Method Statement: Single Position STOPPLE® TRAIN 28in

METHOD STATEMENT
Single Position STOPPLE® TRAIN 28in
Client:
Contractor:
T.D.WILLIAMSON sprl. Belgium
Project reference:
967-1904-008-EGY
Document number:
MS-967-1904-008-EGY-ND
Name: Title: Sign
Originator: Naïmi Diallo Senior Application Engineer
Checker: Hughes Franceschini HT&P Field supervisor
Approver Philippot Cedric CSG Manager
Client
Rev 00 22-Jan-20
T.D.Williamson © Page 1 of 46
T.D. Williamson sprl. 22 January 2020
Repair and Rehabilitation Services Project N°: 967-1904-008-EGY
Single Position STOPPLE® Train 28in Review: 00
Contents
1. REVISION HISTORY ....................................................................................................................................... 4
2. CONFIDENTIALITY ........................................................................................................................................ 5
3. INTRODUCTION............................................................................................................................................... 5
4. OBJECTIVES ..................................................................................................................................................... 5
5. DEFINITIONS .................................................................................................................................................... 5
6. RESPONSIBILITIES ......................................................................................................................................... 6

6.1. TABLE OF RESPONSIBLITIES ........................................................................................................................ 6
6.2. PROJECT PREPARATION............................................................................................................................... 7
6.2.1. Job Analysis .......................................................................................................................................... 7
6.2.2. Safety risk Analysis ............................................................................................................................... 7
6.2.3. Application Data sheet ......................................................................................................................... 7
6.3. HOT TAPPING & PLUGGING EQUIPMENT................................................................................................... 7
6.3.1. Equipment Selection & Preparation .................................................................................................... 7
6.3.2. Equipment Rigging ............................................................................................................................... 7
6.3.3. Equipment Storage................................................................................................................................ 7
6.3.4. Equipment disassembly......................................................................................................................... 7
6.3.5. Equipment decontamination & repacking ........................................................................................... 7
6.4. EQUIPMENT SUPPORT .................................................................................................................................. 8
6.5. TDW FIELD TECHNICIANS .......................................................................................................................... 9
6.5.1. Qualification & mobilization process .................................................................................................. 9
6.5.2. TDW field Technician stay ................................................................................................................... 9
6.5.3. Timetable............................................................................................................................................... 9
6.5.4. Daily Work Sheet .................................................................................................................................. 9
6.5.5. Pre-job Site assessment form................................................................................................................ 9
6.5.6. Calculation sheet .................................................................................................................................. 9
6.6. MANPOWER ................................................................................................................................................ 10
6.7. JOB OPERATIONS ........................................................................................................................................ 10
6.7.1. Fitting Examination ............................................................................................................................ 10
6.7.2. Leak test operations ............................................................................................................................ 10
6.7.3. Purging and draining operations ....................................................................................................... 10
6.7.4. Fitting installation .............................................................................................................................. 10
7. WORK METHODOLOGY ............................................................................................................................. 11
7.1. FITTING LOCATION .................................................................................................................................... 11
7.2. OPERATION SEQUENCES. ........................................................................................................................... 12
7.3. LEAK TEST .................................................................................................................................................. 14
7.4. STOPPLE® TRAIN SECURITY SECTION MONITORING .................................................................................... 15
7.5. HT&P PROCEDURE ................................................................................................................................... 16
7.5.1. T101 std & T101XL operation manual or pneumatic operation ....................................................... 16
7.5.2. Tapping Machine 1200 hydraulic ...................................................................................................... 17
7.5.3. Hydraulic cylinder Stopple® train ..................................................................................................... 18
7.6. LOCK O RING® PLUG PREPARATION AND INSTALLATION ........................................................................... 21
7.7. COUPON REINFORCEMENT AND CENTERING DEVICE ................................................................ 22
7.7.1. Centering device ................................................................................................................................. 22
7.7.2. Reinforcement Coupon ....................................................................................................................... 23
7.8. STACK UP ..................................................................................................................................................... 24
7.8.1. Stack up of the 28” Hot Tap on the STOPPLE® position (A1)......................................................... 24
7.8.2. Stack up of the 28” Stopple Train position (A1) ................................................................................ 25
7.8.3. Stack up of the 2” equalization/vent (A2-A3) .................................................................................... 26
8. ATTACHMENT................................................................................................................................................ 27

8.1. DATA SHEET ............................................................................................................................................... 27
8.2. EQUIPMENT RIGGING ................................................................................................................................. 28
8.2.1. Tapping Machine ................................................................................................................................ 28
8.2.2. Hydraulic cylinder .............................................................................................................................. 28
8.2.3. Sandwich Valve ................................................................................................................................... 29
8.3. DAILY WORK SHEET.................................................................................................................................. 30
8.4. PREJOB SITE ASSESSMENT FORM .............................................................................................................. 31
8.5. HT&P CALCULATION SHEET .................................................................................................................... 32
8.6. TORQUE VALUES ...................................................................................................................................... 33
8.7.1 TORQUE REQUIREMENTS: ........................................................................................................................ 33
8.7.2 TORQUE SEQUENCE DIAGRAMS .................................................................................................... 33
8.7.3 HYTORCK PICTURE & RECOMENDATIONS ................................................................................. 34
8.7. SCAFFOLDING GUIDELINES AND CHECK LIST ............................................................................... 35
8.8. GENERIC RISK ANALYSIS .......................................................................................................................... 42
8.8.1. Risk analysis tools............................................................................................................................... 42
8.8.2. Risk analysis........................................................................................................................................ 43
1. REVISION HISTORY
Page Reason for Change Rev Reviewer Date Revised
2. CONFIDENTIALITY
This document contains information which T.D. Williamson sprl considers confidential to itself and its affiliated
companies. No part of it may be disclosed to third parties without the prior written approval of T.D. Williamson sprl.
This document and all of its parts, including tables, drawings and photographs, are © T.D. Williamson sprl, 2010.
Unauthorised copying or distribution is prohibited.
3. INTRODUCTION
The contract 967-1904-008-EGY includes the execution of one single position STOPPLE® train operation according to
the information on the application data sheet (paragraph 8.5). As the existing line cannot be taken out of service, the
“IN service STOPPLE® method” offered by T.D. Williamson sprl has been adopted.
The approach described in this document are based upon API RP 2201 and proven TD Williamson methods to achieve
the required results with total security for both equipment and personnel.
4. OBJECTIVES
TD Williamson is strongly committed to safety. Our HSE program focuses on ensuring that our personnel, the
environment and you remain protected and confident in knowing safety is our number one priority. This method
statement is focused on taking the necessary “proactive” steps to ensure that personnel exposure to HSE hazards are
eliminated or managed to an acceptable level.
This method statement is intended to prepare the Hot Tap and Plugging activities.
It describes the responsibilities of both parties to ensure a successful job completion. It records the technical data
utilized by TDW to select and prepare equipment to be mobilized and used on site. It also gives an overall view of the
operation sequences.
The document should be read carefully, commented upon (where necessary) and returned signed, to TDW. The
signature will mean that the client agrees and approves the responsibility matrix. In case of any doubt please call the
TDW Project Coordinator.
Note: The procedure included in this document is not sufficient to perform any part of TDW works without the presence
of TDW Field technicians. Only TDW Field technicians are qualified to perform these activities.
5. DEFINITIONS
 The Hot Tap operation is the technique of drilling a pipeline in service.
 The STOPPLE® operation is the technique of isolating a section of pipeline in service.
 The Plugging operation is the technique of setting a plug onto a fitting.
 A gasbag is a balloon insert in the pipeline to increase the security and containment of any leaks.
 The Equalization is the technique of balancing the pressure between equipment.
 The By-pass is the technique of by passing a section of pipeline.
 The Fitting LOR ® is a welded branch fitting which is working with the Lock-O-Ring ® Plug.
 The Fitting TOR™ is a welded branch fitting which is working with the Thread-O-Ring™ Plug.
 The Sealing Element is a seal inserts in the pipeline to isolate a section.
6. RESPONSIBILITIES
6.1. TABLE OF RESPONSIBLITIES
Final
Step Task Responsible* Assistance** Paragraph****
Approval***
Perform Job Analysis Client TDW NA 6.2.1

