clear Safety Glasses lf2A/,I OtAJAd. .//' r - Name ./oust Mask ./FaceShield

Ocotton Prepare d By: Gloves (.I') appropnate boxes

Special Tools and Equipment Required:

4.0

JHA No.:

Under Ground GRP/GRE Piping

Company: AHEC

I O Non-Destructive Test I O.Night W ./Dark Safety Ochem KameshwarRao M WJ-.-Name Glasses Owelding Oweld I

Signature Signature Date ./Earmuffs Mask 0Esca Reviewed By: Approved By: 0Leather Gloves (rigging) ./Cartridge Respirator 0Rubb ./Disposable Coverall

0Leather Gloves

./Hi-vi

0Gas Badge Ooosimeter

0Multi-Gas Monitor 0Thermometer

(welding) 0Gas Detective ./Ventilation Fans

Ough ./Air B

Oufeline

ORetrieval Line

DPadlock, Hasp, Tags

Ought

0Air Horn

OWhistle

./Traffic Flags

./Traffi

ONoise Osofl erosion

./Air Pollution (dust)

0Air P

Ocarcinogen

Olrritant

0Air Pollution (smoke) Ospills (wadi) ./Highly Flammable

0Toxi

./Electrical

0Pressure (air, water, gas)

0Mechanical (crush

./Ergo

Ought I Dark

OIgnition Sources

points) Ooust I Vapor

Osuffo

./Spills (to ground)

"Eye wash" to be provided. People No injury or health effect Slightinjury or health effect Minor injury or health effect Major injury or health effect PTO or up to 3 fatalities More than 3 fatalities

Asset No damage Slight damage Minor damage Moderate damage Major damage Massive damage

Environment No effect Slight effect Minor effect Moderate effect Major effect Massive effect Page 1 of 14

DA.LIM

t'etrorac GI PETROFAC INTERNATIO NAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl2022

JHA Title:

./Haz

JOB HAZARD ANALYSIS I RISK ASSESSMENT

I Under Ground GRP/GRE Piping

Sohar Refinery Improveme nt Project Sohar, Sultanate of Oman JV Job No. 120476

,1 .,JQi

Orp 1c

Activity

Step

1.

Handling & Storage

2

Lowering & installation of pipes

Hazards • • • • • •

Transportation Falling materials Improper lifting of GRP pipes Improper storage Slips & Trips Suspendedload

• Heavy (elevated) loads Bad lifting equipment Existing facilities • Communication Dust & debris Incompetent banks man I riggers • Defective • Lifting equipment • Poor procedure • Hitting • Falling • Use of chemicals (adhesive) • Over stressing of pipes

Risk Rating P4

P4

Control Measu

TBT to be conducted fo designated task and re • Ensure the transportat in inspected, approve certifiedVehicles. • Ensure the drivers are and adheres the safe requirements. • Ensure the pipes arelo lashed as per the man instruction. • Ensure the no chains or clamps to lift the G Ensure proper housekeepin • Ensure the pipes are s the manufacture instr • Ensure no persons und suspended load. • Ensure signboards are •

TBT to be conducted for the designated task and re • Ensure the PTW requir are met. Ensure theloads are within • Trained, certified & co operators. • Ensure the lifting equ are inspected and fit f purpose. Ensure the existing facilitie identified and taken i prior to lifting I strin • Clear unobstructed vis through all windows • Ensure proper houseke • Avoid the sharp edges • Ensure the riggers I b are certified

Page 2 of 14

JOB HAZARD ANALYSIS I RISK ASSESSMENT

• ••u• Petrotac c., PETROFAC INTERNATIO NAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl2022

JHA Title: Step

Sohar Refinery Improvement Project Sohar, Sultanate of Oman JV

Job No. 120 476

J q i

Orp 1c

I Under Ground GRP/GRE Piping Activity

Hazards

Risk Rating

Control Measu

Banks man to control a movements • Ensure proper commun between the operators • Unauthorized entry to • No other vehicle permi in the area. • Ensure belts & slings ar and certified • Ensure all the lifting ge good condition Ensure use of "tagline" • Ensure the procedure • Barricade thelift area no works or persons un load. Provide enough warning sign • Maintain safe distance trenches. • Ensure hard barricadin ever possible. • Ensure Pinch points a • All pipes to be choked to avoid slippage. • Ensure the MSDS requ met while handling the • Due care to be provide lowering the double jo avoid overstressing of •

3.

