GB1516 Sac 240 CV MS 0003 - D

EPC FOR INSTALLATION OF PWT, CPF
BADRA, REPUBLIC OF IRAQ

Method Statement for Rehabilitation of Pipe Culvert
Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 1 of 17
DOCUMENT DETAILS
EMPLOYER CONTRACT NO. : 1516-23-BD-850-00
PROJECT TITLE :
EPC for Installation of PWT, Republic of Iraq
EMPLOYER : Gazprom Neft Badra B.V.

CONTRACTOR : Suhool Azmer Company. Ltd
CONTRACT JOB NO. : SAC
PROJECT DOCUMENT NO. : GB1516-SAC-240-CV-MS-0003
REVISION NO. : D No. of pages: 17
DOCUMENT DESCRIPTION :
REVISION DETAILS
D Re-Issued for Approval 28/10/2023 Ossama. B.H Samer Salomy ADEL A. ALJUDI
C Re-Issued for Approval 16/09/2023 Hassan H. Hassoun Samer Salomy Bassim Qassim
B Issued for Approval 16/09/2023 Hassan H. Hassoun Samer Salomy Bassim Qassim
A Issue for Review 7/09/2023 Hassan H. Hassoun Samer Salomy Bassim Qassim
REV DESCRIPTION DATE PRPD CHKD APPD

REVISION RECORD
Rev. Para. Revision Description

A Issued for Review
B Issued for Approval
C Re-Issued for Approval
D Re-Issued for Approval
Hold No Para. Description of Hold

Contents
1. SCOPE........................................................................................................................................................................................ 4
2. OBJECTIVE ................................................................................................................................................................................. 4
3. DEFINITIONS AND ABBREVIATIONS ............................................................................................................................................ 4
4. CODES AND STANDARS .............................................................................................................................................................. 4
5. REFERENCES .............................................................................................................................................................................. 5
6. ROLES AND RESPONSIBILITIES .................................................................................................................................................... 5
7. EQUIPMENTS ............................................................................................................................................................................. 5
7.1 Equipment's HSE requirements .......................................................................................................................................... 5
8. SANDBLAST................................................................................................................................................................................ 6
8.1 Materials of sand blast ...................................................................................................................................................... 6
8.2 Equipment's of sand blast .................................................................................................................................................. 6
9. MEASUREMENTS OF CORROSION AND ENFORCEMENT .............................................................................................................. 6
10. PREPARATIONS AND IMPLEMENT OF POST INSTALLED REBAR ................................................................................................ 7

10.1 Sequence of post installed reinforcements works ............................................................................................................... 8
11. QUALITY ................................................................................................................................................................................ 8
12. SAFETY .................................................................................................................................................................................. 8
13. CONCLUSION ......................................................................................................................................................................... 9
14. APPENDICES ................................................................................................................................................................... 11

14.1 APPENDIX 1 – Fosroc Lokfix E Application Guide for Dry Concrete ..................................................................................... 12
14.2 APPENDIX 2 – Management Photo................................................................................................................................... 13
1. SCOPE
This document purpose to establish essential quality base for restoration activities specially for
concrete and uncompleted works for pipe culvert through (EPC for installation of PWT) project.
2. OBJECTIVE
This document specifies methods and procedure to execute the EPC for installation of PWT restoration
works safely and in accordance with construction drawing and adhering to applicable specifications with
consideration to local rules and regulations
3. DEFINITIONS AND ABBREVIATIONS

EMPLOYER Gazprom Neft-Badra B.V. (GPNB
CONTRACTOR Suhool Azmer Company. Ltd. (SAC)
CONSULTANT Petrochemical Engineering Consultant (PEC)
Engineering Procurement Construction (EPC) for Installation of Produced Water
PROJECT
Treatment (PWT)
QA/QC Quality assurance / Quality Control
JSA Job Safety Analysis
RFI Request for inspection
MAR Material approval Request
PTW Permit to Work
PPE Personal Protective Equipment
Shall Indicates a mandatory requirement
Should Indicates that the requirement is strongly recommended to be adhered to.
ISO International Organization for Standardization
ITP Inspection And Test Plan
AFC Approved for construction
4. CODES AND STANDARS
ACI 318M Building Code Requirements for Structural Concrete

