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PREPARED CHECKED DATE QP NO.9 9 0 9 . APPD T NUMBER : .CONTRACT REF: GC 08102800 PROJECT NO: 2678 EPIC OF GAS SUPPLY TO STATION V AND FACILITY C (GSVC) DOCUMENT TITLE: METHOD STATEMENT FOR PIN BRAZING MAIN CONTRACTOR: CONSULTANT: CONTRACTOR: CP 23/ AMG 1 AMG BB Issued for Review/ Approval 11/09 25/ AMG 0 AMG BB Issued for Review/ comments 06/09 REV. REASON FOR BY BY ISSUE DOCUMEN REV6.1 8 .4 2 013 2 7 4 SHT 1 of APPD BY.
NO 1 2 3 4 5 6 7 8 PAGE NO. TITLE 3SCOPE 3 REFERENCES 4 RESPONSIBILITIES 5 HEALTH. SAFETY & ENVIRONMENT 9 METHODOLOGY 12 INSPECTION & TEST PLAN 13 SITE INSPECTION REPORT ENCLOSURE – 1 CONNECTION SCHEME No: 2678-9909-4301 Contract No. PAGE GC 2 of 13 -08102800 Doc.METHOD STATEMENT FOR PIN BRAZING CONTENTS SL. No 2678-9909420 4 Rev. No 1 .
METHOD STATEMENT FOR PIN BRAZING 1. No 1 . 2. REFERENCES: Project Specifications. SCOPE The scope of this method statement is to describe in detail the performing methodology of Pin Brazing associated with connection of cable to pipeline pertaining to the Cathodic Protection system including identification of associated hazards and mitigation to be taken in order to execute all works safely. No 2678-9909420 4 Rev. HSE Plan CP system Design – Drawings CP system Design – Rev 1 2678-9909-4101 TCP Design Document Contract No. PAGE GC 3 of 13 -08102800 Doc. QP Safety Regulations for Contractors. as per project requirement & specifications for the project “EPIC for Gas Supply to Station V & Facility C” (GSVC) in Ras laffan City. QP-PHL-S-001 QP-REG-S-001 2678-8000 2468-9066 2468-9050 QP Corporate Philosophy for Fire & Safety.
3. Contract No. PAGE GC 4 of 13 -08102800 Doc. ¾ Accompany the company representative while carrying out inspections and release of hold points. and all permit/safety requirements are strictly followed.2 The Civil QC Inspector (QCIC) ¾ QCIC will ensure that all activities that are required to be inspected have been inspected and approved by QP. wherever applicable. project specifications & requirements & HSE requirements ¾ Construction Supervisor will ensure that the work is covered with valid work permits from RLC & QP. and all permit & safety requirements strictly followed. 3. ¾ Any unsafe act or condition will be immediately stopped and reported to the HSE Engineer and Construction Supervisor. as per HSE Plan. 3. RLC & QP. ¾ HSE Engineer will ensure that work locations are safe to work in & with safety signs. wherever applicable.METHOD STATEMENT FOR PIN BRAZING 3. and ensure that construction provide & implement the approved corrective action. when and where required. ¾ Conduct daily tool box talks explaining the hazards associated with the work and the mitigation measures.1 RESPONSIBILITIES The Construction Supervisor ¾ Construction Supervisor is required to ensure that all works are carried out as per approved drawings. ¾ HSE Engineer will ensure that daily tool box talks are carried at all work locations. ¾ Issue CAR.3 The HSE Engineer ¾ HSE Engineer will ensure that the work is covered with valid work permits from Government agencies. No 2678-9909420 4 Rev. No 1 .