Spool jointing/ Flange tightening

Rotating parts • Exposure to chemicals • Fine particles while cutting GRP pipes • Fire Chemical spill • Power tools • Electrocution

P4

TBT to be conducted for the designated task and re • Ensure the painting and is done at designated y • Deploy trained personn • Ensure the MSDS requ are met. • Wear appropriate PPE a

& filin of g

Page 3 of 14

JOB HAZARD ANALYSIS I RISK ASSESSMENT

t1etrorac t11 PETROFAC INTERNATIO NAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.: Jl-2022

JHA Title: Step

,..l.,

Sohar Refinery Improvement

DAIII.IM

J

Sohar, Sultanate of Oman JV Job No. 120476

JQi

Orp 1c

Under Ground GRP/GRE Piping Activity

Hazards

Risk Rating

Control Measu

MSDS. MSDS to be discussed during

• Working near excavations • Homemade I damaged tools • Pinch point • Manual Handling

• • •

Ensure barrier creams per the requirements.

Ensure the Dust masks a cutting and filing the Ensure the competency who are involved in c machining, bonding an mixing activity.

•

Balance chemicals to b according to Waste ma procedure

• • • • •

No open flame/ smoki of storage Iichemical m Ensure adequate firefig are available. Ensure spill control me

• • • • •

• • • •

Ensure the power tools inspected and color co Any damages to the po reported and replaced All the electrical conn verified by competent

No make shift arrangem made for power supply

Ensure hard barricadin open trenches Ensure safe distance fr trenches Never store materials n shores. Do not use homemad damaged tools.

Always use plastic ham working on GRP pipes. Avoid pinch points Ensure proper lifting t Page 4 of 14

DAIIUM

JOB HAZARD ANALYSIS I RISK ASSESSMENT

t'etrotac ..., PETROFAC INTERNATIO NAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.: Jl-2022

JHA Title: Step

Sohar Refinery Improvement Project JV Job No. 120476

d.:-,J Qi

Sohar, Sultanate of Oman

Orp 1c

I Under Ground GRP/GRE Piping Activity

Hazards

Risk Rating

Control Measu

• •

adhered to avoid man handling Injuries. Avoid I Minimize repetitive movements. Consider TILE ( time, individual,load, envir handling the loads Always spare the load Ensure the mechanical

.

Conduct TBT for the de

• •

.

4.

Bonding &. Curing of GRE Joints

• Electrocution • Fire • Exposure to chemicals • Falls from height • Slip, trip &. fall • Falling/flying objects • Hazardous GRE fiber dust

and related hazards pri the work every day. PTW requirements to be me • Ensure all the electrica cable &. connectors use condition and to be colo competent electrician. • Only competent peopl be allowed to operate equipment. • People should be aware involved while working equipment. Do not work alone. • All should be aware of procedures in case of e • Maintain a good cable m avoid trip hazard. • Ensure fire extinguishe nearby during the hot w • Remove all inflammab from the vicinity of the activity prior commenc always maintain a good around the area.

• •

Must wear appropriate allthe time at site. Must wear aoorooriate

Page 5 of 14

DAIII.IM t1etrotac

u,

JHA Title:

I Under Ground GRP/GRE Piping Activity

Step

Hazards

I

Risk Rating

• • •

• • • • • • •

Confined space entry

Lack of oxygen • Presence of poisonous gas like H2S, CO etc. Improper access and egress • Lack of emergency evacuation system • Unqualified/inexperience work force • Lack of supervision • Slip,trip and fall • Lack of illumination

P4

JHA No.:

Control Measures •

4.