ACI 347 Guide to Formwork for Concrete
ACI 304R Guide for Measuring Mixing Transporting and Placing Concrete
ASTM C 494 Standard Specification for Chemical Admixtures for Concrete
Standard Specification for Deformed & Plain Steel Bars for Concrete
ASTM A 615M
Reinforcement
EN-196 Methods of testing cement
Standard Specification for Admixtures to Inhibit Chloride-Induced Corrosion of
ASTM C1582
Reinforcing Steel in Concrete
Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone
ASTM D 1556
Method
Standard Practice for Classification of Soils for Engineering Purposes (Unified Soil
ASTM D2487
Classification System)
ASTM D4318 Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils
ACI 364.10T-14 TechNote: Rehabilitation of Structure with Reinforcement Section Loss
5. REFERENCES
GB1516-SAC-240-QA-PL-0001 Project Quality Plan
GB1516-SAC-240-CV-TP-0001 Inspection and Test Plan for Civil Works
GB1516-SAC-240-CV-SP-0002 Specification for concrete works
GB1516-SAC-240-HS-PL-0001 HSE plan
GB1516-SAC-240-CV-RP-0002 Structure Analysis for Culvert
GB1516-SAC-240-CV-DD-0004 Pipe Crossing Culvert Drawing for PWT Area
6. ROLES AND RESPONSIBILITIES

Supervisors shall be directly responsible for the monitoring and supervision of the activities on site (field)
and utilizing the resources, effectively maintaining good productivity. He shall obtain relevant work permits
and approved JSA (Job Safety Assessment) as necessary and coordinate with Employer’s acceptability of
cleanliness.
QA/QC engineer shall be responsible for the quality of execution for various works of the project and maintain
the quality of implemented works inside the site of work
Safety In-charge / Supervisor shall be responsible for site surveillance, reporting HSE inaction,
recommending corrective actions and ensuring site compliance with the Employer's Health Safety and
Environmental program.
Skilled Laborers shall be employed for the execution of works. They must understand the extent of works to be
executed, aware of the hazards involved, and receive relevant instructions from Supervisor who is responsible
for the activity
7. EQUIPMENTS
Key Equipment Required Key Tools Required
• TANKERS. • DRILL HAMMER.
• AIR COMPRESSOR. • POWER GENERATOR.
• BLOWER.
7.1 Equipment's HSE requirements

Contractor shall have a fleet of Machinery and Equipment that support all operations and duties. All
Machinery and Equipment shall comply with safety requirements and All equipment is provided with
professional certified operators.
Our team manages those machinery and equipment professionally by applying safety inspections, third-
party inspections, and the required regular maintenance.
All drivers and operators have third-party certificates. Moreover, they have good experiences in oilfields
and engineering project.
The purpose of this procedure is to ensure that specific consideration is provided while performing the
required job to avoid potential hazards / risks that could happened while operating, work with any
mechanical equipment's, machines and instruments all vehicles and machines shall comply with
following:
➢ All Machinery and Equipment shall be certified by 3rd party or tested and certified by employer HSE
department.
➢ All operators shall be certified to use their specific equipment or vehicle
➢ All specific equipment's and instruments shall be calibrated with certification by 3rd party
➢ Initial check for the performance of vehicle's, equipment and instruments shall be made by contractor
QA/QC engineer and HSE engineer separately
8. SANDBLAST
All previous rebars shall be cleaned and sand blasted from rust mud, or any other adhesive materials
to ensure that the surfaces of old rebar is clean.
An inspection shall be made by employer discipline engineer to confirm that the condition of rebar is
suitable and ready to be used for reconstruction of pipe culvert.
8.1 Materials of sand blast

Sand that used in sandblasting must be free of residues, chemicals or moisture, and must have a
suitable granularity meeting the requirements of sand blasting.
8.2 Equipment's of sand blast

