002-MS Nitrogen Filling , Cyrogenic Vaporizer.pdf

Pearl GTL Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT

Project Document Number: T-4.305.139

Purchase Order Number:

2MH127

Tag/Item Number(s):

0E-2091 A 0E-2091 B 0E-2091 C 0E-2091 D 0E-2091 E 0E-2091 F 0E-2091 G 0E-2091 H 0E-2091 J 0E-2091 K 0E-2091 L 0E-2091 M 0E-2091 N 0E-2091 P 0E-2091 R 0E-2091 T 0E-2091 U 0E-2091 V 0E-2091 W 0E-2091 X

Unit(s):

ASU

PCWBS:

Z

Contractor Project No :

Project Rev.: O

0E-2092 A 0E-2092 B 0E-2092 C 0E-2092 D 0E-2092 E 0E-2092 F 0E-2094 A 0E-2094 B 0E-2094 C 0E-2094 D 0E-2094 E 0E-2094 F 0E-2094 G 0E-2094 H

Page 2

5887

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

C

O

Issued for Company Comments

OD

MEY

AG

ICC

B

Issued for Review

OD

MEY

AG

IFR

A

Issued for Internal Review

OD

MEY

AG

IIR

GAMA Rev.

Project Rev

No.

No.

Date

Prepared Checked Approved By By By

Description

Status

ORIGINATOR

Document Title:

METHOD STATEMENT – NITROGEN FILLING, CRYOGENIC VAPORIZER

LINDE ENGINEERING AG

Document No.

Contractor

Gama Qatar Co. W. L. L.

GAM

MTS

PRE

GTL

002

C

Org. Code

Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No

Project Document Number: T-4.305.139

LOC470 Vendor Code

Rev No.: O

Doc. Title

Q A T A R

:

GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer

Date/Rev. No :

TABLE OF CONTENTS 1

INTRODUCTION ____________________________________________________________________ 5 1.1 1.2

GENERAL ____________________________________________________________________ 5 SCOPE AND PRECAUTION _______________________________________________________ 5

2

HSSE ____________________________________________________________________________ 5

3

REFERENCES _____________________________________________________________________ 6

4

DEFINITIONS ______________________________________________________________________ 6

5

RESPONSIBILITIES _________________________________________________________________ 6 5.1 5.2 5.3 5.4

6

SITE MANAGER _______________________________________________________________ FSI MANAGER ________________________________________________________________ CLEANLINESS & PRESERVATION ENGINEER _________________________________________ LIFT SPECIALIST ______________________________________________________________

RESOURCES ______________________________________________________________________ 7 6.1

EQUIPMENT & MANPOWER _______________________________________________________ 7

6.1.1 6.1.2 7

EQUIPMENT________________________________________________________________ 7 MANPOWER _______________________________________________________________ 8

METHOD OF EXECUTION _____________________________________________________________ 8 7.1

PRE-COMMENCEMENT WORKS ____________________________________________________ 8

7.1.1 7.1.2 7.1.3 8

6 6 7 7

WORK PERMIT _____________________________________________________________ 8 TRAFFIC MANAGEMENT PLAN ________________________________________________ 8 EQUIPMENT AND PERSONNEL________________________________________________ 8

MEASURING AND FILLING PROCEDURE __________________________________________________ 8 8.1 8.2 8.3

GENERAL ____________________________________________________________________ 8 ASSEMBLY AND CHARGING ______________________________________________________ 9 DISASSEMBLY AND DELIVERY ____________________________________________________ 9

9

QUALITY ASSURANCE ______________________________________________________________ 10

10

ATTACHMENTS ___________________________________________________________________ 10 10.1 10.2

JOB SAFETY ANALYSIS ________________________________________________________ 10 TAGS AND SIGNS (SAMPLE) _____________________________________________________ 10

GAM-MTS-PRE-GTL-002

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Doc. Title

Q A T A R

:

GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer

Date/Rev. No :

1 INTRODUCTION 1.1 GENERAL This document describes the methods proposed to be used for checking the pressure of and filling with nitrogen (as required) of Cryogenic Vaporizer as part of the preservation activities at ASU area that shall be carried out as part of ASU Construction works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City (RLIC) of Qatar including similar works up to the time of commissioning. The preservation shall be performed at ASU Area. The nitrogen filling and tagging activities shall be carried out by GAMA QATAR in coordination with the Contractor. All parties (LINDE – Contractor, GAMA – Logistics, Mechanical and FSI disciplines) involved in the preservation of the Cryogenic Vaporizer will conduct minuted coordination meetings as required.

1.2 SCOPE AND PRECAUTION N2 (Nitrogen) is hazardous, especially in confined spaces. All measures will be taken prior to start of operations. During the work on and in the vicinity of open flange connections, care will be taken so that dust and moisture can not get inside the equipment. Nitrogen filling will be performed by the GAMA’s Cleanliness and Preservation Engineer. The methodology will be presented to the Contractor and will be approved prior to execution. Wind intensity and velocity is to be taken into consideration. It is important in order to be able to decide if certain works can be carried out safely. Area influenced by the operation of the man-basket will be taken into consideration. Competency of personnel to execute the works on the equipment will be assessed. Availability and safety of man-basket, operator, hand-tools, measuring equipment, connectors, hoses and the N2 Bottle will be ensured.

