TABLE OF CONTENTS
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 :
Sub-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
I.
SAUDI ARAMCO
ENGINEERING PROCEDURE(SAEP)
II.
SAUDI ARAMCO
ENGINEERING STANDARD (SAES)
III.
SAUDI ARAMCO
STANDARD DRAWINGS
IV.
PROCESS
INDUSTRY PRACTICES
V.
ASTM
SPECIFICATIONS
VI.
DESIGN CODES
& STANDARDS
VII.
Insulation Details
for Hot Piping – AA-036911-001- Rev 06.
VII. Insulation
Details for Hot vessels – AA-036912-001- Rev 02.
5.0
RESPONSIBILTIES
The responsibilities of the various personnel on the
project site are as defined below:-
- 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.
- 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.
- 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.
6.0
MATERIAL REQUISITION
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.
7.0 INSULATION & JACKETING PROCEDURE
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
|
Description
|
No. Required
|
1
|
Material storage shed
|
As required
|
2
|
Metal fabrication shed
|
As required
|
3
|
Sheet Metal fabrication machineries such as cutting, rolling, swaging,
folding, lock-form etc
|
As required
|
4
|
Electric tools – battery drill, shear cutter etc
|
As required
|
5
|
Hand tools- saw, band tighter etc
|
As required
|
6
|
Pulley- Manual lifting by rope
|
As required
|
10.0
HSE REQUIREMENTS
·
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).
11.0
QC REQUIREMENTS
·
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
No.
|
Activity
|
Potential Hazards
|
Preventive Measures
|
||||
1
|
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
|
||||
2
|
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.
|
||||
3
|
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.
|
||||
4
|
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.
|
||||
5
|
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.
|
||||
6
|
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.
|
||||
7
|
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.
|
||||
8
|
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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