Tuesday, November 28, 2017



1.0             SCOPE………………………………………………………………………….3        
3.0             DEFINITION…..………………………………………………………………...3       
4.0             REFERENCES……………………………………………………………….…3      
5.0             RESPONSIBILITIES…………………………………………………………...4      
6.0             MATERIAL REQUISITION……………………….……………….………......4       
7.0             INSULATION JACKETTING PROCEDURE….…………………………….5
8.0             REMOVABLE VALVE & FLANGE BOX ...................................................7
9.0             RESOURCES…………………………………………………………….….....8
10.0          HSE REQUIREMENT……………………………………………………........8
11.0          QC REQUIREMENTS……………………………………….…………….…..9
12.0                ATTACHMENT.…………………………………………….………….…..11-12     

1.0         SCOPE
The Scope of work shall be summarized below: -

      I.        To supply and install of basic insulation, cladding and other ancillary’s/fastening material for hot, personnel protection, steam tracing & electrical tracing on Piping where ever insulation is specified as per project specification.

    II.        Sub-Contractor shall provide all scaffolding where required as per work scope suited insulation installation work.

2.0         PURPOSE
The purpose of this Method Statement is to define responsibility, requirements and the execution procedure for the hot insulation on Hot Piping for Refinery Expansion Project.

3.0         DEFINITION
         For the purpose of this specification, the following definitions shall apply:
         Client                :  
         Contractor        :   
                     Project              :   .
         Location            :                

4.0         REFERENCE

   The materials of insulation shall generally meet the requirement of ASTM code, ARAMCO Standards, and PIP. Those not covered in ASTM code shall be conformed to applicable codes, and submitted for Client’s approval. Insulation Specification for Refinery Expansion Project,
   Document. No: LEP-O0-GS-0001

 VII.        Insulation Details for Hot Piping – AA-036911-001- Rev 06.
 VII.    Insulation Details for Hot vessels – AA-036912-001- Rev 02.
   The responsibilities of the various personnel on the project site are as defined below:-

  1. Management has responsibilities to ensure that insulation work adheres to the recognized standard or code of practice with respect to the project specification, safety, quantity and other requirements.          
    II.        Site Manager shall be responsible to the Management and for the overall implementation of this method statement for all construction activities carried out.

  1. QC Operative/QC Inspector shall be responsible for all the inspection and testing works as per approved ITP (SATIP- Rev 5), the preparation of documents and for maintaining all record.

  1. Site Operatives/ supervisor shall be responsible for achieving the stage acceptance of the Inspection & Test Plan.
   V.        Applicator for direct work shall ensure that they perform the insulation application as per project specification and in accordance with project safety procedure.
  VI.        HSE/Safety Supervisor shall monitor regular safety checks and ensure that the work is carried out in accordance to project safety norms.

It shall be the responsibility of the Supervisor to authorize the requisition of the materials required for the relevant items to be insulated using Material Request Issue Form which may consist of:

6.1 Insulation Material

Insulation Material Code as per LEP-OO-GS-0001 with properties meeting to SAEP & SAES.

6.2   Jacketing Material – All Insulation design.
Jacket Material Code as per LEP-OO-GS-0001 with properties meeting to SAEP & SAES

6.1         Ancillary/Fastening Materials:

6.1.1  Insulation fastening Material for hot Piping – SS304 - 1.6 mm thick Tie Wire for < 4’’Ø and interlayer at 250mm spacing.
6.1.2  Insulation fastening Material for hot Piping – SS304 as per A 167 Strap1/2 inch x 0.5mm thick for 4’’Ø to 34’’Ø and ¾ inch x 0.5mm for 36’’Ø and above  at 250mm spacing.
6.1.3  Jacketing fastening Material for hot Piping - SS304 as per A 167 Strap 1/2 inch x 0.5mm thick up to 34’’Ø  and ¾ inch x 0.5mm thick for 36’’Ø all metal jackets at 305mm spacing.
6.1.4  Screws shall be self drilling No.8 by ½ inch (13mm) stainless steel, with elastomeric washer. Screw head shall be hex, Phillips recessed round, round, hex-slotted or Pan type.
6.1.5  Metal sealant shall be RTV Silicone, aluminium or grey color, suitable for continuous service to 204° C and intermittent service to 260° C.
6.1.6  Insulation support on vertical Piping can be either a ring or expanded metal lath with support studs, Maximum support ring spacing shall be 5 meter for piping with temperature below 315°c and 3.65 meter above 315°c.