Preparation
Project
Safety risk analysis Client TDW NA 6.2.2

Complete Data
Client TDW Client 6.2.3
Sheet
Preparation &
TDW NA NA 6.3.1
Selection
HT&P Equipment
Rigging Client TDW NA 6.3.2
Storage Client NA NA 6.3.3
Disassembly Client TDW NA 6.3.4

Decontamination &
Client TDW NA 6.3.5
Repacking
Equipment Preparation &
Support Client TDW NA 6.4
Selection
Qualification &
TDW Client NA 6.5.1
TD Williamson Field Technicians
Mobilization Process
Stay Client NA TDW 6.5.2
Organize Timetable TDW Client NA 6.5.3

Complete Daily Work
TDW Client Client 6.5.4
Sheet
Perform Pre-job Site
Assessment
Complete Calculation
Sheet
Man power Mobilization Client TDW NA 6.6
Fitting examination Client NA TDW 6.7.1

Job Operations
HT&P Operations TDW Client NA 7
Leak test operations Client TDW NA 6.7.2

Purging & draining
Client TDW NA 6.7.3
operations
Fitting Welding/
TDW Client NA 6.7.4
installation
*: The party identified in this column will handle the task.

**: The party identified in this column will support the responsible party.
***: The Task request a document approval. The party identified will sign the document.
****: See the paragraph referred for details.
NA: Not applicable.
6.2. PROJECT PREPARATION.

6.2.1. Job Analysis
It is important to recognize that hot tapping and plugging “by definition” involves hot work (under pressure) on
equipment in service. The First Step in hot tapping and plugging work process is to be sure that the hot tapping and
plugging method used will be suitable with the final objective of the project. TD Williamson is responsible for hot tapping
and plugging operation, but TD Williamson will not take the responsibility for other work (valve replacement or pipe
cutting…) unless these services are specifically detailed in the contract.
6.2.2. Safety risk Analysis

Hot tapping and plugging is a specialized operation that involves working or equipment in service. Hot tapping should
never be considered a “routine” operation. The job Risk analysis has to ensure that all safety measure are implemented
to eliminate or reduce physical hazards, thermal burn hazards, potential acute or chronic health hazards. This Risk
analysis includes elements of a normal hot work procedure (hot work permit, gas checking, firefighting equipment and
personnel, environmental equipment…). TD Williamson will provide the required support to complete the client
analysis.
6.2.3. Application Data sheet

The application data sheet records the basic technical data related to the HT&P intervention, all equipment and
procedures are based on this information. TDW field technicians will check that the application data sheet corresponds
to the operation requested on site. If modifications are observed, they will communicate the modifications to the TDW
Project Coordinator in order to check the feasibility of the job. The modifications and errors might delay or cancel all
operations. The Data sheet is available in attachment 8.1.PLEASE CHECK THE DETAILS CAREFULLY
6.3. HOT TAPPING & PLUGGING EQUIPMENT

6.3.1. Equipment Selection & Preparation
TD Williamson equipment is specially designed to work on in service piping system. All equipment is selected and
prepared to ensure the success of the job. This equipment is mobilized for the duration of the contract. The equipment
list is available in separate document.
6.3.2. Equipment Rigging

Unload HT&P equipment following national lifting regulation and good practice. All HT&P equipment is packed on
pallets or box. Concerning Hot Tapping machine/s, hydraulic cylinder/s and Sandwich™ Valve/s see the specific
recommendation in attachment 8.2. Before the HT&P operation, the TDW field technicians will give their instructions to
the riggers and crane operators.
6.3.3. Equipment Storage

Store the HT&P equipment in a clean, dry and safe place. On arrival, the TDW Field technicians will check that all
HT&P equipment is undamaged prior to use. If any equipment is found to be defective the TDW technicians will
immediately contact the TDW project coordinator.
6.3.4. Equipment disassembly

At the end of the HT&P operation, All the HT&P equipment will be dismantled. All equipment and personal applied for
the HT&P equipment disassembly process i.e. as riggers and crane will remain mobilized until the equipment is ready
to be repacked. The TDW Field Technicians will give their approval for support demobilization.
6.3.5. Equipment decontamination & repacking

In cases whereby, the equipment is contaminated by a potential health hazard substance, proceed to the
decontamination area before the equipment leaves the job site. TD Williamson may request decontamination
certification attesting that the equipment has been adequately decontaminated to safe levels.
At the end of the job, repack all equipment on and or in the respective packing box and contact the TDW Project
Coordinator to effect demobilisation transport. Outside Europe, TDW field technicians can also assist the
demobilization process i.e. checking packing list/s, Identification and tagging of Equipment etc.
6.4. EQUIPMENT SUPPORT

Some equipment essential for the success and the safety of the job has to be available onsite. TD Williamson will not
supply the following equipment. The Client shall provide them for all the duration of the job.
Step Equipment Qty Requirement
Forklift / Crane 1 Offloading and loading equipment and on-site manoeuvring.
Rigging and lifting operation. Check stack up for equipment dimension and weight. Cranes have to
Crane 2
be able to turn Tapping Machines and Sandwich valves form horizontal to vertical and vice-versa.
Chain Block 2 Rigging and lifting operation. Check stack up for equipment dimension and weight.
Rigging
Lifting Belts 4 Rigging and lifting operation. Check stack up for equipment dimension and weight.
Chain set 2 Rigging and lifting operation. Check stack up for equipment dimension and weight.
Spirit Level 1 Equipment alignment
Pallet, box… * Reshipment, repacking...
Flogging Spanners 2 Bolting operation. All Studs and Nuts from TDW are Heavy Hex. with UN design.
Bronzed faced
2 Bolting operation.
Bolting
Hammer
Bolting Machine * Bolting operation. Air/Hydraulic operated.
Set off Dynamometric

1 For Torque Measurement
key
Nitrogen Pack * Leak testing. Check equipment stack up for equipment volume.
1/4" NPT High

2 Leak testing connection.
Leak Testing
pressure Hose
1/4" NPT pressure
4 Leak testing control. Check pipeline pressure for maximum allowable pressure
Gauge
Nitrogen regulator 2 Leak testing control.
Water soap solution Leak testing control
TD Williamson technicians need free and safe access to the top of tapping machine. Check stack up
Scaffolding *
for dimension. Guidelines for scaffolding are available in separate document HSE 0028.
Civil Work
Excavation * Compliant with National excavation regulations and good practice
Pipeline Support * Check Stack up for equipment weight
Tapping Machine
* For all Hot Tapping operations. Check Stack up for equipment weight
Support
Air compressor 1 For tapping machine with air operated. Minimum Power: 150CFM to 90 PSI 180m³/h
Toolbox 1 Including wrench set, hammer, Allen key set…

Others
Lighting * Requested in case of reduced light levels (Fog, night…)
Wooden Block * For equipment support
Diesel * To feed the power unit on TDW Field Technician request
*Following job site requirement and Risk analysis
6.5. TDW FIELD TECHNICIANS

6.5.1. Qualification & mobilization process
TD Williamson field technicians are specially trained to work with TD Williamson equipment. They are specialists in
HT&P operations. They will give all support requested and they will share their experiences and their knowledges of
TDW processes. The client shall communicate any specific qualifications for TDW personal well in advance of
personnel mobilisation (Site regulation, Special safety training etc).
The Client will give all information to the TDW project Coordinator in order to organize the travel of the TDW field
Technicians and the communication between Client representative and TDW field Technicians.
The Client will organize a Kick off meeting with all personnel involved for the job. TDW field technicians will advise the
personnel of the procedures and requirements for performing and completing the job. TDW field technicians are
mobilized for the duration of the contract.
6.5.2. TDW field Technician stay

