01 Installation Work For 3 Inch Console For WGR at 6 Inch Pipe

TO CARRY OUT MODIFICATION PROJECT ON GAS OIL PIPELINE TO INSTALL WIRELESS
GUIDED WAVE RADAR. LOCATION: 6” STAB AT 4000 SERIES GAS OIL SUCTION HEADER LINE
Doc No OBZA‐MOS‐TO‐2017‐001
METHOD OF STATEMENT FOR INSTALLTION WORK Rev 00
Date Nov 21st 2017

TABLE OF CONTENTS
1. INTRODUCTION ...................................................................................................................... 3
2. SCOPE OF WORK ..................................................................................................................... 3
3. JOB METHOD STATEMENT ...................................................................................................... 3
3.1 Preparation Job ......................................................................................................................... 3
3.2 Removal of Existing 6” Pipe ....................................................................................................... 3
3.3 Installation of 3” Pipe Console and GWR Instrument ............................................................... 4
3.4 Completion of Job ..................................................................................................................... 4
4. SAFETY PRECAUTION .............................................................................................................. 4
4.1 PPE ............................................................................................................................................. 4
4.2 Communication ......................................................................................................................... 4
4.3 Environment .............................................................................................................................. 5
4.4 Protection against falling materials/object ............................................................................... 5
4.5 General safety measures ........................................................................................................... 5
5. TOOLS AND EQUIPMENT ........................................................................................................ 5
6. ACCESS AND EGRESS ROUTE ................................................................................................... 6
7. FALL PROTECTION MEASURES ................................................................................................. 6
8. OTHER ESSENTIAL TOOLS ........................................................................................................ 6
9. HAZARDOUS SUBSTANCES ...................................................................................................... 7
10. SPECIFIC TRAINING REQUIRED ............................................................................................ 7
11. SAFE WORKING LOAD ......................................................................................................... 7
12. PERSONNEL PROTECTIVE EQUIPMENT (PPE) ....................................................................... 7
13. MANPOWER ....................................................................................................................... 7
14. SAFETY CONCERN ............................................................................................................... 7
15. LIFTING PLAN ...................................................................................................................... 8
16. ATTACHMENT ..................................................................................................................... 8

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Date Nov 21st 2017

1. INTRODUCTION
This procedure envisages the method of statement for installation of Wireless Guided Wave
Radar Console located at 6” Stab at 4000 Series Gas Oil Suction Header Line.

2. SCOPE OF WORK
Scope of work under this package are as follow:‐

a. Workshop fabrication work to the pipe console including painting work
b. Delivery to the site
c. Pipe dismantling work to the existing 6” pipe – lifting using 20 MT Crane
d. Blinding/drop valve/drop spool (if required)
e. Installation of console
f. Installation of equipment – Wireless Guided Wave Radar
g. De‐blinding
h. Housekeeping
3. JOB METHOD STATEMENT

Detail method of statement and sequence for installation work shall be described below.

3.1 Preparation Job

3.1.1 Submission of Procedure, HIRADC, MOS and any others related documents. Obtain
approval prior start the work.
3.1.2 Manpower attended Safety Induction conducted by Langsat Terminal (One)
(hereinafter called the LTO)
3.1.3 Mobilize crane to site for lifting work. Ensure crane complete with valid documents
(JKKP, PMA and etc.).
3.1.4 Inspection of crane. Ensure crane in good condition and meet standard requirements.
3.1.5 Mobilize all equipment, tools and fabricated item (pipe console) to job area.
3.1.6 Inspection to the electric tools and equipment
3.1.7 Barricade working area (hard barricade or soft barricade). If required put proper
signage.
3.1.8 Cover working area with canvas to avoid any oil spillage onto ground.
3.1.9 For double protection, steel tray will put under pipe before dismantling work.

