PROJECT

CGK 063

DOCUMENT METHOD STATEMENT OF MECHANICAL WORK FOR

TITLE FUEL LEAK DETECTION INSTALLATION
Contents
1.0 PURPOSE.....................................................................................................................................
2.0 SCOPE OF WORK.........................................................................................................................
3.0 DEFINATIONS..............................................................................................................................
4.0 REFERENCE..................................................................................................................................
5.0 RESPONSIBILITIES........................................................................................................................
6.0 PROCEDURE.................................................................................................................................
6.1 General Description..............................................................................................................
6.2 Material................................................................................................................................
6.3 Plants, Machinery & Equipment...........................................................................................
6.4 Manpower............................................................................................................................
7.0 INSTALLATION PROCEDURES......................................................................................................
7.1 General Guidelines...............................................................................................................
7.1.1 Pre-Planning Stage..................................................................................................
7.2 Installation Stage..................................................................................................................
7.2.1 Installation of a fuel leak detection sensor in the tank...........................................
7.2.2 Installation of a fuel leak detection sensor in the chamber....................................
7.2.3 Installation for automatic tank gauge & leak detection..........................................
8.0 APPENDICES................................................................................................................................
8.1 Drawing................................................................................................................................
As Attached Drawing............................................................................................................
8.2 RISK ASSESSMENT (RA).........................................................................................................
8.3 INSPECTION TEST PLAN (ITP)................................................................................................
8.3.1 CGK063-ITP-RFSI - Request for Site Inspection......................................................
8.3.2 CGK063-ITP-M.03 - Site General Report................................................................
8.3.3 CGK063-ITP-M.04 - Site Defect Inspection Report................................................
1.0 PURPOSE
The purpose of this statement is to document the correct procedure and installation of
fuel leak detection for CGK 063 project, and to ensure that all concerned are familiar
with the sequence of activities, utilization of resources and execution of the works in
compliance with applicable safety, quality procedures and project documents and
specification.

2.0 SCOPE OF WORK

This method statement is the necessary measures to ensure that all installation
activities to be identified and established and approved by the Employer’s
representative. All activities will be carried out in accordance with the contract details
and in full compliance to the contract specifications will be done in compliance with
requirements issued by authorities. The scope of this plan is to provide a guideline for
the implementation of quality assurance on installation work of fuel leak detection.

3.0 DEFINATIONS
Terms Definition
Project CGK 063
JO PT Jaya Obayashi
MOS Method of Statement
MSA Material Submission Approval

Table 1: Definitions

4.0 REFERENCE
The following Standards of Practice shall be applicable to the works:
 ISO 19013 : Specifies the requirements for rubber tubing and hoses used
in gasoline fuel circuits for internal combustion engines.
 SAE J2045 : Performance Requirements for Fuel System Tubing
Assemblies.
 NFPA 31 : Standard for the Installation of Oil-Burning Equipment.
5.0 RESPONSIBILITIES
No Designation Qty Responsibility
.
Responsible for overall commercial, contractual
& technical performances associated with
1 Project Manager 1
specific project. Reporting to the Project
Director.
2 M&E Engineer 4 Planning and supervising installation activities.
Inspect, verify, and prepare work statement for a
quality installation works. Material storage, fit
3 QA / QC Engineer 2
for use tools and equipment, and installation
works
To provide toolbox and guidance to work and to
4 Safety Officer 1
ensure that work is carried out in a safe manner.
Obtain permit to work, control the sequence
according to MOS, approved shop drawings, and
MSA, ensure mechanical aspects of the work are
according to the specifications, ensure safe
practices are followed and ensure quality of
workmanships during execution. Ensure material
5 Supervisor 2-4
temporary storage and protection meet vendor
and standards requirement

. Ensure tools being used for installation are

calibrated and meet vendor and standards
requirement
To carry out all the fuel system aspects of the
6 General Workers 5-10
fuel leak detection installation.

Table 2: List of Responsibilities

6.0 PROCEDURE
6.1 General Description
The mechanical work for fuel leak detection Installation to be carried out at
CGK063.

6.2 Material
Materials are as below.

No Item Descriptions
1 BX-PDS General purpose sensor (sump & chamber location)
2 BX-PDWF Sensor for dry double -wall fiberglass tanks
3 OEL8000III-K4 Automatic tank gauge & Leak detection system
4 RD 232 C-75 RS 232 Sensor line cable
5 RD7CTS Mini-Me Remote Display
6 RD-PCK 120 VAC Power Cord Kit
7 RAS-1-NYS Overfill Alarm
8 MTG Series Gauging Probe

Table 3: List of Materials

6.3 Plants, Machinery & Equipment

No Descriptions

1 Step Ledder/ scaffolding

2 Portable Hand Tools

3 Drilling machine
4 Grinding machine
5 Measuring tool

Table 4: List of Plants, Machinery and Equipment

 6.4 Manpower
The actual manpower of each type of installation may vary according to the site
condition and requirement.

All workers shall wear appropriate PPE (Hard Hat, Protective Boots, Goggles,
High Visibility Vest and Protective Gloves) and safety harness when working
above 2 meter in height.