TDW will book all necessary and appropriate for comfortable accommodation i.e. camp, hotel etc.
In the case of hostile locations, Client will provide a Safety Plan approved by TDW including all necessary measures for
TDW field Technician’s security (Bodyguard, escort…).
6.5.3. Timetable
TD Williamson Field technicians have a flexible timetable. They will organize their timetable with the Client
representative. TDW Field technicians are allowed to work 10 hours a day (from/to accommodation) as long as all
safety precautions are undertaken. All overtime work has to be approved by TD Williamson Project Coordinator.
6.5.4. Daily Work Sheet

TDW Field technician completes the Daily Work Sheet for each day on jobsite, the Daily Work sheets will briefly
describe all activities carried out during the job. The Client representative will sign and approve all Daily Work Sheets.
The Daily Work Sheet is available in attachment 8.3.
6.5.5. Pre-job Site assessment form

The pre-job site assessment will be implemented by the TDW technicians to ensure that all potential hazards are
identified, and all safety precautions have been considered. The pre-job site assessment requires Client assistance and
approval. TD Williamson insists that the job cannot begin without Client and TDW Technicians approval. This pre-job
site assessment done by TDW field technicians does not substitute the job Risk analysis performed by the Client. The
pre-job site assessment form is available in attachment 8.4.
6.5.6. Calculation sheet

Before starting the job, the TDW Field technicians will fill in the calculation sheet. The calculation sheet records all
dimensions to ensure consistent HT&P operations. The Client representative will sign the TDW calculation sheet in
order to give his approval to start the operation on the line. The calculation sheet is available in attachment 8.5
6.6. MANPOWER
All personnel (mentioned in the box below) are required to ensure the operation stays in line with the work schedule.
This list is not exhaustive and should be revised following the Risk analysis and the Client requirement. The TDW field
technicians will wear their own standard PPE. This consists of safety shoes, hard hat, gloves, safety glasses, fire
retardant clothing, hearing protection, safety harness and personal gas monitor. The client will provide PPE for all other
personnel involved for the work. In the case of any special PPE requirements, the client will provide this for all
personnel including TDW Field Technicians.
Function Qty Tasks
Coordinate all operations. Sign and approve all documents. Provide all documents work permit,
Client representative 1
Risk analysis… Ensure contact with management.
TD Williamson Field
2 Performs all Hot tap and STOPPLE® processes
Technicians
For rigging and lifting operations, bolting operations, assisting the TDW Field technicians (in all
Riggers/Fitters 2
his activities, as required)
Fire watch * For firefighting operations
First Aid * In case of accident
Crane operator * For rigging and lifting operations
*Following job site requirement and Risk analysis
6.7. JOB OPERATIONS

6.7.1. Fitting Examination
Welding on an in-service piping system requires welding procedures specification (WPS) and welding personnel
specifically qualified for the task. All procedures are to strictly comply with the principal’s rules that are applicable for
this project. Install the fittings as per point 7.1. Fitting location.
The client will ensure (prior to the TDW field technician’s mobilisation) that the fittings have been installed following
principal code and rules applicable for the project. Welding test certificate should be available on site.
6.7.2. Leak test operations

During HT&P operations, leak tests have to be performed with equipment provided by the Client, unless specifically
detailed in the contract this is to be provided by TDW. Details of the equipment required are available in point 7.3. TDW
Field technicians will assist in performing the leak test operations.
6.7.3. Purging and draining operations

The HT&P equipment, the bypass line and the isolated section have to be purged, vented or drained during the job.
The Client will provide the equipment and procedure to perform the purging, venting or draining operations safely. TDW
Field Technicians will assist during the purging, venting or draining operations.
6.7.4. Fitting installation

Whenever welding services are provided by TDW, procedure and documentation will be issued separately in the
welding book document.
7. WORK METHODOLOGY
7.1. FITTING LOCATION
A3 A2 A1
533mm
965mm
1150mm
1880mm
Position Type of Fitting

28” x 28” 600# RF
A1
STOPPLE Tee
A2** 2” TOR Bleed
A3** 2” TOR Equalization
** The TOR Bleed port must be rolled over 45 or 60 degrees to allow clearance for the valve to be installed.
BLEED PORT
711mm
7.2. OPERATION SEQUENCES.
Operation Schematic Installation Procedure
7.2.1. Before starting operation ensure that pipeline operator is in continuous communication with site operation officer as per communication
procedure.
7.2.2. Inspect all Lock O Ring ® Fittings. Control and confirm the perfect working
conditions (no rust, no scratch in O-rings location and no visual showing critical to A1 TDW field Technician
quality and safety)
7.2.3. Install the spool. Align the spool with fitting bore.
A1 TDW field Technician
(TDW will specify the applicable torque value for TDW equipment)
7.2.4. Install the valve. Align the valve with the spool bore. Open and close the
valve to ensure the workability A1 TDW field Technician
(TDW will specify the applicable torque value for TDW equipment)
7.2.5. Install and Align the valves with fitting bore. Open and close the valves to
A2 A3 TDW field Technician
ensure the workability.
7.2.6. Measure and record the distance from the top face of the SANDWICH®
A1-A2-A3 TDW field Technician
Valve, including gasket.
7.2.7. Perform the Leak Test and Hot Tap on equalizations 2” positions and Drain A2 A3 7.5.1
7.2.8. Perform the Hot Tap on STOPPLE® A1 7.5.2
7.2.9. Install bolt on support clamp A1 TDW Field Technician+ 7.1
7.2.10. Prepare the Stopple® train assembly. A1 7.5.3
7.2.11. Measure and record all the required measurement to set the Stopple® train
A1 7.5.3
Set Clearance B as per requirements 7.5.3.3 and record.
Generic sketch of STOPPLE® Train measurements.

WARNING
During insertion and retraction of STOPPLE train plugging head the zero flow rate is mandatory. This is the most critical moment of
operations and should be followed accordingly (to achieve that the client scope of work should be performed first, and valve closed to
divert or stop the flow in order to achieve the zero-flow condition prior setting the STOPPLE® train head).
7.2.12. Insert the STOPPLE Train plugging head to the full set position following
A1 7.5.3
proper setting procedures.
7.2.13. Bleed and Vent the isolated as per vent procedure A3 Client
7.2.14. Connect Stopple® train bleed port to a safe location to vent the gas. A2 TDW field Technician/ Client
7.2.15. Check plugging head for leakage past sealing element #1. Allow sufficient
A2 7.4
time to confirm the seal or if leakage is going to occur.
WARNING
Do not cut into the isolated section of pipe until the seal has been verified as satisfactory.
If plugging head is not sealed, both injury to personnel and property damage are possible
7.2.16. Monitor the seal #1 of the Stopple® train head
At the first attempt TD Williamson does not guarantee a perfect seal.
Several manipulations of the STOPPLE® head may be required to reach an A1 7.5.3
acceptable working seal. If seal quality is not acceptable to work on the line,
re-establish the pressure in the isolated section, retract the stopple machine,
replace the sealing element with a new one and recommence the operation
until an acceptable working seal is achieved
Isolated section
decommissioning
7.2.17. Work on the isolated section can start. A1
according to the customer
procedure
7.2.18. Work on the isolated section is completed NA Client
7.2.19. Close the Stopple train® bleed port and set the bleed port plug. A2 TDW field technician
7.2.20. Equalize pressure in the isolated section A3 Client
CAUTION
Pressure must be equalized across the plugging head before the head can be withdrawn. If a line pressure differential exists, the plugging
head will remain locked in the line. Attempts to retract it will result in damage to the hydraulic cylinder.
Equalize pressure before retracting, and keep it equalized and ensure the zero-flow condition.
7.2.21. Retract the STOPPLE Train plugging head fully following proper retraction
A1 7.5.3
procedures.
New section is now commissioned according to the customer procedure
7.2.22. Sandwich valves can be closed. A1 TDW Field technician
7.2.23. Stopple assembly can be vent according customer procedure. A1 Client
7.2.24. Insert LOR Plug in the STOPPLE®, bypass fittings and remove temporary
A1 7.6
valves
7.2.25. Install blind flange and torque it to the right torque value A1 Client + 8.6
7.2.26. Insert TOR™ Plug in the equalization fittings and remove temporary valves A3 7.5.1.2
7.2.27. Equipment Cleaning and Job completion 6.3.5 NA
CAUTION
Make sure all pipeline product is removed from the components.
This is necessary prior to proceeding to the next job or returning components to storage.
7.3. LEAK TEST
7.3.1.1. Preparations for the leak test
7.3.1.1.1. Perform the leak test after the installation of the TDW equipment on the valve. This test will be executed before
working on the line.
7.3.1.1.2. The test medium shall be Nitrogen (N2), pipeline product or both. Note that if there is a leak between the
connections, all of the assembly will have to be drained.
7.3.1.1.3. Warning! Leak test performed at a higher pressure could collapse the pipe wall. Do not exceed the maximum
working pressure for each element of the tapping machine assembly.
7.3.1.2. Leak test
7.3.1.2.1. Connect the bleeder valve to the tapping machine.