3.2 Removal of Existing 6” Pipe

3.2.1 Obtain permit to work and gas check prior start the work.
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Date Nov 21st 2017

3.2.2 Close all valve connected to the line – refer blind list that provided by LTO
3.2.3 Install spade/blind flange at specific location as per blind list that provided by LTO
3.2.4 Set‐up crane at correct position. Remove any obstruction for lifting operation.
3.2.5 Set‐up lifting gear to the pipe that be removed – 6” pipe. Install tag line.
3.2.6 Loosen all stud bolt.
3.2.7 Rig‐up and hold the load
3.2.8 Remove all stud bolt and lifting the pipe spool. Locate the pipe spool at designated
area – Refer Section 15 for Lifting Plan

3.3 Installation of 3” Pipe Console and GWR Instrument

3.3.1 Set‐up lifting gear to the pipe consul
3.3.2 Cleaning flange surface
3.3.3 Lifting the pipe consul to the position.
3.3.4 Install gasket and stud bolts
3.3.5 Lifting GWR Instrument
3.3.6 Install Gasket and stud bolts
3.3.7 Flange alignment work
3.3.8 Bolt tightening work using manual torque wrench. Refer Attachment 4 for torque
value for bolt tightening work.

3.4 Completion of Job

3.4.1 Site inspection is carried out to ensure conformance of the installation work
3.4.2 De‐blinding work – remove blind flange/spade and reinstatement work
3.4.3 Open valve as per initial condition
3.4.4 Inform to LTO when work completed and closed PTW.
3.4.5 Housekeeping and demobilization
4. SAFETY PRECAUTION

4.1 PPE

4.1.1 All workers shall wear proper PPE such as white color safety helmet, safety glass and
safety shoes at all time.
4.1.2 Wear suitable hand glove during operation

4.2 Communication

4.2.1 Tool box meeting with all workers prior start the work every morning
4.2.2 All works at site shall be carried out as per approved Method of Statement. Supervisor
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Date Nov 21st 2017

at site need to ensure all works carried out in proper manner.
4.2.3 During lifting operation communication between rigger and crane operator using
hand signal.

4.3 Environment

4.3.1 Working in bad weather condition are not allowed.

4.4 Protection against falling materials/object

4.4.1 When working at height at the pipe rack, protection shall be made against falling
materials, such as hand tools, cable tray, etc.
4.4.2 Close or barricade the area during work.

4.5 General safety measures

4.5.1 Report any incident or near‐miss to LgT‐1 HSSEQ personnel.
4.5.2 Daily safety toolbox to be executed before start any work.
4.5.3 Risk assessment (HIRADC) shall be reviewed and approved before start any work.
4.5.4 Daily permit to work (PTW) to be obtained and approved.
5. TOOLS AND EQUIPMENT

Basic tools and equipment to be used during operation are as follow:‐

5.1 Spanner Set size 19mm, 22mm, 27mm, 30mm, 32mm, 36mm (Common Ring &
Hammer Ring)
5.2 Manual Torque Wrench c/w socket
5.3 Lifting Belt 1.0 MT x 3m
5.4 Shackle 2.75 MT
5.5 Chain Block 1.0 MT
5.6 Hammer
5.7 Nylon Rope

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Date Nov 21st 2017

6. ACCESS AND EGRESS ROUTE

Access route for transfer all material and assembly point during emergency shows in Figure 1.0
below.

Figure 1.0: Access Route
7. FALL PROTECTION MEASURES

Not applicable for this type of work
8. OTHER ESSENTIAL TOOLS

All tools used shall be non‐spark tools.

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Date Nov 21st 2017

9. HAZARDOUS SUBSTANCES

Not applicable for this type of work
10. SPECIFIC TRAINING REQUIRED

Crane operator – hold valid JKKP crane operator certificate
11. SAFE WORKING LOAD

Routine lifting operation only – load below than 1 MT
12. PERSONNEL PROTECTIVE EQUIPMENT (PPE)

13. MANPOWER

14.1 Supervisor
14.2 Fitters
14.3 Semi‐skilled
14. SAFETY CONCERN

15.1 Vehicles movement
15.2 Finger injury
15.3 Ergonomics – poor body posture
15.4 Slip, trip and fall
15.5 Dehydration
15.6 Strong wind
15.7 Uncertain weather condition
15.8 Falling lifting object
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Date Nov 21st 2017

15. LIFTING PLAN

Lifting analysis for lifting work are as follow:‐

Weight of item to lift (approximately) : 200 kg
Weight (contingency) : 1.5 x 200 kg
: 300 kg
Weight of lifting gear (approximately) : 50 kg
Weight of crane block (approximately) : 200 kg
Total weight : 550 kg
Crane Radius : 20m
Crane capacity at 20m radius : 2,200 kg
Safety factor (2,200 kg / 550 kg) : 4.0 > 1.0  OK!