Sohar Refinery Improvement Project Sohar, Sultanate of Oman JV Job No. 120476

JOB HAZARD ANALYSIS I RISK ASSESSMENT

PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022

• •

• •

,") .,JQi

Orp1c

09 Residual Risk

Responsible Person

inhalation of GRE fiber dust. MSDS requirements shall be met and MSDS copy shall be made available at the work location. Portable eye wash station shall be provided at the work location. Adequate and suitable platforms with proper access and egress shall be provided. Scaffolding platforms to be inspected by competent personnel and should hold a valid 'scaff tag' . Equipment and tools to be secured properly in designated area only. Ensure fall protection is available before commencing the work at height activity. Ensure scaffolds used are meeting with the standards and erected by competent person. Allpersons performing work at height activity should attend 'WAH' training by DPJV. Ensure the warning signs are posted as per the requirement. Area to be barricaded Carry out 'housekeeping' every day (prior and post job).

TBT to be conducted for the designated task and related hazards. Permit to work system to be followed and full fill all PTW requirements prior commencing the work at confined space area. Conduct gas test prior starting the work and repeat the gas test depending up on the nature of work Proper access and egress to provided

P2

Page 6 of 14

DAIII.IM

Petrorac tJ,

PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022

JOB HAZARD ANALYSIS I RISK ASSESSMENT

JHA Title: Step

I

I Under Ground GRP/GRE Piping Activity

Hazards Presence of explosive gases/fumes Standard operation • Absence of procedures

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Sohar Refinery Improvement Sohar, Sultanate of Oman JV Job No. 120476

Risk Rating

JHA No.:

Control Measures Forced ventilation fan to be provided. Sufficient illumination to be provided. • Hole watcher to be positioned and confined space entry log sheet to be maintained. • Allpersonnel workingin confined space must have under gone confined space entry training by DPJV. • Follow SOPs. • Maintain good housekeeping inside the pipes to avoid slip, trip and fall. • Ensure continuous supervision while confined space activity is going on. • Emergency evacuation arrangement should be in place and procedure for workinginside the is as follows. a) The person entering in confined space should wear the safety harness with life line attached to the back of the harness b) The other end of the life line should be with the hole watch. c) In case of any emergency the person inside the confined space shall communicate the emergency to the hole watch by continuously pulling the life line. d) The hole watcher should immediately arrange for the rescue. e) If person inside is not responding further he can be pul ed out by the help of life line. f) A stand by vehicle should be available at the location at all the time when the activity is going on. • Mock drill shall be conducted at the

PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022

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09 Residual Risk

Responsible Person

Page 7 of 14

JV Job No. 120476 Sohar, Sultanate of Oman

JOB HAZARD ANALYSIS I RISK ASSESSMENT

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Sohar Refinery Improvement Project

JHA Title: Step

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I Under Ground GRP/GRE Piping Hazards

Activity

I

Risk Rating

JHA No.:

Control Measures

09 Residual Risk

Responsible Person

of the emergency preparedness.

•

All the emergency contact number to be posted at the work location. Use approved type of respirator (FFP3)

5.

Excavation &: Backfill ng

•

Moving Equipments Cave in • Fall ng Objects • Use of defective hand tools for hand excavation • Slip, trip, Fall Working near Plant equipments • Existing services (if any) Terrain Condition • Unauthorized entry Improper access • Noise • Dust • Vibration Adverse weather condition • Spillage

•

Personal Injury

P4

• • •

• • •

• • • • • • • • •

TBT to be conducted for the designated task and related hazards. Obtain valid PTW from DPJV before starting the work. Ensure the equipments used are inspected approved and fit for purpose.