7.3.1.2.2. Connect a high-pressure hose between the 1/4” valve on the Tapping machine and the pressure regulator on the
Nitrogen Pack or Bottle. Install the pressure gauges, one on the TM bleeder valve and one on the Nitrogen pack or
on the bottle outlet valve.
7.3.1.2.3. Gradually open the Nitrogen pack. Relive the air from the housing.
7.3.1.2.4. Gradually increase the N2 pressure up to the final test pressure. (maximum 1.1 the actual line pressure) The rate of
increase should be in accordance with the Client’s pressure test procedure
7.3.1.2.5. Check all flanges and connections during the hold period (15 to 30 minutes) for any leakage with water/soap solution
or other authorized gas leak detector medium.
7.3.1.2.6. Keep nitrogen pressure into adapter/housing slightly above line pressure.
Nitrogen regulator
Pressure Gauge ¼’’ high pressure Hose
Machine
¼’’ Valve
N2
7.4. STOPPLE® TRAIN SECURITY SECTION MONITORING
7.4.1 Procedure
a. Bleed security section using 2” valve (A2) according to Client process

b. 2 times a day, monitor pressure gauge on the housing A1
c. Record pressure gauge indication
d. Report to TDW field technician any variation of pressure
7.5. HT&P PROCEDURE

7.5.1. T101 std & T101XL operation manual or pneumatic operation
7.5.1.1. Hot Tapping

7.5.1.1.1. Inspect the Tapping Machine.
7.5.1.1.2. Install the pilot drill into the boring bar of the Tapping Machine.
7.5.1.1.3. Measure, record and calculate all the required tapping measurement.
See attachment 8.5.
7.5.1.1.4. Install the nipple 2” NPT on the Tapping Machine.
7.5.1.1.5. Install the tapping assembly onto the closed valve.
7.5.1.1.6. Open the valve fully.
7.5.1.1.7. Perform the leak test. Follow the instruction paragraph 7.3.
7.5.1.1.8. Confirm with the Client representative for starting drilling by signing the
calculation sheet.
7.5.1.1.9. Hot tap the line. Report to your calculation.
7.5.1.1.10. Retract the boring bar and close the valve.
7.5.1.1.11. Open the bleeder valve to remove pressure from the tapping machine
7.5.1.1.12. Remove the tapping machine assembly from the valve.
7.5.1.2. Plug setting
7.5.1.2.1. Inspect the Tapping Machine and the equipment.

7.5.1.2.2. Install the Thread O Ring Assembly on the Tapping Machine
7.5.1.2.3. Use the measurements recorded previously. See attachment 8.5.
7.5.1.2.4. Install the bleeder valve onto the Tapping Machine and the assembly
onto the valve.
7.5.1.2.5. Perform the leak test. Follow the instruction paragraph 7.3.
7.5.1.2.6. Set the Thread O Ring with handle; respect your calculation to prevent
damage to O-ring and threads.
7.5.1.2.7. Open the bleeder valve and check the Thread O Ring™ Plug seal.
7.5.1.2.8. If the Thread O Ring™ Plug does not seal, remove the Thread O
Ring™ Assembly, check the Thread O Ring™ Plug, replace the O-

Ring if necessary and restart.
7.5.1.2.9. Retract the boring bar.
7.5.1.2.10. Open the bleeder valve to remove pressure from the tapping machine
7.5.1.2.11. Remove the Tapping Machine.
7.5.1.2.12. Remove the valve.
7.5.1.2.13. Apply protective grease to the Thread O Ring™ Plug.
7.5.1.2.14. Install the Thread O Ring™ Cap on fitting.
7.5.2. Tapping Machine 1200 hydraulic
7.5.2.1. Hot tapping
7.5.2.1.1. Inspect the Tapping Machine and the requirement.

7.5.2.1.2. Install the adapter onto the tapping machine.
7.5.2.1.3. Install the cutter, the cutter holder and the pilot onto
the boring bar and assure that the U-rods turn freely.
7.5.2.1.4. Check the concentricity of the adapter.
7.5.2.1.5. Measure, record and calculate all required tapping
measurement. See annex 8.5.
7.5.2.1.6. Install the tapping machine assembly onto the closed
Valve.
7.5.2.1.7. Open the valve fully.
7.5.2.1.8. Perform the leak test. See paragraph 7.3.
7.5.2.1.9. Once the Leak test on the drilling machine assembly is
successful, the HT drilling operations can begin. It is
not mandatory to bleed out the remaining nitrogen
pressure from the HT assembly prior to start the HT as
the leak test is performed at a pressure a little higher
than the line pressure when the pilot will enter in the
pipe wall the nitrogen pressure will automatically drop
to the line pressure giving the confirmation the Pilot
went through the pipe wall.
7.5.2.1.10. Confirm with Client representative for starting drilling
by signing the calculation sheet. Sign the TDW field
Technician Calculation Sheet.
7.5.2.1.11. Start the hot tap.
7.5.2.1.12. When the hot tap is completed, fully retract the cutter.
7.5.2.1.13. Fully close the valve.
7.5.2.1.14. Drain the pipe product from the hot tapping assembly.
7.5.2.1.15. Remove the tapping machine from the valve.
7.5.2.1.16. Remove the coupon and give it to the Client.
7.5.2.1.17. Remove the cutter, the cutter holder and pilot from the
Tapping Machine and retract the boring bar fully.
7.5.3. Hydraulic cylinder Stopple® train

7.5.3.1. Stopple Train assembly procedure
7.5.3.1.1. Install the STOPPLE® cylinder on to the STOPPLE® housing with the cylinder control valve and the equalization
connection facing the same direction.
7.5.3.1.2. Place the STOPPLE® cylinder and STOPPLE® housing in a horizontal position with the equalization connections
facing up.
7.5.3.1.3. Position the STOPPLE® Train Cradle (with the STOPPLE® Train inside) at the end of the housing. Use jacks on
cradle to ensure that it is level and the control bar is aligned with the socket in the control bar head. To prevent
cradle movement during subsequent operations, use the two studs and nuts to temporarily attach the cradle to the
housing. Use alignment pins to line up control bolt holes to control bar head bolt holes.
7.5.3.1.4. Remove nose piece #2 from nose piece #1

7.5.3.1.5. Insert hydraulic cylinder control bar into control bar head.
7.5.3.1.6. Retract plugging head #1 into housing until control bar head foot is
flush with the raised face of the stopple housing.
7.5.3.1.7. Record control bar retraction number (hydraulic cylinder in site
hole) into D dimension. See appendix 8.5
Control Bar Head
7.5.3.1.8. Install sealing element, nose pad & ring to the nose piece #1
7.5.3.1.9. Set clearance B as per appendix 7.5.3.3
7.5.3.1.10. Torque nose as per appendix 7.5.3.4
7.5.3.1.11. Install sealing element, nose pad & ring to the nose piece #2
7.5.3.1.12. Torque nose as per appendix 7.5.3.4
7.5.3.1.13. Re-install Nose piece #2 with Nose piece #1
7.5.3.1.14. Retract Stopple® train into the housing until top nose roller #1 is Nose piece #1
flush with the raised face of the stopple housing
hole) into C dimension. See appendix 8.5
7.5.3.1.16. Retract Stopple® train into the housing until top nose roller #2 is
flush with the raised face of the stopple housing
hole) into A dimension. See appendix 8.5 Nose piece #2
7.5.3.1.18. Retract Stopple® train into housing stopple until complete stop
7.5.3.1.19. Check hydraulic cylinder in site hole is 0
Plugging head retraction into stopple

housing
7.5.3.2. Setting the plugging head
7.5.3.2.1. Measure, record and calculate all required measurements.