7.1       Scope of work & Explanation of Procedure
   The total process consists of surface cleaning, fixing of insulation & cladding material and its securement. This procedure covers stage wise activities including quality control checks for insulation work.
7.2       Release Note
   All the areas prior to start of insulation will be officially released to Insulation Sub-contractor. No other activities shall be allowed in the area released for insulation without information to Insulation Sub-contractor. Proper release note has to be provided duly signed by the Contractor concerned engineer / authorized person. The release note receipt should be signed by KAEFER QC or Site-in Charge after physically confirming the readiness of area for insulation.

7.3         Application Of Insulation & Jacketing

7.3.1 General        
·         Insulation shall be applied per all applicable engineering specifications and standard insulation details.
·         It shall be the responsibility of the Supervisor to ensure the insulation and jacket materials are applied correctly including the correct order of layering, and with correct securement / fastening and sealants.
·         Ensure the Piping mechanical work completed prior to release for insulation by the Contractor’s Representative has all previous work including hydrostatic or other testing and touch of painting completed and is in a fit state to insulate.
·         Piping surface shall be clean, dry and the surrounding area is free of obstacles and debris as per specification.
·         When weep or aeration holes in jacket are required, it will be provided.
·         Thickness selection shall be made from Thickness Tables in the insulation specifications specified for the job.

7.3.2  Insulation Application:
I)         Hot Insulation
·        The surfaces to be insulated shall be dry and reasonably clean prior to the application of the insulation.
·        Check the insulation sections are of correct type, size and thickness including thickness orientation for application as per the project specification.
·        Single layer of insulation shall be applied with longitudinal joints staggered. In multiple layer application all joints of adjacent layers shall be staggered.
·        Insulation of single or multiple layers shall be secured properly with stainless steel 304 Tie wire or Strap as specified fastening material in project specification.

II)    Steam Tracing & Electrical Tracing Insulation

·       Steam tracing & Electric tracing pipe insulation shall be oversized.

III)   Personal Protection 

·      Piping & equipment  operating above 60° C shall be provided with insulation for
            Personal Protection where accessible
·      Personal Protection shall be provided to 7 ft (2.13 m) above grade or platforms and
            3ft (0.91 m) horizontally from the periphery of platforms, walkways or ladders.

·      For Hydrogen service or where heat conservation insulation is not required for
            flanges a sheet metal shroud should be installed over flanges for personnel protection.

7.3.3      Jacketing Application

·        Insulated surface shall be weatherproofed by applying fabricated flat metal jackets.
·         Check the material issued is the correct thickness as specified in specification.
·        Jacketing shall be fitted in such a manner as to provide a close fitting assembly without gaps.
·        After the installation of the Jacketing, sufficient clearance to be maintained from nearby spools with or without Jacketing.
·        Jacketing for Insulation on electric tracing & Steam tracing piping shall be installed with bands only.

7.3.4      Insulation Excluding Welding Joint

·        Weld joint exclusion is only applicable in combination with PMT/C/PID written approval on the exclusion of the particular weld joint in view of delayed hydro testing.

·        For the welding joint near the valve & Flange, clearance will be Bolt length plus 25mm as per specification

8.0         Removable Valve & Flange Box
·        Valve and flange box shall be removable type
·        Secure Insulation to metal cover with clips
·        Valve & Flange cover shall be secured with quick release toggle clips (1” & 2” )
·        Box shall have 50mm overlap & top sloped to drain water
·        Sealant shall be used to weather proof openings

9.0         RESOURCES

Machinery Lists
Sl No
No. Required
Material storage shed
As required
Metal fabrication shed
As required
Sheet Metal fabrication machineries such as cutting, rolling, swaging, folding, lock-form etc
As required
Electric tools – battery drill, shear cutter etc
As required
Hand tools- saw, band tighter etc
As required
Pulley- Manual lifting by rope
As required