P3

Only experienced operators/ drivers to be deployed. Ensure qualified banks men are deployed along with all the equipments. Ensure Reverse horns/ Revolvinglights of equipments are working prior to job. Keep safe distance from moving equipments I Bucket Swing radius. Ensure the excavations are done as per the engineering standards. Provide necessary shoring to avoid any cave Ensure the excavation spoils are kept away from the shores and are transported to dump area in regular intervals. Ensure the hand tools are fit for purpose. Random inspections of the hand tools to be conducted. Ensure proper housekeeping in and around the excavations to avoid Slip &: trip Ensure the area is hard barricaded and

Page 8 of 14

DAIILIM t1etrorac t»

PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.: Jl-2022

JOB HAZARD ANALYSIS I RISK ASSESSMENT JHA Title: Step

I Under Ground GRP/GRE Piping Activity

Hazards

Sohar Refinery Improvement Project Sohar, Sultanate of Oman JV Job No. 120476

I

Risk Rating

JHA No.:

Control Measures

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09 Residual Risk

Responsible Person

warning signs to be placed to alert about • the hazard. • Ensure safe distance from the movihg • Never rest under or near the equipments. • Always wear Hi visibility vests while working near the equipments. Ensure all existing services are identified and taken care before starting the activity. • Ensure the terrain conditions prior to the deployment of plant equipments to avoid any capsize. • Barricade the area and post sign boards to avoid accidental entry by third party. •

• • • • • • • • •

Ensure the access and exits to the excavations are clearly marked and kept free of obstructions. Ensure ear protection requirements are adhered.( Banks man, Operators, Etc) Ensure preventive maintenance of the plant equipments. Ensure proper dust control measures are adhered. (Sprinkling water) Share the job to avoid Hand arm vibration syndrome. Ensure the equipments used are designed I maintained to reduce the Vibration effects Ensure Appropriate the PPE's are used. Ensure the works are suspended during adverse weather condition. Welfare facilities like shades I shelters, drinking water and rest Page 9 of 14

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PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.: Jl-2022

Sohar Refinery Improvement Project Sohar, Sultanate of Oman JV Job No. 120476

JOB HAZARD ANALYSIS I RISK ASSESSMENT

JHA Title: Step

I Under Ground GRP/GRE Piping Activity

Hazards

I

Risk Rating

Control Measures

• •

• • •

6.

Filling Water into the Pipe(Using by diesel driven pump)

Pressurized water Noise • Water Spillage • Bad weather condition (General for all activities)

P3

JHA No.:

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09 Residual Risk

Responsible Person

breaks to be ensure during extreme temperatures. Regular inspection by the operators to find theleakage from the equipments. Spillages to be contained and disposed properly. Ensure 100% PPE compliance prior & during the job. Ensure the proper TBT is conducted and confirm the control measures are in place. Proper toilet facility to be provided.

Follow the PTW System. • TBT to be conducted for the designated task and related hazards. • Ensure filling water should be prior approved by QC • Using certified diesel pump • Securing hoses and connections safely

P2

• •

Use PPE such as Safety Goggles, Face Shield, Safety boot, Ear plug Etc. Tool Box talk to the workmen Proper supervision Proper barricading of the work area

•

Restriction on movement of personnel and vehicles Display of safety sign boards Following work permit system Releasing air through vent, gently by competent person • Maintaining good housekeeping Use of portable fire extinguishers • Keeping unwanted material Iequipment away from the working area • Use ear plug during work. • Resting shelter available on site. Page 10 of 14

DAIIUM Petrotac G

PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022

JOB HAZARD ANALYSIS I RISK ASSESSMENT JHA Title: Step

Sohar Refinery Improvement Project Sohar, Sultanate of Oman

JV Job No. 120476

I Under Ground GRP/GRE Piping

I Hazards

Activity

Risk Rating

JHA No.:

Control Measures

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09 Residual Risk

Responsible Person

Drink water as much as possible • Take rest when feel tired • In dusty &. stormy weather ,job to be stopped • Use dust mask during dusty environment

7.