See attachment 8.5.
7.5.3.2.2. Center the full plugging system on the SANDWICH® Valve
with equalization connection centred over the pipe and facing
the section to be isolated.
7.5.3.2.3. Perform the leak test. See paragraph 7.3.
7.5.3.2.4. Install the equalization piping system.
7.5.3.2.5. When the pressures are equalized on both sides of the Valve,
open the valve fully.
7.5.3.2.6. Open the equalization valve between the housing and the
equalization Fitting.
7.5.3.2.7. Prior setting the STOPPLE® makes sure that the bypass line
is working and the flow in the line is in the allowed flow rate for
the planned stopple operation.
7.5.3.2.8. Set the plugging machine. Report to the calculation
attachment 8.5.
7.5.3.2.9. When the plugging head is set, return the control valve lever to
neutral position, and check the measurement in the
observation hole to make sure it corresponds with the
calculated distance required to set the plugging head.
7.5.3.2.10. Close the valves on the equalization valve.
7.5.3.2.11. TD Williamson does not guarantee a perfect seal. Several manipulations and chip sweeping of the STOPPLE® head
may be required to reach an acceptable working seal. If seal quality is not acceptable to work on the line, re-
establish the pressure in the isolated section, retract the stopple machine, replace the sealing element with a new
one and recommence the operation until an acceptable working seal is achieved.
7.5.3.2.12. Tighten the cap screw on the bar lock clamp. Torque: 230-245 Nm
7.5.3.3. Stopple train clearance B
7.5.3.4. Nose bolt torque value

7.5.3.5. Position of Bolt-On Clamp and Torque value
7.5.3.6. Retracting the plugging head
7.5.3.6.1. Ensure the pressure is equalized into the isolated section.

7.5.3.6.2. Release the bar lock clamp.
7.5.3.6.3. Slowly retract the plugging head until full retraction.
7.5.3.6.4. Close the Sandwich® valve. Make the internal bypass is closed.
7.5.3.6.5. Close the equalization valve.
7.5.3.6.6. Drain the pipe product from the STOPPLE® assembly
7.5.3.6.7. Remove the plugging machine.
7.5.3.6.8. Remove the plugging head from the STOPPLE® machine.
7.5.3.6.9. Remove the housing from the STOPPLE® machine.
7.6. LOCK O RING® PLUG PREPARATION AND INSTALLATION

7.6.1.LOCK-O-RING® + plug setting
7.6.1.1 Inspect the tapping machine and equipment.

7.6.1.2 Install the adapter onto the tapping machine.
7.6.1.3 Set the Lock O Ring® PLUS plug and the plug holder on the boring bar.
LOR® Plus plug

7.6.1.4 Check the disengagement and the engagement of the plug holder.
7.6.1.5 Retract the boring bar to zero position
7.6.1.6 Use the measurement recorded previously. See
attachment
7.6.1.7 Install the Lock O Ring® PLUS plug assembly onto
the Sandwich valve.
7.6.1.8 Install the equalization piping system.
7.6.1.9 Perform a leak test. See paragraph Error!
Reference source not found..
7.6.1.10 Install equalization piping system.
7.6.1.11 Equalize the pressure on both side of the valve.
7.6.1.12 Open the valve completely.
7.6.1.13 Extend the Lock O Ring® PLUS plug leaves by
rotating the tapping machine worm gear assembly
(as per number of turn previously recorded).
7.6.1.14 Lower the plug. When the bottom of the plug
approaches the LOR® plus flange groove
7.6.1.15 Inject nitrogen into the assembly using the 1/2”
drain valve on the upper flange of the sandwich
valve and push back the diesel below the sandwich
valve gate.
7.6.1.16 Turn crank slowly to extend leaves. Check the Lock
O Ring® PLUS plug is retained by slowly
advancing and retracting the boring bar (leave plug
set in the up position).
7.6.1.17 Release the plug holder from retainer rod.
7.6.1.18 Retract the boring bar.
7.6.1.19 Vent and Drain the pipe product from the Lock O Ring® assembly as per client draining and venting process.
7.6.1.20 Check the pressure to confirm the Lock O Ring® Plug seal.
7.6.1.21 Retract fully the boring bar, close the valve.
7.6.1.22 Remove the equalization piping and the pressure gauge. (Where applicable)
7.6.1.23 Remove the tapping machine assembly from the valve.
7.6.1.24 Remove the plug holder from the Lock O Ring® Plug.
7.6.1.25 Remove the valve from the Lock O Ring® flange.
7.6.1.26 Close the fitting with the blind flange.
7.7. COUPON REINFORCEMENT AND CENTERING DEVICE

7.7.1. Centering device
7.7.1.1. Introduction
The coupon reinforcement and centering device are recommended to ensure consistent hot tap
operations. The centering device prevents offset of the pilot whilst the reinforcement coupon decreases
vibrations and prevents deformation of the coupon. Correct installation and alignment of these support
fittings are critical to the success of the hot tap.
Figure 1 - Centering device and coupon reinforcement
7.7.1.2. Installation
CAUTION!
TDW recommends the installation of the centering device in the presence of a TDW Field Technician.
7.7.1.2.1. Install and weld the fitting in accordance with the applicable WPS.
7.7.1.2.2. Check the verticality and horizontality of the flange after welding of the longitudinal weld.
7.7.1.2.3. Grind all longitudinal and spiral weld seams that pass by the nozzle.
7.7.1.2.4. Fix the centre of the flange by using plumb ball, laser pointer or any other suitable means.
DO NOT use the centre of the branch ID as a reference point as it may differ from the
centre of the flange.
7.7.1.2.5. Axis of the bar of the tapping machine will be represented using the plumb ball, laser pointer
or any other suitable means.
7.7.1.2.6. Mark the position of the pilot drill on the header using permanent ink or punch mark.
7.7.1.2.7. Install the coupon reinforcement, aligning the centre of the centering device with the
permanent mark.
7.7.2. Reinforcement Coupon

7.7.2.1. Installation
7.7.2.1.1. Tack weld the reinforcement coupon into place, immediately reinforced by applying another
pass on top.
7.7.2.1.2. After verifying the alignment and tolerances, a continuous weld should be used in minimum
of 2 passes as per applicable WPS for the fitting.
7.7.2.1.3. Continuous weld seams are MANDATORY as highlighted by the
locations in red.
7.7.2.1.4. Use same pre-heating and electrodes as required by WPS used to weld the fitting on the line.
7.7.2.1.5. Each bead will be immediately reinforced by another pass on top, before starting another
one.
7.7.2.1.6. The minimum weld seam length shall be 2 inches and 50% of the accessible place.
Red – Mandatory
Orange - Recommended
7.7.2.1.7. Continuous welds seams are RECOMMENDED depending on the space between pipe and
reinforcement coupon as highlighted by the locations in orange.
7.7.2.1.8. Use same pre-heating and electrodes as required by WPS used to weld the fitting on the line.
7.7.2.1.9. Each bead will be immediately reinforced by another pass on top, before starting another
one.
7.7.2.1.10. The weld seam length depends of the space between pipe and reinforcement coupon.
7.8. STACK UP
7.8.1. Stack up of the 28” Hot Tap on the STOPPLE® position (A1)
The same Stack up is applicable for the LOR® Plug Setting
7.8.2. Stack up of the 28” Stopple Train position (A1)
7.8.3. Stack up of the 2” equalization/vent (A2-A3)
8. ATTACHMENT
8.1. DATA SHEET
8.2. EQUIPMENT RIGGING

8.2.1. Tapping Machine
Material to be lifted: Tapping Machine (weights are given in the stack up - paragraph 7.8)
Application: Moving materials to and from point of operation
Rigging Equipment Needed: Correct weight rated adjustable single-leg chain sling with safety hook and a correct weight rated
device. See stack up for Weights and dimensions.
Safe rigging procedure:
1) Determine weight of object to be lifted.