2 HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL and/or its PMC requirements and instructions. In addition all employees and GAMA subcontractor employees on site will have gone through GAMA Qatar Site Safety Induction, LINDE ENGINEERING AG Site Safety Induction and QSGTL Safety induction for site safety, health, environmental and security prior to resuming work activities at site. Other training courses (i.e. Working in Confined Spaces, Working at Heights, etc.) will be attended as required by LINDE ENGINEERING AG or QSGTL and/or PMC. Risk Assessment will have been prepared by the Risk Assessment Team (RAT) ranking the hazards associated with project works and control measures to be taken to mitigate the hazards to an acceptable level. Each scope work or task will have a completed and approved Job Safety Analysis (JSA) GAM-MTS-PRE-GTL-002

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GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer

Date/Rev. No :

identifying the potential hazards and control measures that will be implemented to protect people and environment. The JSA (RA) will be used by Supervisor as the basis of conducting his daily TSTI meeting and his weekly Tool Box Talk. For additional safety requirements for a particular or specific task please refer to the JSA prepared for that task. All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves) at site at all times as required.

3 REFERENCES T-4.233.760

:

T-4.233.891

:

T-13.376.921 T-13.377.539

: :

Cryogenic Vaporizer Steam Heated-O2 Vaporizer and Condensate Vessel Cryogenic Vaporizer Air Heated – N2 Vaporizer Preservation Procedure Preservation of New Equipment, Technical Specification Flawless Start-up

4 DEFINITIONS Company Contractor Sub Contractor Contract QCP ITP QA/QC HSSE JSA (RA) FSI CA

: : : : : : : : : : :

Package Unit

:

CV ASU MSDS

: : :

QSGTL and/or its PMC Linde Engineering AG GAMA QATAR Co. W.L.L. QSGTL Pearl Project – C2 ASU Construction Works Quality Control Procedure Inspection and Test Plan Quality Assurance / Quality Control Health, Safety, Security and Environmental Job Safety Analysis (Risk Assessment) Flawless Start-up Initiative Construction Area Major components assembled at the manufacturers plant e.g. Linde Engineering AG Cryogenic Vaporizer Air Separation Unit Material Safety Data Sheet

5 RESPONSIBILITIES 5.1 SITE MANAGER The Site Manager will provide inputs to the project execution plan to ensure that strategies & philosophy of the project are properly addressed.

5.2 FSI MANAGER The FSI Manager is responsible for the overall management of the Preservation Team to ensure that safe and effective operations are conducted and properly documented.

GAM-MTS-PRE-GTL-002

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Doc. Title

Q A T A R

:

GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer

Date/Rev. No :

5.3 CLEANLINESS & PRESERVATION ENGINEER He will be overall responsible for planning and safe execution of the whole job including: Organizing of equipments, material and tools needed for the job. Confirming the preservation location. Assigning skilled personnel for the job. Conducting TSTI with the concerned work force prior to start of work. Ensuring that relevant work permits and Method Statement for the job are obtained prior to start of work and made available at site. Conducting of activities to be carried out for the work in a safe manner as per this method of statement. Tagging of the vessel(s) and keeping the records. Records are auditable by Company. Conduct inspection and surveillance. Notify to Contractor engineer for inspection as applicable. Ensure that all Contractor and Company regulations are followed. Ensure that all personnel involved are in safe working condition at all times.

5.4 LIFT SPECIALIST Shall be operating the man-basket (if and as required), to achieve a safe measuring and filling of N2 gas in the Cryogenic Vaporizers.

6 RESOURCES 6.1 EQUIPMENT & MANPOWER A list of equipment and manpower is given below.

6.1.1 EQUIPMENT Manometer T-piece Hose Gas Pressure Regulator Atmospheric Monitoring Equipment Nitrogen Bottle Holding Clamps Hand Tools Full PPE and Safety Harness Aerial Platform/ Manlift/ Man Basket

GAM-MTS-PRE-GTL-002

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:

GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer

Date/Rev. No :

6.1.2 MANPOWER Site Manager FSI Manager Cleanliness & Preservation Engineer Man-Basket Operator HSSE Personnel Helpers

7 METHOD OF EXECUTION 7.1 PRE-COMMENCEMENT WORKS 7.1.1 WORK PERMIT The measuring of internal pressure and filling with Nitrogen gas of the Cryogenic Vaporizer starts with the preparation of Method Statement and issuance of a Permit to Work.

7.1.2 TRAFFIC MANAGEMENT PLAN Area will be soft barricaded and secured. Access road to operation area and enough space for movement of man-basket during operation will be arranged and made available.

7.1.3 EQUIPMENT AND PERSONNEL All equipment shall be inspected, tested and approved by the CONTRACTOR. All equipment and tools shall be available at the site. All personnel shall be inducted and trained before they commence work on site and have sufficient knowledge. All personnel shall be competent to execute all the works pertaining measuring N2 pressure and filling as required of Cryogenic Vaporizer.

