115063_mathod_statement_of_duct_insulation

EPC CONTRACTOR: PROJECT MANAGEMENT CONSULTANT: VENDOR / SUBCONTRACTOR:

China Petroleum Engineering & Construction Corporation Abu Dhabi Branch P.O. Box 127345

ILF Consulting Engineers P.O. Box 73250 Abu Dhabi, UAE

China State Construction Engineering Corp. M.E. L.L.C. P.O. Box 63932 Dubai, UAE

PROJECT: ADCOP - ABU DHABI CRUDE OIL PIPELINE PROJECT-Habshan To Fujairah

EPC Contractor Doc. No.: ADCOP/CP/ PAGE: 1 of 14

DOCUMENT No.: C024-25-50-90-3938 Rev. A Project No: E30153 DATE: 23/02/2011

CONSULTINGENGI NEERS

ADCOP - ABU DHABI CRUDE OIL PIPELINE PROJECT Habshan - Fujairah

METHOD STATEMENT FOR INSTALLATION OF DUCT INSULATION

C024-25-50-90-3938

DOCUMENT TITLE : Method Statement for Installation of Duct Insulation Project No: E30153

PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT Habshan - Fujairah of 14

DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011

REVISION RECORD

REV DATE ORIGINATOR REVIEWED APPROVED DESCRIPTION

A 23.10.2010 Yang Weifeng Hamid Victor Zhao For Approval

© Copyright China Petroleum Engineering &Construction (Group) Corporation 2008 All rights reserved. “This document is issued for the execution of Abu Dhabi Crude Oil Pipeline (ADCOP) project.

Copying this report without the permission of CPECC, ILF and IPIC is not permitted.




TABLE OF CONTENT

1. Scope …………………………………………………………………… 4 2. Definition & Abbreviation ……………………………………… 4 3. References/Standard ……………………………………………… 5 4. Equipment & Tool …………………………………………………… 5 5. Material ……………………………………………………………… 5 6. Installation Procedure …………………………………………… 5 7. Organizational Responsibilities ……………………………… 6 8. Manpower ……………………………………………………………… 7 9. Distributions ……………………………………………………… 7 10. Safety ………………………………………………………………… 7 11. Appendix A Risk Assessment ……………………………………… 8 12. Appendix B Inspection Test Plan ………………………………11

13. Appendix B Check List………………………………………………14




1.0 SCOPE

This Method Statement covers the insulation of G.I. ductwork. This procedure defines the method used to ensure ductwork insulation to be carried out as per contract requirements (Shop Drawings / Specifications / Contract Documents and best commercial practices).

2.0 Definition & Abbreviation

2.1 Definition

Client International Petroleum Investment Company

Project Abu Dhabi Crude Oil Pipeline Project

Project Management

Consultant ILF Consulting Engineers

Contractor China Petroleum Construction and

Engineering Company

Third Party Inspector Germanischer Lloyd

Sub Contractor China State Construction Engineering Corporation ME LLC

MUST signifies a legal or statutory requirement

MAY signifies a feature which is discretionary

SHALL signifies a requirement made mandatory by

this Method Statement

2.2 Abbreviation

CSCEC China State Construction Engineering Corporation ME LLC

ITP INSPECTION & TEST PLAN means the document which contains sequence of activities in a process, highlights the applicable Quality Documents, and inspection criticalities.

SITE means the place, designated by Company for further development, where the construction activities shall be carried out by Sub-contractor.

PROCEDURE describes how a process is performed.

QA - QUALITY ASSURANCE is the planning and organizing of a system or program to maintain a required level of quality or reliability. This includes auditing the system’s operation and related controls to assure that they are being executed properly and functioning as expected. Quality shall be assured by S u b - Contractor/ Contractor.




QC – QUALITY CONTROL is a part of Quality Assurance, implements the latter by examining physical characteristics and comparing them to established and acceptable Quality Documents as stated in the quality assurance program or plan. Quality shall be controlled by Sub-Contractor in accordance with the Quality Documents.

TPI - Third Party Inspection

RFI Request for Inspection

3.0 REFERENCES/STANDARD

1. Project Specifications:

HVAC System for Residential Area - 30.99.24.3811

2. International Standards and References： NFPA 90A

ASHRAE Handbook

3. Material Submittal Approval: Material Submittal for Fibre Glass Insulation & Liner: C024-25-50-83-3961

Material Submittal for Adhesive & Vapour Barrier: C024-25-50-83-3950

4. Approved Shop Drawings.

4.0 Equipment & Tools No heavy equipment and tools are required

5.0 Materials 5.1 Material List

1. Rigid Fibre Glass Insulation. Produced by KIMMCO, 25mm thickness for supply air/return air duct located in air conditioning area, 50mm thickness for others.

2. Insulation Adhesive. CP-129, produced by Childers, USA. 3. Vapour Barrier. CP-45, produced by Childers, USA.

5.2 DELIVERY & STORAGE

1. Receive materials from suppliers, CSCEC site Engineer will check against the model, quantity and ensure the received materials are as per specification.

