STORK Mechanical Services & Maintenance Co.

KSCC
Doc. No.1/CTP -HSE/00
Tel. 2398 0773 Fax. 2398 0779
Critical Task Procedure – Drill & Injection Date 14.Nov.2019
Page 1 of 4
12/15/2023

Critical Task Procedure – Drill & Injection

Issue: 01 Revision: 00 Date: December 15, 2023 Page 1 of 4

 STORK Mechanical Services & Maintenance Co. KSCC
Doc. No.1/CTP -HSE/00
Tel. 2398 0773 Fax. 2398 0779
Critical Task Procedure – Drill & Injection Date 14.Nov.2019
Page 2 of 4
12/15/2023

Title: Drill & Injection

Customer: KNPC -MAA

Plant / Location:

Job Ref. No.:

DWG No.:

OBJECTIVE: This method statement was prepared for drill and injection with respect to Stork Cooperheat Leak
Sealing procedure GSOP 2059 _1for leak sealing on bolted flanges.

Details of Leak:
Type
Size
Design Pressure
Design Temp.
Line Content

PPE Required:

1. Nomex / FRC Coveralls

2. Safety Helmet
3. Safety Boots / Shoes
4. Safety Glasses(clear and dark),
5. Hearing Protection
6. Safety Cotton Gloves
7. Barricades/ Signage in the Work Area
8. Gas Sniffer, Fire Extinguishers
9. First aid Kits
10. Potable Water for the Workforce
11. Refer to Scaffolding/ Materials Handling and Transportation JSA’s

Issue: 01 Revision: 00 Date: December 15, 2023 Page 2 of 4

 STORK Mechanical Services & Maintenance Co. KSCC
Doc. No.1/CTP -HSE/00
Tel. 2398 0773 Fax. 2398 0779
Critical Task Procedure – Drill & Injection Date 14.Nov.2019
Page 3 of 4
12/15/2023

1.0 EQUIPMENT TO BE USED:

a) Standard leak Sealing kit, including Pneumatic Drilling Machine (if required), Pneumatic Caulking
machine, Hydraulic hand pump, Injection adaptor
b) Brass wire (caulking wire)
c) Compressed Air – Min. 7 bar @ 100cfm. (Plant Air / Compressor required).
2.0 SUBSTANCE/SEALANT TO BE USED:
Name: 402
Qty: 3 Boxes
Injection Adaptor M10 to be used.
3.0 ACCESS TO THE SITE:
To be agreed with the client site representative. Access restrictions shall be set up barrier tape. Minimum
two emergency evacuation route from the leak shall be arranged.
4.0 SPECIAL PROTECTIVE CLOTHING REQUIRED:

Standard Stork Cooperheat PPE.

5.0 NUMBER OF TECHNICIANS:

Two Stork Cooperheat Technicians.

6.0 SAFETY HAZARDS:

6.1 Does the standard risk assessment cover all the hazards for this job? Yes

7.0 STEPS TO FOLLOW:

7.1 Locate customer’s representative responsible for progression of work in his area. Open all permits required
for completion of work.

7.2 Sign on any PERMIT/CLEARENCE required and inspect the work area to identify any features that may
impair safety during operational activities.
7.3 Confirm the work scope and specifications with the customer representative ensuring it corresponds with
the information received from operations Department.

7.4 Check all the equipments to be used and make sure equipment is in good condition, drills are sharp and
clean
7.5 Drilling and tapping prior to fitting a caulking wire.
Points shall be selected in the flange connection where the restriction adaptor entry holes are to be drilled.
Requires minimum 6 injection points.

Issue: 01 Revision: 00 Date: December 15, 2023 Page 3 of 4

 STORK Mechanical Services & Maintenance Co. KSCC
Doc. No.1/CTP -HSE/00
Tel. 2398 0773 Fax. 2398 0779
Critical Task Procedure – Drill & Injection Date 14.Nov.2019
Page 4 of 4
12/15/2023

7.6 Selection of Caulking wire.

Caulking wire shall be selected that is approximately the same size or slightly larger than the gap between
the flanges.

7.7 Fitting of caulking wire.

The caulking wire shall be lightly tapped into the gap with a hammer beginning at the side opposite of the
leak working in a clockwise or anti clockwise direction tap the wire in until the leak point is reach allowing at
least 50mm for overlap.
With caulking unit and chisel ground correctly, lightly pein the edge of the flanges over the outside of the
wire in the flange gap.
7.11 When satisfactory fitting of caulking wires are completed, Inject the compound in to the flange gap with the
required compound packing pressure.
The relief valve in the hydraulic pump shall be closed and pumping shall begin until approximately 69 bar
(1000 psi) registers on the pressure gauge. At this point the shut-off in the restriction adaptor shall be
opened and pumping continued, continually monitoring the hydraulic pressure as pumping progresses.
Note: Using minimum pressure to allow the compound to flow (Injection Pressure = Line pressure + 10% =
1.397 Bar.).
7.12 Inject to seal. Complete injection and pressurize to required pressure

7.13 Check for leaks. Clean work area of any swarf/debris and make safe, clean and remove any equipment from
work area/site. Clean area. Think Green

7.14 Sign off the PERMITS/CLEARENCES and complete relevant administrative documentation.

8.0 PLANNED START DATE: TBA

9.0 EMERGENCY CONTACT NO: +96597274250 (Cooperheat OPS Supervisor).

10.0 ANY DEVIATION:

Issue: 01 Revision: 00 Date: December 15, 2023 Page 4 of 4