¾ Physical barricading shall be placed at the work area to control the vehicles & traffic. ¾ All operators shall have the certification by third party. materials and equipment. ¾ During the hours of darkness the working area must be clearly illuminated or have sufficient warning lights correctly positioned. ¾ Make available drinking water. HEALTH.METHOD STATEMENT FOR PIN BRAZING 4. PAGE GC 5 of 13 -08102800 Doc. ¾ Contractor shall maintain good house keeping at all the times. RLC & QP. ¾ No night travel other than approved deviations. fluids and insulated tents/shelters for the employees & appropriate ablution facilities commensurate with size of workforce. will be obtained and available on site at all times. ¾ Barricades. SAFETY & ENVIRONMENT ¾ Prior to commencing with any work on site. Contract No. ¾ Vehicles to be insured. ¾ Works shall be carried out according to Safe Construction Practices. ¾ Vehicles to be maintained in road worthy & Licensed. sign boards must be present at the work site/ ROW. ¾ Permit conditions checklist to be attached to permit. ¾ According to the QP Regulations ail equipment shall have a Third Party certification. ¾ Safety sign boards shall be placed all along the temporary access road. ¾ Vehicles must have backup alarms. work permits from Government agencies. ¾ Avoid set up of work behind equipment operator. ¾ All access / exit points to work areas shall be maintained free from obstacles. ¾ HSE engineer shall monitor the site personnel during all construction activities. QP's Safety Regulations. ¾ All personnel involved in works shall be aware of Safety requirements of the project the site shall be kept clean and in tidy conditions. wherever applicable. ¾ All worksite locations are to be well barricaded with sufficient safety signs indicating type of work being performed and only authorized personnel permitted to access worksite and the signs to indicate the danger of the worksite. ¾ Drivers must have the valid Qatari driving licenses ¾ Drivers must follow defensive driving skills. No 2678-9909420 4 Rev. No 1 .
pits and wells. PAGE GC 6 of 13 -08102800 Doc. use a bridge or walk around. in location near to the utilities hand digging only permitted. ¾ Stop blocks to be fitted when tipping in to excavation to prevent vehicles from falling in. Contract No. regardless of depth should be provided with sufficient barriers/display boards. ¾ Employees working in excavations should be provided with valid excavation permit and the necessary protective equipment. No 2678-9909420 4 Rev. ¾ All excavations in public places. ¾ Prior to the start of work. ¾ If required excavation should be supported with shielding. If unexpectedly discovered. ¾ For excavation over one meter in depth an entry to Confined Space Permit shall be required in restricted areas. shoring. ¾ Do not drive nearer than 3m around the excavation. ¾ Ensure excavations do not undermine the footings of scaffolds or the foundations of near by buildings or walls. step and bench to prevent collapse hazard. warning signs and barricades must be provided at all times to all trenches. ¾ Use ladders to access structures. these must be checked by a competent person before excavation continues in the affected area. ¾ Gas testing in regular intervals. ¾ Wear PPE at all times. Excavated material should not be placed nearer than 1 m from the edge of the excavation at all times. No 1 . Access across excavation shall be by appropriate walkways in sufficient numbers to prevent jumping across excavation. excavations should be inspected by the competent site engineer. ¾ Before digging. All areas to be scanned & scanning report provide start of any excavation. ¾ While excavating pay attention to possible buried services. check if under ground utilities are present.METHOD STATEMENT FOR PIN BRAZING ¾ When excavating. ¾ Barricades should be placed above 2m from the edge of the excavation. sloping. placement of fire extinguisher should be present. ¾ Before the commencement of any excavation the entire route is to be scanned for under ground services and the scanning report to be attached to excavation permit. ¾ Jumping across excavations is prohibited.