All equipment that used in sand blasting shall meet the requirements of employer HSE System to avoid
any hazards/risk that could happen while implementing.
Initial check shall be made by contractor HSE staff to ensure that these equipment's are qualified to
be used inside the project field.
9. MEASUREMENTS OF CORROSION AND REINFORCEMENT
After sand blast is done and confirmed the steel shall be measured by specialized engineer from
contractor side to estimate the percentage of occurred corrosion in the rebar steel
Compensation of the steel shall be according to ACI standard
Calculations of post installed rebar
The consolidation of structural part for pipe culvert shall be according to ACI 364-10T-14
These calculations were made according to several measured samples from site
The following calculation representing the actual condition of existed rebar in pipe culvert:
C: section
D: diameter
O: origin
Origin area (AO) = 0.785*D2
Current area (AC) = 0.785* D2
Area lost (AL) = Ao – Ac
Lost area percentage = area lost (AL) / origin area (AO)
Sample #1
D1c= 10.66mm
D2c= 10.92mm
Dc= (10.66+10.92) / 2 = 10.79mm
(AO) = 113.04mm2
(AC) = 91.393mm2
Area lost (AL) = 113.04 - 91.393 = 21.647 mm2
Lost area percentage = (21.647/ 113.04) * 100 = 19.149 assume 20%
Sample #2
D1c = 9.49mm
D2c = 10.55mm
Dc = (9.49+10.55)/2 =10.02 mm
(AO) = 113.04 mm2
(AC) = 78.814 mm2
Area lost (AL) = 113.04 – 78.814 = 34.225 mm2
Lost area percentage = (34.225/ 113.04) * 100 = 30.27 mm2 assume 31%
Existing bar shall be cleaned with sandblasting and wire brush then the area lost due to corrosion
is compensate by adding new post-install rebars.
10. PREPARATIONS AND IMPLEMENT OF POST INSTALLED REBAR
➢ Drill locations to the proper size, ensuring it is larger than the rebar diameter by at least 4mm
and a depth of 110mm, using a drill hammer. This is to ensure that the position is suitable for
epoxy and reinforcement, as per the instructions in Table 3 of the setting parameters in
Appendix 1.
➢ After drilling, all holes must be cleaned thoroughly. Utilize an air compressor or a suitable blower
to remove dust, debris, and any other materials.
➢ Fill the holes with epoxy material that meets the project's requirements and specifications
(GB1516-SAC-240-CV-SP-0002, Para # (Non-Shrink Grout). The designated material for this
purpose is (Fosroc – Lokfix E77), issued as GB1516-SAC-240-CV-MR-0001.
➢ Prior to use, steel reinforcement shall undergo testing and meet the reinforcement requirement
of GB1516-SAC-240-CV-SP-0002.
➢ All cutting, bending, and installation of reinforcements must align with the AFC drawings and
meet the required specifications.
➢ Secure the rebar into the holes with 250 mm deep, ensuring they are properly alignedwith
each other without any defects or damages.
10.1 Sequence of post installed reinforcements works

1- Survey for positions of post installed rebar
2- Marking the positions for rebars
3- Drilling with suitable drill
4- Cleaning with a brush
5- Cleaning with air
8- Epoxy application
9- Placing the new reinforcement rebar
10- Curing the epoxy.
11. QUALITY
All works under this Method Statement shall comply with the approved drawing(s) for the culvert and all epoxy
work shall be as per the epoxy manufacturer's instructions in Appendix 1. and approved Material Approval
Request (MAR) for the epoxy (GB1516-SAC-240-CV-MR-0001).
QA/QC manager and engineers shall maintain the quality of execution step by step and the always
must keep good coordinating with site supervisor and engineers.
Any activity shall not be proceeded without a prior RFI and approval of employer as per inspection and
test plan
All documents that relate to the construction shall be prepared already to ensure the level of quality
All test shall be made according to the specifications and requirements of the inspection and test
plan.
12. SAFETY
Work to be carried out safely and accordance with the HSE program and Safety Policy. Site
operatives shall be well inducted for the safe operation of the machinery,
equipment and tools to be used.
• Safe access and Safe working area shall be maintained.
• Safe lifting and placing of steel components.
• Stability and structural adequacy of the part-erected structure.
• Personnel protective equipment will be used by all staff and labors.
The minimum personnel protective equipment is as follows:
➢ Safety Helmet.
➢ Safety footwear.
➢ Eye protection.
➢ Full body safety harness.
➢ High visibility vest
➢ Safety gloves
• Any other equipment required by the site operator or deemed necessary by the task.
• All regulation implemented by authority at site will be considered.
• Proper barricades and traffic signs shall be placed around the work site location wherever
required.
13. CONCLUSION
As per the analysis provided in the Structure Analysis for culvert GB1516-SAC-240-CV-RP-0004
on page seven, it has been concluded that a minimum embedment percentage of 21% is required
(Percentage (%) = ( ρmin / ρact ) * 100).
To prioritize safety and take necessary precautions, an additional ten percent will be added, resulting
in a required embedment percentage of 31%.
Figure 1 represents 1 meter unit section of the wall it is just a sketch details are incorporated in Pipe
Crossing Culvert Drawing for PWT Area (GB1516-SAC-240-CV-DD-0004).
The embedment length provided by the vendor is 110 mm and as per ACI-318 calculated
development length is 250 mm. Since structural analysis uses the ACI-318 standards for
reinforcement distribution, hence 250 mm embedded length shall prevail.
For 1 m Analysis:
According to Design Drawing GB1082-MSK-240-MP-PL-004
Wall reinforcement T12@200c/c therefore total area = 5*113.04= 565.2 mm2
Losing area (31%) = 565.2*0.31= 175.212 mm2
Compensation area =2*113.04= 226.08 mm2 for each face
since 226.08> 175.212 mm2 then it’s OK.
Figure 1 (New Post-Installed Reinforcement Scheme)