2. Store relevant materials in a designated storage area. 3. The storage area must be well shielded and should be kept in proper manner to avoid

any damages. 4. Obtain approval from the consultant on every batch of materials delivered to site before

installation. 5.3 INSPECTION OF MATERIALS

1. CSCEC site Engineer will inspect the received material and make sure the delivered materials are as per the approved material submittal.

2. After inspection by CSCEC, RFI will be submitted to the consultant for further checking and approval.




3. After consultant’s approval, the materials will be ready for installation 6.0 INSTALLATION PROCEDURE

6.1 Pre Installation Checks 1) Before installation ensure all insulation and adhesive have been inspected on site

and have been approved. 2) Inspect all materials and verify that they are undamaged. 6.2 Installation 1) Installation shall be done on a clean, smooth and dry surface. 2) Check for the external sizes of the duct to be insulated and cut the insulation

accordingly on a cutting table with knifes. 3) Clean the duct surface to be insulated and brush approved adhesive CP-129 on the

duct surface in strips about 15cm wide, at a coverage rate of 200ft/gal. Adhesive shall not completely cover the surface.

4) Apply the insulation, foil face up, to the duct surface while the adhesive is still wet. Do not let it dry too much. There are two different kinds of installation according to the duct size: a. Duct width ＜300mm:

Wrap the insulation around the duct surface, making sure all edge joints are closely butted. Apply uniform hand pressure to outside surface of insulation to obtain good bond.

b. Duct width ≥ 300mm: Fix self adhesive pins to each face of duct, at least 1 pin per 0.09 square meters. Position the insulation, press firmly until the pins penetrate through the insulation totally, fit the lock washer over pins. Apply uniform hand pressure to the insulation, making sure good bond.

5) Tape all joints and openings with 75mm wide glass reinforced self adhesive aluminium tape. Make sure the insulation is well sealed from vapour.

6) For duct with width larger than 600mm, add light gauge galvanized angle to the edges of insulation to prevent them from being damaged by support angles.

External Duct surface (Item No. 7, 8, 9 are designed only for external ductwork) 7) Clean the surface of insulation KSF foil, apply 1 coat of CP-45 Vapour barrier &

Weather proofing coating (Gray) as a tack coat, at coverage rate of 2 gal/100 sq. ft. 8) While the tack coat is still wet, apply 1 layer of glass fibre reinforced mesh to the

duct surface with seams overlapped at least 5cm. 9) Apply the finish coat of CP-45 (White) at coverage rate of 4 gal/100 sq. ft. 10) Clean and clear the workplace immediately after insulation. 11) Ensure no damage of the insulation during and after the insulation procedure. 6.3 Inspection after Installation.

1) After duct insulation work is completed，the CSCEC site Engineer will inspect the

installation and make sure that the insulation is done as per approved material submittal and the installation is done as per standard.

2) After inspection by CSCEC site Engineer, RFI can be submitted to the consultant. This inspection may be done together with the inspection of duct installation.

7.0 Organizational Responsibilities




1. The Project Manager will

1) Be responsible for all interfaces and other communications as required during the execution of all activities.

2) Reviews the method statements prior to execution and explain the same to his subordinates ahead of the job plan.

3) Manage and lead his workforce to ensure good workmanship and a quality result.

4) Must be aware of all test results, test frequencies and approved materials to be used.

2. The QA/QC Engineer

1) Shall conduct inspections as per the method statement. 2) Ensure that all the procedures in the method statement are implemented and

followed. 3) Ensure that all necessary records such as Request for Inspection(RFI), test

reports, material approval and others must be in-place prior to commence with the work

3. The Site Engineer & Foreman

1) Shall execute the job as per the approved method statement, drawings and specification.

2) Issue the correct and approved materials and explains the daily tasks to his workforce.

3) Works hand in hand with the Project Team to deliver a quality output. 8.0 Manpower

1. Construction Manager 2. Site Engineer 3. Foreman 4. General Workers

9.0 Distributions

1. Project Manager 2. Construction Manager 3. Site Engineer 4. QA/QC Engineer 5. Foreman

10.0 SAFETY

1. All appropriate safety protective gear, i.e. helmet, safety shoes, gloves, goggles,

etc should be worn by workmen and approved by safety Engineers. 2. Wear the safety belt while working on a scaffold or step ladders at high levels.




APPENDIX A

Risk Assessment




Attachment A: RISK ASSESSMENT for Asphalt Road/Pavement Project: Abudhabi Crude Oil Pipeleine Owner : IPIC

TITLE: Construction of roads DEVELOPED BY: Sign: Date:23 Feb 2011 PRELIMINARY IMPLEMENT REVISION APPROVED BY: Sign: Date:

1 BASIC PPE REQUIRED FOR THIS JOB

Long Shirt Sleeves Long Trousers Hard Hat Safety Footwear Overalls P2 Mask Ear Plugs Safety Glasses Goggles Gloves

2 EXTRA PPE REQUIRED FOR THIS JOB (AS IDENTIFIED IN THE RECOMMENDED PROCEDURES BELOW) ADDITION REFERENCES Plant Hazard Assessments Construction Drawings HSE Procedures Other (Risk Assessment)

2.1.1 HEALTH & SAFETY: Assessment of Risks and Hazards

STEP 3:

STEP 4: Hazard Risk Assessment H = High Risk (INTOLERABLE, significant and urgent actions required- ImmediateAction). M = Medium Risk (ALARP, reduce risk to As Low As Reasonably Practicable). L = Low Risk (TOLERABLE, monitor and manage risk).