No 2678-9909420 4 Rev. PAGE GC 7 of 13 -08102800 Doc. ¾ No equipment with axle loads greater than 30 Tons shall cross through the existing track crossings. placed at work locations. barricaded and protected in accordance with the excavation procedure. ¾ Contractor shall obtain from the operator and owner of any existing pipelines a permit-to-work within 15m either side of existing pipelines. prior to commencing with installation works on site. Example. No 1 . camel & machine from falling into the trench. Q-TEL. barricades or excavated material at all times to prevent man. ¾WORK SITE SUPERVISOR will be available on site at all times. ¾Qualified first aider will be available on site at all times.METHOD STATEMENT FOR PIN BRAZING ¾ During the hours of darkness any excavations openings or obstructions near or on road ways and walk ways must be indicated by a sufficient number of warning lamps and whether day or night. Provision of a permitto-work by QP does not release contractor by obligation of obtaining relevant permits to expose or near utilities/ facilities not under QP area or responsibility. ¾Mitigation measures identified in the Job Hazard Analysis. ¾ Plastic bags or food packets/cans will never be thrown around but will be contained in appropriate skips. ¾ Daily check will be carried out for exposed trench sections and it will be ensured that proper barricade and warning signs are in place. ¾ All underground services are to be exposed by hand excavations & the pilot holes barricaded. ¾ Platforms. Mobile phones are not allowed within live stations. will be in place. ¾ Required construction tools and materials will only be brought to site. ¾ Excavated material will be placed 1meter and safety barricades will be placed 2 meter away from the edge of the excavation. walkways and pedestrian crossovers must be of sufficient width as per HSE standards minimum with handrail and toe boards. as per CONTRACTOR’s approved HSE Plan. Excavated trench will be protected by warning signs. ¾Daily Safety toolbox talks will be carried out at all work locations. ¾ Communication on site will be provided by mobile phones. Contract No. KHARAMMA etc. ¾ All excavations will be provided with barricades & warning signs. ¾ Appropriate PPE will be worn by all workers at all times.
¾ Work permit to be displayed at work site in permit boxes at all times. ¾ HSE Manager will conduct periodical audit and report to the project manager for corrective actions. ¾ Approved Ladders will be used for access into pipeline trenches or any other excavations. No 2678-9909420 4 Rev. No 1 . PAGE GC 8 of 13 -08102800 Doc. ¾ Prior approval will be obtained from QP. Construction Manager and QP representative immediately. Work shall proceed only after investigation & corrective actions are in place and approved by QP to proceed further. ¾ All work will be stopped in case of any incident and reported to the HSE Manager. Contract No. Project Manager. ¾ List of emergency contact telephone numbers will be provided to all key personnel associated with the pipeline civil works & displayed at work site.METHOD STATEMENT FOR PIN BRAZING ¾ Any excavation at underground services location will be by hand digging only. Machine excavation will not be carried out within 3 meters of any such facility. if works are to proceed beyond the normal working hours.
5.METHOD STATEMENT FOR PIN BRAZING 5.1 Scope This procedure covers Pin Brazing for cable connection with pipeline for “C” type of Test Station Connection Scheme related to Cathodic Protection System.No 1 Application Material/Tool Pin BrazingPin Brazing& Igniting Equipment Brazing Connection to pipe For Encapsulation of 2 Pins 3 Cables 4 5 Intergard 821 or Equivalent exposed portions Sand Paper Surface cleaning 5. Contract No. PAGE GC 9 of 13 -08102800 Doc. No 2678-9909420 4 Rev. Demonstration of Pin Brazing shall be performed by the Technician before starting the job at site.3 Pre-requisite i.2 Materials Required S. ii. iii. METHODOLOGY 5. Pin Brazing Equipment / materials approval shall be done by QP / TPI Test reports of live pipeline shall be approved by owner before starting pin brazing activities. No 1 .