7.0 INSTALLATION PROCEDURES

7.1 General Guidelines

7.1.1 Pre-Planning Stage

 Secure all necessary design information and prepare all the necessary
designed drawings.
 Submission of design drawings for approval.
 Prepare all necessary shop drawings and determine the actual position to
commence installation with the mobilization of required work force, tools
and equipment.
 Prepare all documents required in specification submittals and all
documents/certification required in specification.
 Prepare material approval document, complete with confirmation of
conformance between delivered material with approved material
(code/model/type, length, weight, width, materials, quantity, etc).
 Prepare confirmation of conformance between temporary storage and
vendor storage requirement/standard.
 Prepare confirmation of conformance between tools and its calibration
meet vendor requirement/standard.
 Ensure all approval required to perform work are obtained and conform
with approved documents by Consultant Engineers and Architect.
7.2 Installation Stage

7.2.1 Positioning the Fuel leak detection sensor on the tank

 Check and make sure the sensor installation location is in accordance
with the approved drawings.
 Make sure that the tank installation is complete.
 Clean the area of the tank where the sensor will be installed.
 Assemble the sensor components according to the manufacturer's
instructions.
 Correctly position the tank sensor according to the drawing.
 Pull the tank sensor cable to the automatic tank gauge monitor
according to the path in the approved drawing then connect the
cable.

7.2.2 Positioning the Fuel leak detection sensor on the chamber

 Check and make sure the sensor installation location chamber area is
in accordance with the approved drawings.
 Make sure that the chamber installation is complete.
 Check and make sure the chamber clean and free of water and dirt.
 Make sure the chamber area is no longer water and dirt in it.
 Mount the bracket using a dyna bolt or attach to the floor using the
stainless steel’s bracket provided.
 Install the sensor and position it according to the approved drawings.
 Pull the sensor cable to the Automatic Tank Gauge (ATG) monitor
according to the path in the approved drawing.
 After you have finished pulling the cable and installing the sensor in
the chamber location, connect the cable to the ATG monitor.
 Do the steps as above for the positions in the other chambers.
7.2.3 Installation for Automatic Tank Gauge & Leak Detection
 Electrical Wiring Installation
 Wires and cable
1. Run a single, 4-conductor cable for each sensor bus. Up to 16
sensors may be connected to one bus in K4 model only
2. Two or more probes may not be combined into a single cable.
Probes and sensors may not be combined into a single cable
3. Splice sensor wires using the SK-4 connector sealing kit.
4. Splice probe wires using the SK-4 connector sealing kit.
5. Probe cables and sensor cables must be completely enclosed
in conduit from the junction
6. box to the console (contact factory for direct-burial
applications).
7. Probe cables and sensor cables may share the same conduit.
8. Probe cables and sensor cables must be run in conduits that
are separate from other wiring.
9. All wiring must enter the controller through the designated
preformed knockouts.
 Conduit
1. Check the location and number of channels required for
installation on the number and diameter of cables and
sensors.
2. Use a junction box inside the building to combine the cables.
Observe the applicable codes pertaining to which cables may
or may not be combined into a single conduit.
3. 120 VAC power cables must be combined in a separate
(isolated) conduit.
4. All annunciator (RAS Series) cables must be combined in a
separate (isolated) conduit.
 5. MTG Probe and sensor cables may share a separate (isolated)
conduit.
6. Alarm relay cables must be combined in a separate (isolated)
conduit.
7. Keep the following in mind when selecting and installing
channels:
8. Determine the size of the conduit based on the number and
size of cables it will carry.
9. Plan the installation of conduit so that the junction box in the
manway is not submerged in water after heavy rains.
10. Rigid metal conduit, inch or larger (use damper coupling, do
not drill into the box), is recommended between controller
and tank area.
11. Do not combine the probe and sensor cables with other cables
in the same line.

 Controller Installation
 Inspect all parts for shipping damage.
 Determine all the conduit paths, probe and sensor installation
locations, and controller and annunciator mounting locations.
 Install the OEL8000III-K Controller in a non-hazardous area
requiring 100-240 VAC, 50/60 Hz, 60 watts.
 Install the controller indoors, in a non-hazardous and protected
location. Place the controller at eye level in an easily accessible
place, and the alarm will sound.
 Mount it on an inner wall close to where the duct will enter the
building for easy installation. Use the correct anchor bolts for the
wall type.
 Make sure that there is sufficient clearance to open the controller
door. Provide adequate clearance around the controller for
channel access.
 Connected all censor cable installation to controller.

Picture 1: Illustration Fuel Leak Detection Installation

8.0 APPENDICES
8.1 DRAWING
As attached drawing

8.2 RISK ASSESSMENT (RA)

8.3 INSPECTION TEST PLAN (ITP)

8.3.1 CGK063-ITP-RFSI - Request for Site Inspection

8.3.2 CGK063-ITP-M.03 - Site General Report

8.3.3 CGK063-ITP-M.04 - Site Defect Inspection Report