2) Attach correctly weight rated lifting sling to crane using master link. Ensure safety closed.
3) Position crane directly over the load to be moved. Attach lifting hook to each end of tapping machines lifting eyes.
4) Ensure safety latches are closed.
5) Perform a “lift test”. Raise load slightly to test balance of the load, if load is not balanced, make the necessary to
the chain lengths and re-test.
6) Move the load to the appropriate position, keeping it as low as possible, for as long as possible.
8.2.2. Hydraulic cylinder

Material to be lifted: Hydraulic cylinder - horizontal – Multiple sizes (weight are given in the stack up - paragraph7.8)
Application: Moving materials to and from point of operation
Rigging Equipment Needed: Two – correctly weight rated nylon slings and a correct weight rated device. See stack up for
weights and dimensions.
Safe Rigging Procedure: Note: Determine weight of object to be lifted.
1) Position crane directly over the load to be moved. If other personnel are present, inform them of the move and the
need to leave the immediate area. Clear travel path of any obstacles.
2) Secure both nylon slings to hydraulic cylinders using choker hitch. Use device to connect both nylon slings
together. Attach device to hook on crane.
3) Perform a “lift test”. (Raise load slightly to test balance of the load, if load is not balanced, change sling location
and re-test)
4) Move load to the appropriate position, keeping load as low as possible, for as long as possible.
8.2.3. Sandwich Valve

Material to be lifted: Sandwich® Valve – lifting eyes – vertical - multiple sizes (weights are given in the stack up - paragraph
7.8)
Application: Movement of materials in a vertical position to point of operation.
Rigging Equipment Needed: Correct weight rated “no hook” design four-legged lifting sling and four “shouldered” lifting eyes.
Note: A two-legged sling can be used if load rating is suitable.
Safe Rigging Procedure: Note: Determine weight of object to be lifted.
1) Attach correctly weight rated lifting sling to crane using master link. Ensure safety latch is closed.
2) Install lifting eyes in Sandwich® valve outside plate holes as shown.
3) Position crane directly over the load to be moved. If other personnel are present, inform them of the move and the
need to leave the immediate area. Clear travel path of all obstacles.
4) Run chain through both lifting eyes on one end and secure chain in hook back at top near master link. Do the
same with other sling leg.
5) Perform a “lift test”. (Raise load slightly to test balance of the load, if load is not balanced, change the length of
chain leg and re-test)
6) Move load to the appropriate position, keeping load as low as possible, for as long as possible.
8.3. DAILY WORK SHEET
T.D. WILLIAMSON S.A. Service Center

DAILY WORK SHEET
Date / Datum:_____________ REF.:_________________
Customer / Client / Klant:

______________________________________________________________
Supervisor / Responsable / Verantwoordelijke:

______________________________________________________________
Arriv. / AanKomst:__________ Dep. / Vertrek: ___________
Work / Operation / Werk:

______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
Remarks / Remarques / Opmerkingen:
______________________________________________________________
______________________________________________________________
______________________________________________________________
TDW Tech. Signature / Signature Superv. /

Handtekening TDW Tech. Handtekening Verantwoordelijke
______________________ ___________________________
8.4. PREJOB SITE ASSESSMENT FORM
8.5. HT&P CALCULATION SHEET
8.6. TORQUE VALUES

Torque Values # of bolts Bolt size Nut size TDW equipment Permanent Blind
(Nm) Flanges (Nm)
Min Max Min Max
30”-600 RF 28 2” 3.125” 2783 2938 3832 5220
28”-600 RF 28 2” 3.125” NA NA 3832 5220
8.7.1 TORQUE REQUIREMENTS:
Once the bolts /nuts are hand tight the application of torque can begin. It is recommended that the
torque be applied in a minimum of 4 stages
STAGES % of Final Recommended Torque

st
1 30 Percent
nd
2 60 Percent
rd
3 Recommended Final Torque
th
4 Bolt
8.7.2 TORQUE SEQUENCE DIAGRAMS
8.7.3 HYTORCK PICTURE & RECOMENDATIONS

RESPONSIBILITY OF CLIENT TO PROVIDE
8.7. SCAFFOLDING GUIDELINES AND CHECK LIST

This scaffolding guide is as per TDW HSE document guideline number HSE_0028_EAM.
This form is only a guide and scaffolds should be erected to the industry standards for example:
Good Guide Practice for scaffolding: TG20, to comply with BS EN 12811 (Part 1) or equivalent.
This guide does not constitute a replacement of scaffolding engineering analysis.
The responsibility of the scaffolding remains under the manufacturer, builder and the competent person validating
the assembly.
1. Protection of employees working near scaffolding “Danger areas”
2. Foundations or footing for scaffolding on soils or uneven ground
3. Detail bracing for added rigidity to the structure
4. Connecting to structures
Using “Ring Bolts”
5. Expectation of working Platform
6. Access to scaffolding
7. Supported scaffold – connected to a structure
Safety checklist
Check from ground Check from inside scaffold or connecting structure
1. Base soundness; adequate spread of load;
1. Check connection
manholes, excavations, power lines etc.
2. Ties, particularly on lift below working platform or,
2. Line of standards and ledgers. Standards vertical
in early vertical
3. Working on platform: Check line and even support
3. Platform loading
of boards; overhang; lapped boards and fillets
4. Guard rails and toe-boards 4. Condition of tubes and fittings
5. Security of boards, toe-boards and guardrails 5. Damage from falling material
6. Longitudinal bracing 6. Security of stacked materials
7. Means of access
8. Self-Supported scaffold – not connected to a structure
Safety Checklist
Check from inside scaffold or connecting structure Check from inside scaffold or connecting structure
1. Ties, particularly on lift below working platform or,
in early stages, rakers on alternate standards.
1. Base soundness; adequate spread of load;
Special attention to 'through' ties on large flank
manholes, excavations, power lines etc.
ends without windows. Load-bearing couplers to
be used
2. Special loadings by protective fans, wind sails,
2. Line of standards and ledgers. Standards vertical
etc.; anchorage and spread of load
3. Working on platform: Check line and even support
3. Security of boards, toe-boards and guard-rails
of boards; overhang; lapped boards and fillets
4. Guard rails and toe-boards 4. Condition of tubes and fittings
5. Damage from, by loads swinging from cranes or
5. Security of boards, toe-boards and guardrails
by falling material
6. Longitudinal, ledger and plan bracing 6. Security of stacked materials
7. Means of access 7. Overloading of platform
8. Security and correct use of all fittings (couplers),
8. Staggering of joints (vertical and horizontal
particularly on transoms and bracing
9. Staggering of joints
9. Bridcage scaffold
1. Safety checklist
2. Base
3. Line of standards and ledgers
4. Line of transoms
5. Diagonal bracing in both directions
6. Plan bracing
7. Security of boards, toe-boards and guard-

rails.
8. Security and correct use of couplers and
fittings
9. Condition of tube and fittings
10. Even spread of load on platform
11. Even spread of load on platform
12. Means of access
13. Overloading
14. Security of stacked materials