Hydro test activity(Develop pressure in section)

• •

Spillage of diesel &. water • Pressurized water • Noise Inferior quality hoses Substandard hose connection • chemicals

P3

•

Follow the work permit system • TBT to be conducted for the designated task and related hazards. Using certified diesel pump • Securing hoses and all connections safely Conducting Tool Box talk • Proper supervision Cordoning off the working area and restriction on movement of personnel and vehicles • Pressurizing the water at a steady and uniform rate as per the approved method of statement

•

• • •

•

• • 8.

Discharging of Hydro test water

• High pressurized water • Noise • Impactinglocal environments

P2

P3

• • • •

Do not tighten any bolts while

under pressure. Monitoring of pressure and temperature constantly. Maintaining good housekeeping Use of fire extinguishers Use Proper PPE Ensure the MSDS requirements are met during handling the chemicals TBT to be conducted for the designated task and related hazards. Release the pressure as per the procedure. Identify the area for disposal and mange as per the approved procedure. Water discharging under DPJV instruction

P2

Page 11 of 14

DAIIUM Petrotac G

PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.: Jl-2022

Sohar Refinery Improvement Project Sohar, Sultanate of Oman JV Job No. 120476

JOB HAZARD ANALYSIS I RISK ASSESSMENT

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I Under Ground GRP/GRE Piping Hazards

Activity

I

Risk Rating

JHA No.:

Control Measures

09 Residual Risk

Responsible Person

Avoid use of contaminated water Ensure use of job specific PPE • Ensure effective communication system is placed during water discharging activities. • Continuous monitoring for avoid water leakage from the hoses • Proper supervision • Controlling the area. • Possible area should be barricade. • Restriction on movement of personnel and vehicles • Ensure No spills and impact onlocal environment while discharge. • Display of safety sign in assigned places.

9.

Emergency at worklocation

Personal injury • Traffic incident Incident, near miss etc.

P3

DPJV HSSE and Medical numbers posted at work site Numbers informed to AHEC supervisor I HSSE • Any incident I emergency shall be reported to DPJV HSSE within 30 minutes or less. Initial written notification to DPJV HSSE within 24 hours orless • All personnel will be instructed on procedure to take and system of contact (AHEC I DPJV) should an incident occur • Reporting of incidents shall be informed in daily TBT's • Supervisor I engineer in charge is responsible for leading HSE and compliance by workforce.

P1

10.

Weather /Climate Conditions

Bad weather

P3

Resting shelter to be available on site • Take rest when feel tired. Drink water as much as oossible

P1

condition

•

Same as Above

Page 12 of 14

DA•L11111 t1etrorac o,

Sohar Refinery Improvement Project Sohar, Sultanate of Oman JV Job No. 120476

JOB HAZARD ANALYSIS I RISK ASSESSMENT

PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.: Jl-2022

JHA Title: Step

I

I Under Ground GRP/GRE Piping Activity

Hazards

Risk Rating

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09

JHA No.:

Control Measures

Residual Risk

Responsible Person

P2

Same as Above

In dusty &. stormy weather job to be stopped. • Use dust mask during dusty environment

11.

Health and Welfare

Personal hygiene • Personnel welfare

P4

Provide portable bathroom washroom faci ity at work location • Consumption of food is not permitted at working.

I

Page 13 of 14

Sohar Refinery Improvement Sohar, Sultanate of Oman JV Job No. 120476

JOB HAZARD ANALYSIS I RISK ASSESSMENT

DAEI.IM Petrorac PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022

JHA Title:

I Under Ground GRP/GRE Piping

JHA NO.:

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PRE-START TOOLBOX TALKS NOTE: As the worksite Supervisor, my signature (next column) confirms that I understand the hazards and control measures on the previous page(s) and have communicated all requirements with my work crew and will abide by all conditions and restrictions stated therein. List of names of work crew detailed below. No.

Name

Company

Date

Signature

1. 2.

3. 4. 5. 6. 7. 8.

'

9. 10. 11. 12.

13. 14. 15. 16. 17. 18. 19. 20. Page 14 of 14