vi. Seam or Circumferential Weld Joint of the pipeline.of cable shall be kept at both pipe and Test Station end. No 1 . Contract No. Cable shall be laid in accordance with cable laying drawings. consecutive marking shall be minimum 300 mm apart. If there are more than one connection as per design document. Clean the surface of the pipeline to white metal finish using sand paper and cleaning with fine file as required. PAGE GC 10 of 13 -08102800 Doc. Pin Brazing is for the live pipeline crossing the GSVC pipeline and Permission should be taken from the foreign pipeline owner before carrying out the pin brazing ii. iii.METHOD STATEMENT FOR PIN BRAZING 5. Carefully braze the Pin over the exposed pipeline using the pin brazing machine Wait for 1 min after brazing and remove the gun Clean the braze with brush and conceal the exposed pipeline and cable with suitable coating repair material / Epoxy encapsulation like Intergard 821 or equivalent. ix. vii. Cut open the coating on the pipeline with care and without damaging the pipe for a size of approximately 50 mm x 50 mm v. Only manual excavation shall be carried out over pipeline. Cable route shall be carefully measured and cable cut to be required length from test station to pipe. Care should be taken not to damage the coating of buried pipeline. viii. Excavate a pit over the pipeline to expose the pipeline top surface at location of Pin Braze where cable to pipe connection is to be done as per design document. iv. No 2678-9909420 4 Rev.4 Procedure i. Connection location shall be minimum 300mm apart from other connection and Welding joint. The location for cable to pipe connection shall be selected such that the pipe joints and field-coated areas are avoided. A loop of approx 0. Mark where connection is to be carried out.5mtr.
No 2678-9909420 4 Rev. ii. Only Manual excavation to be done after nearing the pipe surface without damaging the coating. Necessary PPE to be utilized Only trained personnel to be deployed for this activity.5 Precautions i. Location of cable to pipe connection shall be minimum 300mm apart from other connection and from Pipe weld joint. iii.METHOD STATEMENT FOR PIN BRAZING 5. ii. iv.6 Health. 5. PAGE GC 11 of 13 -08102800 Doc. i. All cables are to be appropriately tagged. No 1 . Safety & Environment Hazard Identification and risk assessment will be carried out and Operational Control measures shall be adopted for the said activity. Seam or Circumferential Weld Joint Check hardness of encapsulation by applying pressure with thumb/Wooden Stick. Contract No.
S – Surveillance – Notification not required. PAGE GC 12 of 13 -08102800 Doc.METHOD STATEMENT FOR PIN BRAZING FOR PIN BRAZING S. Work Shall proceed if client representative does not attend H – Hold point – RFI to be issued. No 1 . Client / Client representative may carryout surveillance work without advance information. No 2678-9909420 4 Rev. R – Review – Review of Documents QP Signature Name Date TYCO / L & T TPI Contract No. No Responsibility Remark Activity Description Acceptance Criteria INSPECTION & TEST PLAN Reference Document Method of Inspection TTC / L&T TPI QP 2 3 4 5 6 Check the Location SS Check the Cables S Check the Braze S Check the WW S Continuity Check S Encapsulation Check as per Design Check as per Design Visual Perfectness Continuity Visual Perfectness TCP Design Document / Drawings TCP Design Document / Drawings Method Statement Method Statement Method Statement Visual Visual Check Visual Check Visual Measurement Visual Check W W W S S W S Inspection Report Reference No: 2678-9909-420401 Reference Document No: 2678-9909-4104 Legend W – Witness check – RFI to be issued to client. Work may proceed subject to Hold point approval / clearance from responsible party.
Sq.mm. DATE Location ( Chainage in Km) Test Station Type Size of Cable. PAGE GC 13 of 13 -08102800 Doc. : 2678-9909-4204-01 TYCO THERMAL CONTROLS. Length of Cable. Mtrs Pin Brazing to Pipe /Not Acceptable Acceptable Check the Continuity Acceptable/Not Acceptable Check the Encapsulation OK / Not OK Coating repair / Not Reqd.METHOD STATEMENT FOR PIN BRAZING SITE INSPECTION REPORT FOR PIN BRAZING PROJECT CATHODIC PROTECTION SYSTEM FOR GSVC PIPELINE PROJECT CP CONTRACTOR: REPORT NO: FORMAT NO. No 1 . Done – If Any Restoration Check OK OK / Not NOTES: QP Signature Name Date TYCO / L &T TPI Contract No. No 2678-9909420 4 Rev.
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