·         Comply with all Requirements of LUBREF EHS Standards procedure.
·         Task Risk Assessment shall be carried for all critical activities. Risk Assessment to address all the hazards and how to reduce them.
·         Toolbox talks shall be conducted on daily basis prior to commencement of the work.
·         All personnel shall adhere to all relevant procedures set out in the KAEFER/SAMSUNG/LUBREF HSE plan.
·         Flexible hoses shall be armoured type, and shall be protected against external damage.
·         Work crews and supervisors will attend weekly HSE meetings.
·         All Machinery for the fabrication work should be well-maintained and safe to use.
·         All mandatory PPE (Helmet, Safety Gloves and Shoes) shall be provided all the time.
·         Materials used on this project contain no asbestos and causes no known health hazards either during or after installation. During application, however, the following precautions will be taken.
·         Follow the safety instruction given in material safety data sheet.
·         Protect skin from irritation by wearing loose clothing; wash work clothing separately from other garments.
·         Protect eyes and respiratory tract from airborne product by wearing dust masks and goggles/safety glasses or eye shields.
·         All waste to be disposed-off in safe manner.
·         Unauthorized person not allowed to entire work area.
·         MSDS to be made available.
·         Workers at height 100% tie off and suitable working platforms (Scaffolding).


·               KAEFER will issue RFI to Contractor wherever applicable as per approved Inspection and Test Plan (ITP) requirement.
·               Upon final acceptance of the installation of the insulation and metal cladding, the QC department shall issue an insulation installation and completion report as per project approved form. 
·               All required documentation will be maintained by QC department.

12.0       ATTACHMENTS

·         Attachment I  SATIP-N-001-02

·         Attachment II JSA for Insulation work

Potential Hazards
Preventive Measures
Manpower/Personnel transportation to and from site
Ø  Incompetent vehicle driver
Ø  Over speeding of driver
Ø  Personnel injury and manage to asset
Ø  H2S gas leakage
Ø  Hydrogen gas leakage
Ø  Conduct tool box meeting.
Ø  Competent driver to drive,
Ø  Speed limit and safety signs posted on the road and strictly followed.
Ø  All vehicles to be used on site are CONTRACTOR inspected and approved for used.
Ø  Speed limit is 30 km / hour and safety sign board posted on the road.
Ø  Gas test shall be carried out.
Ø  Use proper gas monitor
Tools and  materials handling and transportation
Ø  Improper arrangement
Ø  Overloading
Ø  Personnel injury
Ø  Damage to asset
Ø  Proper stacking and arrangement of materials on the transport vehicle.
Ø  During transportation all materials shall be secured by using nylon rope.
Ø  Do not over speed follow speed limit.

Materials loading and unloading
Ø  Sharp edges of materials
Ø  Ergonomics
Ø  Slits, trips and falls
Ø  Falling of materials, tools and equipment during lifting
Ø  Personnel injury and damage to asset

Ø  Tool box meeting shall be carried out and all hazard associated with the job shall be discussed.
Ø  Ensure all workers involve are issued with correct type of PPE and wearing is strictly enforced.
Ø  All equipment and machinery that will be used unloading heavy load shall be in good condition, free of defects, CONTRACTOR inspected.
Ø  Tag line shall be provided for proper control of the load when lifting by crane.
Ø  Barricading and warning signs shall be posted around the work location.

Working inside the trench excavation more than 1.2meters deep
Ø  Oxygen deficiency
Ø  Collapse of soil
Ø  Improper/unsafe access
Ø  Personnel injury
Ø  Cave-in
Ø  Fall