With birdcage scaffolds, the floor of the
building has to carry the full weight of the
scaffold and its load. Sole plates are therefore
necessary to help distribute the load as
widely as possible - and they should always
be set at right angles to the underlying floor
beams or joists.
10. Check at each inspection that your scaffold does not have these faults:
Description Good Average Poor N/A Comments
Footings
 Soft and uneven ☐ ☐ ☐ ☐
 No base plates ☐ ☐ ☐ ☐
 No sole plates ☐ ☐ ☐ ☐
 Undermined ☐ ☐ ☐ ☐
Standards
 Not plumb ☐ ☐ ☐ ☐
 Jointed at the same height ☐ ☐ ☐ ☐
 Wrong spacing ☐ ☐ ☐ ☐
 Damage ☐ ☐ ☐ ☐
Ties
 Some missing ☐ ☐ ☐ ☐
 Loose ☐ ☐ ☐ ☐
Bracing
 Loose ☐ ☐ ☐ ☐
 Wrong fittings ☐ ☐ ☐ ☐
Putlogs and transoms
 Loose ☐ ☐ ☐ ☐
 Wrongly spaces ☐ ☐ ☐ ☐
 Wrongly supported ☐ ☐ ☐ ☐
Boarding
 Bad boards ☐ ☐ ☐ ☐
 Trap boards ☐ ☐ ☐ ☐
 Incomplete ☐ ☐ ☐ ☐
 Insufficient support ☐ ☐ ☐ ☐
Ledgers
 Loose ☐ ☐ ☐ ☐
 Not level ☐ ☐ ☐ ☐
 Joint in same level ☐ ☐ ☐ ☐
 Damage ☐ ☐ ☐ ☐
Couplings
 Wrong fitting ☐ ☐ ☐ ☐
 No check couplers ☐ ☐ ☐ ☐
 Loose ☐ ☐ ☐ ☐
 Damaged ☐ ☐ ☐ ☐
Guardrails and toe-boards
 Loose ☐ ☐ ☐ ☐
 Wrong height ☐ ☐ ☐ ☐
Bridles
 Weak support ☐ ☐ ☐ ☐
 Wrong spacing ☐ ☐ ☐ ☐
 Wrong coupling ☐ ☐ ☐ ☐
Ladders
 Not tied ☐ ☐ ☐ ☐
 Damaged ☐ ☐ ☐ ☐
8.8. GENERIC RISK ANALYSIS

8.8.1. Risk analysis tools
The risk assessment approach has been divided into different steps. The first column of the document is dedicated to
the sequence of activity (the different task undertaken), whilst the second column shows the potential hazard linked to
that activity. The third column shows the potential consequence to person, equipment or environment. The fourth
column of the Risk analysis is dedicated to the risk rating. The Risk is the combination of the likelihood of a specific
unwanted event and the potential consequences if that event should occur. For Risk Assessments related to TDW, the
following risk ranking criteria will be used. The following matrix divides the likelihood and consequences of a hazard
being realized into “high”, “medium” and “low”. The criteria for exactly what constitutes “high”, “medium” and “low”
likelihood of occurrence/recurrence in the matrix are also given.
TDW Risk Rating Matrix
High A3 B3 C3
Likelihood of
potential
consequence Medium A2 B2 C2
being realized
Low A1 B1 C1
Low Medium High
Hazard Severity, i.e. potential consequences

of hazard being realized
Likelihood of Potential Consequences being Realized
Damage to Equipment/
Level Harm to Personnel Score
Environment
Low 1 person at risk from that hazard  Nonessential systems at risk, or essential 1
systems with immediate back-up available.
Failure would require minor adjustments to
system parameters or procedures.
Medium 2 to 4 people at risk from that hazard  Essential systems at risk, back-up available 2
or repairs feasible, but not immediately.
Failure would require minor modifications or
repairs to equipment and systems or
procedural rewrite.
High 5 or more people at risk from that  Essential systems at risk, no back-up. 3
hazard Failure would require major modifications or
repairs to equipment and systems, or
organizational change.
Hazard Severity, ie Potential Consequences of Hazard being Realized

Scor
Level Harm to Personnel Damage to Equipment/ Environment
e
Low First Aid injury up to a Medical  Less than $1,000.00 U.S. A

Treatment Only
Medium Up to a Restricted Work Case  Between $1,001.00 and $2,499.00 B

U.S.
High Lost Time Incident and/or a fatality  More than $2,500.00 U.S. C
or fatalities
In front of each risk you will find a fifth column, the mitigation, which leads to the final risk rating.
8.8.2. Risk analysis
Generic written by: G Gillet Date: Feb

EAM Generic RA Reviewed by: Cédric Philippot 2009
To be filled with
Loaction / ref. project name & Doc: Risk Assessment Field personnel Rev 01
reference
Step 1: Step 2: Step 3: Step 4: Step 5:
Consequences to
Quantify Recommended Corrective actions / control
Hazard Identification people, equipment or Residual Risk
the risk measures
environment
Access to the jobsite

Use safe driving practices
Collision - fuel spill-
Vehicle incident on route to Provide first aid kit on all vehicles and survival bags
extreme weather C2 B2
the jobsite (including water, food, blankets, flashlights... ) for
exposure
extreme weather conditions
Unstable footing (muddy/
Slip, trip and fall B1 Wear proper footwear and floor stabilized A1
loose material)
Poor communication of the
Panic in case of incident
emergency procedures, C2 Safety meeting and pre-jobsite assessment completed B1
/ bad reactions
signals and muster points
Struck by object / Restrict vehicle assess to work area (barricades should
Exposure to moving traffic C1 B1
vehicles be used)
Jobsite conditions
Hot weather conditions: refer to best practises (incl
breaks at regular intervals- sufficient drinking water-
Extreme weather Exposure to hot/ cold
C2 shelter) B2
conditions environment
Cold weather conditions : winter survivals course +
best practises
Poor communication - No Personnel not aware of Hold safety meeting with all involved personnel present
toolbox prior to start the job steps or hazard C3 Emergency duty call list from client and adequate B2
activity potential communication means ( satellite phone if needed)
Work without permission
Lack of adequate
& pre-job assessment C3 Job not to start without appropriate supervision B2
supervision on site
not signed
Elevated above work Only use approved/certified scaffolding + Fall arrest
Falling from height C1 B1
surface equipment
Excavation work (trench/ Collapsing of the
C2 Shoring (trench box, sheeting, timbers) B2
pit) excavation
Poor communication of the
Panic in case of incident
emergency procedures, C2 Safety meeting and pre-jobsite assessment completed B1
/ bad reactions
signals and muster points
Panic in case of incident 2 escape routes opposed to each other at a maximum
No escape routes C2 B2
/ bad reactions distance of 25 feet from the workers
Exposure to asbestos and Job to be stop awaiting decontamination + reporting to
Health hazard C3 C3
lead Nivelles
Exposure Bio/ radioactive Job to be stop awaiting decontamination + reporting to
Health hazard C3 C3
hazard Nivelles
Exposure to asphyxiates Health hazard C3 Continuous atmospheric monitoring B2
Exposure to H2S or sulphur
Health hazard C3 Continuous atmospheric monitoring B2
dioxide
Flammable gas/
Appropriate PPE following MSDS recommendation;
combustible gases or Explosion/burns C3 B2
continous atmospheric monitoring
corrosive liquids
Exposure to chemicals Contamination C1 Emergency eyewash/ shower/ appropriate PPE B1
Overhead or swinging Injury to personnel or
C2 Access to jobsite to be restricted and banksman B2
loads damage to equipment
Hearing loss/unable to
High noise levels C1 Hearing protection B1
Hear instructions
Unstable footing (muddy/
Slip, trip and fall B1 Floor stabilized A1
loose material)
Static electricity Electric shock / ignition C3 Earthing B1
Extreme temperature (hot/ Hypothermia/ Appropriate PPE / sun protection (shading) / adequate
C1 B1
cold) dehydration / heat water supply
exhaustion
Electric cables ( Electric shock / ignition Lock out tag out procedure to be in place, lines located
C3 B2
underground or overhead) Source and properly marked
Rotating parts Caught by C1 Proper guarding, barricade when guarding not practical B2
Simultaneous operations Bad communication C2 Safety meeting and pre-jobsite assessment completed B2
2 escape routes opposed to each other’s at a
Potential of flooding Drowning C1 B1
maximum distance of 25 feet from the workers
Work permit/ Appropriate PPE following MSDS