14. APPENDICES
APPENDIX 1 – Fosroc Lokfix E Application Guide for Dry Concrete.
APPENDIX 2 – Management Photo.
14.1 APPENDIX 1 – Fosroc Lokfix E Application Guide for Dry Concrete

14.2 APPENDIX 2 – Management Photo





GB1516
EPC For Installation of PWT and HCU at CPF Badra,Republic of Iraq
PETROCHEMICAL TRANSMITTAL NO. DOCUMENT NO. DOCUMENT TITLE GAZPROM TRANSMITTAL NO. GAZPROM REVIEW CODE
DOCUMENT REVISION NO.
METHOD STATEMENT FOR REHABILITATION OF PIPE

- GB1516-SAC-240-CV-MS-0003 C 2
CULVERT
RESPONSE BY: PEC/SAC GAZPROM-REVIEW BY
NAME Meesam Ali NAME

DISCIPLINE Civil Engineering DISCIPLINE
DATE 10/26/2023 DATE
DOCUMENT REVIEW SHEET:
S.NO GAZPROM COMMENTS/HOLD PETROCHEMICAL RESPONSE/UPDATES

1 Update revision record Incorporated
2 REFERENCES Incorporated
ACI 364.10T-14
3 ACI 364.10T-14 is already added in Para 4
ADD TO PARA 4
For 1 m Analysis :
According to Design Drawing GB1082-MSK-240-MP-PL-004
Wall reinforcement T12@200c/c therefor total area = 5*113.04= 565.2 mm2
4 Incorporated
Loosing area (31%) = 565.2*0.31= 175.212 mm2
Compensation area =2*113.04= 226.08 mm2 for each face
since 226.08> 175.212 mm2 then its OK.
Comments from Rev B
For detailed of vertical cross-section and other drawings please refer to DWG No. GB1516-SAC-240-CV-DD-
5 Contractor should be add all necessary information to this MS such as : - Provide vertical cross section to
0004
show new embedded parts with all details
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GB1516 Sac 240 CV MS 0003 - D

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EPC FOR INSTALLATION OF PWT, CPF

BADRA, REPUBLIC OF IRAQ

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 1 of 17

EMPLOYER : Gazprom Neft Badra B.V.

REV DESCRIPTION DATE PRPD CHKD APPD

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 2 of 17

Rev. Para. Revision Description

B Issued for Approval

C Re-Issued for Approval

D Re-Issued for Approval

Hold No Para. Description of Hold

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 3 of 17

3. DEFINITIONS AND ABBREVIATIONS ............................................................................................................................................ 4

4. CODES AND STANDARS .............................................................................................................................................................. 4

6. ROLES AND RESPONSIBILITIES .................................................................................................................................................... 5

9. MEASUREMENTS OF CORROSION AND ENFORCEMENT .............................................................................................................. 6

10. PREPARATIONS AND IMPLEMENT OF POST INSTALLED REBAR ................................................................................................ 7

11. QUALITY ................................................................................................................................................................................ 8

12. SAFETY .................................................................................................................................................................................. 8

13. CONCLUSION ......................................................................................................................................................................... 9

14. APPENDICES ................................................................................................................................................................... 11

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 4 of 17

3. DEFINITIONS AND ABBREVIATIONS

4. CODES AND STANDARS

ACI 318M Building Code Requirements for Structural Concrete

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 5 of 17

6. ROLES AND RESPONSIBILITIES

7.1 Equipment's HSE requirements

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 6 of 17

8.1 Materials of sand blast

8.2 Equipment's of sand blast

9. MEASUREMENTS OF CORROSION AND REINFORCEMENT

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 7 of 17

10. PREPARATIONS AND IMPLEMENT OF POST INSTALLED REBAR

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 8 of 17

10.1 Sequence of post installed reinforcements works

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 9 of 17

Figure 1 (New Post-Installed Reinforcement Scheme)

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 10 of 17

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 11 of 17

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 12 of 17

14.1 APPENDIX 1 – Fosroc Lokfix E Application Guide for Dry Concrete

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 13 of 17

14.2 APPENDIX 2 – Management Photo

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 14 of 17

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 15 of 17

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 16 of 17

Doc. No.: GB1516-SAC-240-CV-MS-0003 Rev.: D Page 17 of 17

METHOD STATEMENT FOR REHABILITATION OF PIPE

NAME Meesam Ali NAME

DOCUMENT REVIEW SHEET:

S.NO GAZPROM COMMENTS/HOLD PETROCHEMICAL RESPONSE/UPDATES

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