A B C D E

1 H H H M M

2 H H M M L

3 H M M L L

4 M M L L L

5 M L L L L

STEP 1: Likelihood of Occurrence STEP 2: Severity of Result

1. Expected To Occur (once per week) A Fatality 2. Common (once per month) B Permanent Disability 3. Sometimes (once per year) C Lost Time Injury (LTI) 4. Rarely (once in < 20 years) D Medical Treatment 5. Highly Unlikely (once in > 20 years) E First Aid Injury

RISK CATEGORY (RESIDUAL)

BASIC JOB STEP POTENTIAL ACCIDENT OR HAZARD RISK CONTROL MEASURES

LIKELIHOOD SEVERITY Risk Rating

A Insulation

HEALTH CONDITIONS AFFECTED BY EXPOSURE TO ADERHISIVES

1. Keep good ventilation in working areas. 2. Wear gloves to avoid body contact.

1.Highly Unlikely 2. Sometimes

1.Medical Treatment 2. First Aid Injury

1.Low 2.Medium




ADDITIONAL SAFETY COMMENTS:

• 　 All personnel working within upon foundation operations must be made of the hazards related to trench collapse

• 　 All persons in the crew to be instructed that they are not required to work in any situation or with any equipment that they do not believe is safe (If personnel feel at risk they are to stop work, inform their supervisor of their concerns).

• 　 Ensure adequate communications are available to ensure the safety of all personnel involved in the above operation.

• 　 No unauthorised personnel will be allowed in to the works area.

• 　 Supervisors to ensure all requirements of this document are complied with.

• 　 Crew to be inducted prior to commencing work on the project. Prior to the commencement of the work shift;

• 　 Plant pre-start checks to be completed. Report any safety related faults to supervision.

• 　 Permits to be arranged as required. Reporting of incidents/accidents: Report to CPECC Project Management (HSE Manager or Project Manager) immediately. CPECC to report to ILF/IPIC within 60minutes of serious incidents/accidents including significant near miss events. Pre-investigation report required within twenty four hours. Final investigation report required within seventy two hours. Refer to Incident Management and Reporting Procedure and the Emergency Response Plan for further details.




APPENDIX B

Inspection & Test Plan




ABU DHABI CRUDE OIL PIPELINE PROJECT QUALITY EXAMINATION PLAN

DEFINITION OF INSPECTION AND TEST PLAN SYMBOLS

“H” - HOLD: A point beyond which work shall not proceed without formal approval by appropriate inspectorate. Achievement of “H” points shall be notified to Owner. “W” - WITNESS: A point beyond which work may proceed without formal documented approval by any of the inspectorate. Achievement of “W” points shall be notified to Owner. “S” - SURVEILLANCE: A point where CONSORTIUM and others may carry out surveillance of work in progress and documentation associated on an unscheduled basis, with no notification required by any party and without amendment to the scheduled production programme. “R” - REVIEW: The documents are to be submitted to the appropriate inspectorate for review by Owner. Note that where a document is subject to Owner approval, work shall not proceed until the Owner’s approval is given. “C” - CERTIFICATION: Specific and appropriate certification documentation is to be included in the document package. “A1” - 100% ACTUAL “A2” - RANDOM ACTUAL

REMARKS:




ABU DHABI CRUDE OIL PIPELINE PROJECT Habshan - Fujairah(ADCOP)

INSPECTION AND TEST PLAN OF DUCT INSULATION

Date:23-Feb-11 DOCUMENT NO.: C024-25-50-90-3938

Item No.

Inspection Activity & Specific Check Point Area

Acceptance Criteria, Code & Standard

Verifying Record

Sub-Contractor

Contractor TPI Owner

1 Material and test report submittal Specifications , technical Data sheet

Submittals & Acceptance Letter R R H H/R

2 Method Statement Submittal Specifications Submittals & Acceptance Letter R R H R

3 Set out survey for Materials Specification & Material Submittal Approval RFI W W/S H R

4 Set out survey for Procedure & Finished Product Specifications, Method Statement & approved

Drawings Checklist & RFI W W/S H R




ABU DHABI CRUDE OIL PIPELINE PROJECT Habshan – Fujairah (ADCOP)

Form No: 3938-01 CHECK LIST OF DUCT INSULATION

Project Description Area

Construction Drawing RFI No

Inspection Content Yes No

1 Materials are approved and undamaged.

2 Insulated ductworks were approved by TPI.

3 Insulation thickness is according to specification.

4 Installation followed the approved method statement and shop drawing.

5 Finished products are protected well.

Acceptance result

APPROVALS

SUB CONTRACTOR CONTRACT TPI OWNER

Signature

Name

Date

115063_mathod_statement_of_duct_insulation

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