*Note:‐
1. Crane to be used: Mobile Crane 25 MT
2. Wire Sling: Web sling 1 MT x 6m
3. Shackle: 1.25 MT
16. ATTACHMENT

ATTACHMENT 1: Risk Assessment HIRADC
ATTACHMENT 2: Lifting Arrangement
ATTACHMENT 3: Crane Load Chart
ATTACHMENT 4: Bolt Tightening Torque Value

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Date Nov 21st 2017

ATTACHMENT 1: Risk Assessment HIRADC

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Assessment No: Obza/HIR/LTO/001
HAZARD IDENTIFICATION, RISK ASSESSMENT & DETERMINE CONTROL (HIRADC) REGISTER
Revision No: 00
Department: Technical/Maintenance Revision Date: 28th 2017
Title Of Activity: Installation of GWR Instruments & Console Assessors: Khaidir, Yunizar, Farid, Ariff, Latiff
Job Performed by (Designation & Name): Technician & Contractor Section: LGT1
Prepared By / Date: Khaidir / 28th 2017 Checked By / Date: Mr Spencer / 30th Nov 2017 Approved By / Date: En Mohd Shahriwan Idris / 30th Nov 2017
Hazard Identification Risk Assessment Determine Risk Control
Legal Compliance Recommendation
1. Elimination of hazard
2. Substitution
Safety & Applicable OSH Legislations
Existing Control Risk Risk 3. Engineering
No Sub‐Activity Type Hazard Health ECM L S (please state specific section/reg.
Measure Rating Categ 4. Administration (min control
Effect excl. OSH Act
requirement for S>4)
5. PPE
Competence lorry driver
with valid driving
Injury, Administration – do not allowed lorry
Vehicle license, provide traffic
property 0.3 3 4 4 II OSHA Sect 15 & 24 driver without valid driving license to
accident controller & short
damage enter to plant
briefing to driver prior
enter to plant
Wear safety
Foot and
Falling of shoes & leather
hand 0.6 2 2 3 I OSHA Sect 15 & 24 Nil
handling item hand gloves,
injuries
Mobilization of competent person
equipment, tools,
machinery and material. Awkward
Upper body Adopt proper
Unload the equipment, posture during 0.6 2 2 3 I OSHA Sect 15 & 24 Nil
pain working posture
tools, machinery and lifting
1 R
material by manual
handling. Transfer the Personnel
Hand and Wear safety
equipment, tools and injuries during
finger shoes & leather 0.3 2 2 1 I OSHA Sect 15 & 24 Nil
machineries using handling
injuries hand gloves
lorry/pick‐up vehicle. materials
Equipment
Damage to Demarcation and
damage due to
client barricade work 0.3 3 3 3 I OSHA Sect 15 & 24 Nil
in‐proper
equipment areas
handling
Psychosocial ‐
fatigue, Obtain enough
Physical
prolonged rest, buddy 0.6 2 2 3 I OSHA Sect 15 & 24 Nil
injury
work, heat system
stress
Page 1 of 4

Revision No: 00
Department: Technical/Maintenance Revision Date: 22nd 2017
Prepared By / Date: Khaidir / 22nd 2017 Checked By / Date: Mr Spencer / 30th Nov 2017 Approved By / Date: En Mohd Shahriwan Idris / 30th Nov 2017
2. Substitution
5. PPE
Hand caught in Bruise,
Pipe Isolation Work Wear hand glove 0.3 3 3 3 I OSHA Sect 15 & 24 Nil
between hand injury
‐ Blinding, de‐blinding
2 and reinstatement R
work Wear safety goggles,
‐ Bolt Tightening Work Releasing of Eyes, face, tool inspection, approval
0.6 3 2 4 II OSHA Sect 15 & 24 Nil
pressure in pipe body injury from client to drop
valve/pipe