Confined space access Asphyxiation C2 B2
recommendation/ continuous atmospheric monitoring
Hot work permit- open flame restriction signs up and
Open flame Explosion/ burns C3 B2
Firefighting equipment available
Inadequate lightning Fall/ strike against C2 Adequate lightning B2
Personal Protective Equipment

No Hard Hat Struck by object C1 Hard hat B1
Hearing loss/unable to
No hearing protection C1 Hearing protection B1
hear instructions
No safety glasses /
Goggles (Particle or Flying particles or debris C1 Safety glasses / Goggles (Particle or Chemical) B1
Chemical)
Flying particles or debris
No face Shield C1 Face shield B1
/ chemicals splash
No escape/emergency Exposure to hazardous
C1 Emergency escape air mask B1
mask gas
No fire Retardant Clothing Burns C1 Fire retardant clothing B1
No adequate protection Hypothermia/
Appropriate PPE / sun protection (shading) / adequate
against adverse weather dehydration / heat C1 B1
water supply
conditions exhaustion
No appropriate gloves (
working gloves or rubber Cut / burns B1 Appropriate gloves ( working gloves or rubber gloves) A1
gloves)
No safety boots Crush injuries B1 Steel-toed safety boots A1
Improper medical
No first aid kit C1 First aid kit available B1
treatment
No personal multi gas Explosion and
C3 Personal gas monitor B2
monitor asphyxiation
Machine preparation
Pure Safety lifting training + TDW rigging manual +
Manual lifting Back injury C1 used of certified and checked equipment - use B1
mechanical lifting equipment when possible
Inadequate lifting Proper lifting equipment and perform pre-use checks of
Dropped object C2 C1
equipment lifting equipment
Damaged machine / Uncontrolled risk during
C3 Never use damaged equipment C3
equipment the operation
Handling equipment with Wear the appropriate type of gloves and manual
Cut C1 B1
sharp edges handling devices - use mechanical lifting equipment
Improper equipment for the Uncontrolled risk during

C3 Never use incorrect equipment C3
job the operation
Set up of the valve and the equipment

Manual lifting Back injury C1 B1
used of certified and checked equipment

Loss of balance Dropped object C1 B1
Handling heavy or sharp Wear the appropriate type of gloves and manual
Cut C1 B1
equipment handling devices
Obstruction within the work
Slip, trip and fall B1 Good housekeeping A1
area
obstruction of the escape No emergency
C2 Good housekeeping- keep escape routes clear B2
routes evacuation possible
All electrical equipment and cables must be tested and

Store energy / inspected, earthed prior use
Electrical power tools C2 B2
electrocutions all equipment can only be used by trained personnel
safe work permit procedure must be followed
Bad posture Back injury C1 B1
Hot tap
Pneumatics hose
Flying objects C1 Whip checks in place B1
disconnected
Climbing on the machine Falling from height C1 Work platforms, ladders or scaffolding B1
Flying particles or debris
Projection during purging C1 Safety glasses / Goggles (Particle or Chemical) B1
/ chemicals splash
Cut C1 B1
equipment handling devices - use mechanical lifting equipment
Simultaneous operations Bad communication C2 Safety meeting and pre jobsite assessment completed B2
Uncontrolled risks
Machine failure C3 Stop the activity and call Nivelles C3
during the operation
Fluids, high pressure gas Leak / explosion C3 Pressure test before the job B2
Environmental damage,
Spill of chemicals C3 Spill response kit, escape routes in place, proper PPE B2
injury to personnel
Remove the hot tap machine

Handling heavy or sharp wear the appropriate type of gloves and manual
Cut C1 B1
area
Obstruction of the escape No emergency
C2 Good housekeeping - keep escape routes clear B2
Preparation of the STOPPLE head


Cut C1 B1
area
Placing of the STOPPLE head


Cut C1 B1
area

Retracting the STOPPLE head


Cut C1 B1
area
Demobilisation

Cut C1 B1
area
Health Concern
Loss of hearing, unable
High noise levels C1 Hearing protection B1
to hear instructions
Potential contact with local
Health hazard C2 Vaccination B1
sickness

Method Statement: Single Position STOPPLE® TRAIN 28in

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Method Statement: Single Position STOPPLE® TRAIN 28in

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METHOD STATEMENT

Single Position STOPPLE® TRAIN 28in

T.D.WILLIAMSON sprl. Belgium

Name: Title: Sign

Originator: Naïmi Diallo Senior Application Engineer

Checker: Hughes Franceschini HT&P Field supervisor

Approver Philippot Cedric CSG Manager

Repair and Rehabilitation Services Project N°: 967-1904-008-EGY

Single Position STOPPLE® Train 28in Review: 00

2. CONFIDENTIALITY ........................................................................................................................................ 5

4. OBJECTIVES ..................................................................................................................................................... 5

5. DEFINITIONS .................................................................................................................................................... 5

6. RESPONSIBILITIES ......................................................................................................................................... 6

Repair and Rehabilitation Services Project N°: 967-1904-008-EGY

Single Position STOPPLE® Train 28in Review: 00

8. ATTACHMENT................................................................................................................................................ 27

Repair and Rehabilitation Services Project N°: 967-1904-008-EGY

Single Position STOPPLE® Train 28in Review: 00

Page Reason for Change Rev Reviewer Date Revised

Repair and Rehabilitation Services Project N°: 967-1904-008-EGY

Single Position STOPPLE® Train 28in Review: 00

Repair and Rehabilitation Services Project N°: 967-1904-008-EGY

Single Position STOPPLE® Train 28in Review: 00

Perform Job Analysis Client TDW NA 6.2.1

Safety risk analysis Client TDW NA 6.2.2

Rigging Client TDW NA 6.3.2

Storage Client NA NA 6.3.3

Disassembly Client TDW NA 6.3.4

Organize Timetable TDW Client NA 6.5.3

Man power Mobilization Client TDW NA 6.6

Fitting examination Client NA TDW 6.7.1

HT&P Operations TDW Client NA 7

Leak test operations Client TDW NA 6.7.2

*: The party identified in this column will handle the task.

Repair and Rehabilitation Services Project N°: 967-1904-008-EGY

Single Position STOPPLE® Train 28in Review: 00

6.2. PROJECT PREPARATION.

6.2.2. Safety risk Analysis

6.2.3. Application Data sheet

6.3. HOT TAPPING & PLUGGING EQUIPMENT

6.3.2. Equipment Rigging

6.3.3. Equipment Storage

6.3.4. Equipment disassembly

6.3.5. Equipment decontamination & repacking

Repair and Rehabilitation Services Project N°: 967-1904-008-EGY

Single Position STOPPLE® Train 28in Review: 00

6.4. EQUIPMENT SUPPORT

Step Equipment Qty Requirement

Forklift / Crane 1 Offloading and loading equipment and on-site manoeuvring.

Spirit Level 1 Equipment alignment

Pallet, box… * Reshipment, repacking...

Bolting Machine * Bolting operation. Air/Hydraulic operated.

Set off Dynamometric

1/4" NPT High

Nitrogen regulator 2 Leak testing control.

Water soap solution Leak testing control

Excavation * Compliant with National excavation regulations and good practice

Pipeline Support * Check Stack up for equipment weight

Toolbox 1 Including wrench set, hammer, Allen key set…

Lighting * Requested in case of reduced light levels (Fog, night…)

Wooden Block * For equipment support

Diesel * To feed the power unit on TDW Field Technician request

*Following job site requirement and Risk analysis