Ø  Tool box meeting shall be carried out
Ø  If the trench excavation is more than 1.2 meters deep, confined space entry permit shall be ensured and all confined space entry procedures shall be complied.
Ø  Ensure all worker assigned are confined space entry trained. Log sheet of personnel entering and exiting the excavation shall be maintained.
Ø  Frequent gas and oxygen monitoring shall be ensured.
Ø  Ensure the both the edges of trench excavation are properly sloped to allowed entry personnel inside.
Ø  Ensure sufficient safe access and egress ladder shall be provided and maintained properly.
Ø  Daily excavation checklist shall be ensured and maintained at all times.
Ø  Supervisor must be there.
Equipment to be used Mobile crane, hiab, trailers, air compressor, cold cutting machine, welding machine.
Ø  Equipment operated by unauthorized by person.
Ø  Improper vehicle movement.
Ø  Over speeding of diesel engine whipping of hoses due to improper hose coupling
Ø  Untrained person
Ø  Working platform
Ø  Cut metal chips
Ø  Fire
Ø  Uninspected welding machine
Ø  Relevant work permits to be obtained from the authority concerned.
Ø  Operator must be assigned to the equipment to operate.
Ø  Use approved equipments with regular maintenance and inspection of equipments.
Ø  Movement should be controlled by authorized banks man.
Ø  Arrestor to be fixed for engine exhaust pipe.
Ø  Fire extinguisher.
Ø  Use proper PPE.
Ø  Good housekeeping.
Ø  Blanket must be placed below the cut pipe to collect all metal chips.
Ø  Welding machine should be inspected by CONTRACTOR.
Scaffolding/temporary working platform erection and dismantling
Ø Slips, trips and falls.
Ø Tools and materials falling from height.
Ø Personnel injury and damage to asset.
Ø High wind velocity.
Ø Tool box meeting shall be carried out daily.
Ø All workers must be issued with the correct type of PPE.
Ø Full body harness with two lanyards must be issued to all workers working on 1.8 meters above and 100% tied off shall be strictly enforced whilst on height.
Ø All area should be barricaded.
Ø Housekeeping
Ø Only competent and certified workers shall be carried out the works.

Working at heights
Ø Tools and materials falling from at heights
Ø Personnel injury and damage to asset.
Ø Equipments falling from heights
Ø High wind velocity
Ø Slips, trips and falls
Ø Can tip over
Ø Fire
Ø explosion
Ø Full body harness with two lanyards must be issued to all workers working on 1.8 meters above and 100% tied off shall be strictly implemented.
Ø Samsung work at height training must be completed by the involve workers prior to mobilization to the site.
Ø Tools and materials must be secured and tied properly when using and lifting on heights respectively.
Ø Working area should be barricaded.
Ø Scaffolding material shall be free of defects, inspected and approved by Samsung.
Ø Mobile elevated working platform must be good running condition, free of defects and with valid third party inspection certification.
Ø Barricading and warning signs must be posted around the working area.
Ø All working platform should be inspected and tagged.


Insulation works

Ø Permit inadequate.

Ø Poor safety attitudes of workers.
Ø Minor injuries to finger/hand.

Ø Operating the machineries by unauthorized personnel.
Ø Bits/scraps falling on eyes.
Ø Exposure to sunlight/wind/mixing with soil or sand.
Ø Electrical fault.

Ø Fire source.

Ø Physical contact with eye /skin.

Ø Inhalation of insulation dust/dirt.

Ø Sheet metal cut pieces/scraps left over.

Ø Ensure company is processed and authorized and competent persons.
Ø Safety audits and unsafe act auditing.

Ø Conduct daily tool box meeting for safe handling of sheet metal.
Ø Make sure that personnel are wearing hand gloves while handling the sheet metal.
Ø Make sure that only authorized /trained personnel are operating the machines.

Ø Check that all the personnel are using eye protection safety glasses at all times.
Ø All material will be stored on pallet and properly covered.

Ø Check that all the electrical connection are properly protected.
Ø All tools and equipments must be color coded and inspected by CONTRACTOR.

Ø Ensure all insulation packaging materials are correctly removed prior to installation.
Ø Provide fire extinguisher.

Ø All PPE such as helmet, safety glass, dust mask, coverall, hand gloves and safety shoes must be worn at all times.

Ø Particle must be worn at all times.

Ø Use of garbage bag to collect bits and pieces of insulation material to avoid dust/dirt arising from it.

Ø All waste and left over materials must be collected on daily basis and disposed as per MSDS and project waste disposal procedure.

Ø Provide MSDS.

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