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Revision No: 00
7. Substitution
10. PPE
Wear safety
Slips, trips and shoes & leather
Injury 0.3 3 2 2 I OSHA Sect 15 & 24 Nil
falls hand gloves,
competent person
Competence crane
operator with valid JKKP
Injury, Cert, provide experience Administration – do not allowed crane
Falling of
property rigger and signal man 0.6 3 3 6 II OSHA Sect 15 & 24 operator without valid JKKP Cert to
Lifting item
damage c/w cert, eliminate involve lifting work
obstruction prior lifting
work
Lifting Work using Crane
Competence crane
‐ Removal of existing
operator with valid JKKP
piping line
3 R Injury, Cert, Crane set‐up at
‐ Installation of console Crane topple
property solid area & ground, 0.6 3 3 6 II OSHA Sect 15 & 24 Nil
‐ Installation of and overload
damage provide experience
equipment
rigger and signal man
c/w cert
Boom/lifting Eliminate obstruction
item crash with property prior lifting work, good
0.6 3 3 6 II OSHA Sect 15 & 24 Nil
equipment / damage communication ‐
structure operator and signalman
Rigger at correct
Workers
Serious position, good
trapped at 0.3 3 2 2 I OSHA Sect 15 & 24 Nil
injury communication ‐
pinch point
operator and signalman
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Revision No: 00
2. Substitution
5. PPE
Awkward
posture Adopt proper
Back pain 0.3 2 2 1 I OSHA Sect 15 & 24 Nil
during work posture
housekeeping
4 Housekeeping R
Beware and
Bruise and
Slip and trip safety shoes not 0.3 2 2 1 I OSHA Sect 15 & 24 Nil
body injury
worn out
Note:
OSHA ‐ Occupational Safety & Health Act 1994
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Date Nov 21st 2017

ATTACHMENT 2: Lifting Arrangement

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LIFTING ARRANGEMENT
LIFTING ARRANGEMENT
TOP ELEVATION
obza-dwg-to-2017-001

Date Nov 21st 2017

ATTACHMENT 3: Crane Load Chart

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Date Nov 21st 2017

ATTACHMENT 4: Bolt Tightening Torque Value
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Title: Document No: Rev: Date:
FLANGE MANAGEMENT PROCEDURE PRO-FM-FSO-BER-000-16 FM/CWS/04 14/2/2017
Generated from license ATW Joint Integrity Software
Table 1. Recommended Torque Value - Class 150#
FLANGE RATING 150#

SPIRAL WOUND / NON-ASBESTOS
Gasket
TORQUE VALUE (Nm) Dry (µ-0.20) TORQUE VALUE (Nm) Moly (µ-0.13) TORQUE VALUE (Nm) PTFE (µ-0.12)
BOLT MATERIAL B7 / L7 /
B7 / L7 / B7 / L7 /
Line Size Bolt Nut Size No. of B8M Remarks B8M Remarks B7M / B8M Remarks
B7M / L7M B7M / L7M
(NPS) Size(Inch) AF Bolt Hole L7M
1/2 1/2 22 4 61 61 42 42 39 39
3/4 1/2 22 4 61 61 42 42 39 39
1 1/2 22 4 71 71 49 49 45 45
1 1/2 1/2 22 4 92 92 62 62 58 58
2 5/8 27 4 180 180 122 122 114 114
3 5/8 27 4 200 200 136 136 127 127
4 5/8 27 8 180 180 122 122 114 114
6 3/4 32 8 351 351 238 238 221 221
8 3/4 32 8 351 351 228 228 221 221
10 7/8 36 12 449 449 304 304 283 283
12 7/8 36 12 506 506 342 342 319 319
14 1 41 12 753 753 509 509 474 474
16 1 41 16 669 669 453 453 422 422
18 1 1/8 46 16 985 985 663 663 618 618
20 1 1/8 46 20 985 985 663 663 618 618
24 1 1/4 50 20 1383 1383 929 929 864 864
28 1 1/4 50 28 1383 1383 929 929 864 864
Page 36

01 Installation Work For 3 Inch Console For WGR at 6 Inch Pipe

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01 Installation Work For 3 Inch Console For WGR at 6 Inch Pipe

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Copyright:

Available Formats

Generated from license ATW Joint Integrity Software

Table 1. Recommended Torque Value - Class 150#

FLANGE RATING 150#

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