8 MEASURING AND FILLING PROCEDURE 8.1 GENERAL The Cryogenic Vaporizer is filled with N2 gas to avoid oxidation of internals and needs to be kept at this state during storage and after erection up to the time of commissioning. The N2 pressure will be checked at intervals of one month by the CONTRACTOR, and will be refilled as required to achieve 0.5 bar internal pressure. Observations will be properly recorded, and copies will be forwarded to COMPANY. The vessel(s) (Cryogenic Vaporizer) and or the container will be tagged appropriately after GAM-MTS-PRE-GTL-002

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GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer

Date/Rev. No :

each inspection and/ or refilling to reflect the status of preservation. (See Attachment-2 for samples).

8.2 ASSEMBLY and CHARGING Read the dials supplied on Cryogenic Vaporizer and record the readings. If the readings are below 0.5 bar (50 kPa/ 7.25 psi/ 0.5 atm) fill as required. Perform Gas Testing if the Cryogenic Vaporizer is in a confined space. Adjust the filling nozzle to properly connect with filling equipment. Position the N2 Bundle securely on ground. Do not expose the N2 Bundle to direct sun-light for elongated durations. Operate and position the man-lift so that the measuring and filling operation can be performed safely and effectively. Remove the plug on the ½” Ball Valve on a suitable charging nozzle. Attach the T-Piece on the Ball Valve. Install the Manometer on one of the free ends of the T-Piece. Connect the hose to the other end of the T-Piece. Connect the other end of hose to the Isolation Valve. Ensure the Isolation Valve is at “closed” position. Connect the Isolation Valve to the Gas Pressure Regulator. Check that Gas Pressure Regulator is at its lowest setting. Connect the Gas Pressure Regulator to the N2 Cylinder . Turn the Ball Valve (existing valve on the vessel) open. Record the internal pressure displayed on the Manometer. If it is less than 0.5 bar, open N2 Cylinder valve slowly to avoid pressure shock. Increase output of the Gas Pressure Regulator to 0.5 bar. Turn the Isolation Valve slowly to “open” position. Check the Manometer to read 0.5 bar. Turn the Isolation Valve off, when 0.5 bar is reached. Turn the Ball Valve on the vessel off.

8.3 DISASSEMBLY and DELIVERY Disconnect the T-Piece from the Ball Valve. Plug the Ball Valve with the previously removed ½” plug and use a gasket to ensure tightness. Dismantle the arm of the Ball Valve and using a duct tape attach on or near to the Ball Valve to alleviate future operations. Affix (if missing) an A4 size easily readable “danger notice” (supplied) on all sides of the vessel or on to the door of container, as required to ensure visibility at both sides of the vessel. Affix (if missing) an A4 size easily readable “warnings” (supplied) on all sides of the vessel or on to the door of container, as required to ensure visibility at both sides of the vessel. Affix (if missing) an 10cm X 10cm size easily visible “safety signs” (supplied) on all sides of the vessel or on to the door of container, as required. Store the N2 Bundle as instructed on MSDS.

GAM-MTS-PRE-GTL-002

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Doc. Title

Q A T A R

:

GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer

Date/Rev. No :

9 QUALITY ASSURANCE A Quality Assurance System shall be operated conforming to related standards.

10 ATTACHMENTS 10.1 JOB SAFETY ANALYSIS 10.2 TAGS and SIGNS (Sample)

GAM-MTS-PRE-GTL-002

Page 10 of 10

Q A T A R

JOB SAFETY ANALYSIS / RISK ASSESSMENT

JSA Number: T-4.305.139

NEW

Page No: 1 of 5

REVISED

Job being analysed: NITROGEN FILLING, MOLECULAR SIEVE ADSORBER JSA Members: Mr. Oguz Baskoylu, Mr. Emre Yazıcı Department/Section doing JSA: HSSE & Mechanical Dept. Job Performers: Mr. Osman Davaslıgil, Mr. Seyfettin Bayrak Normal Approvals: Name Signature Date General job requirements / Common Personnal Protective Equipment. JSA by:

Job Supervisor:

Mr.Emre Yazıcı

23.09.2008

Mr. Osman Davaslıgil

23.09.2008

Additional Approvals (Determined by Job Supervisor in correlation with LINDE HSSE Manager). Name Signature Discipline Superindent(LINDE) SHES Representative(LINDE) OTHERS (List Below):

Date

1. The following Personal Protective Equipment shall be worn while installing manbasket: Approved coveralls, safety glasses, safety helmet, safety steel toe shoes and gloves.

2. Permit To Work.

Approval required for hazardous work detailed in the LINDE work permit procedure. Changing conditions and emergency procedures: Stop work. Switch of equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing employees are reported to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning to work. LINDE EMERGENCY TELEPHONE NO.

HSSE MANAGER: RLIC HOT LINE :

583 40 72 474 88 88

Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work. 2) Use additional sheets as necessary. 3) Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and shell Safety and Environment Procedures.

JOB SAFETY ANALYSIS / RISK ASSESSMENT T-4.305.139

JSA Number: QT- 4.xxx.yyy A T A

Q A T A R

Job Performers: Mr. Osman Davaslıgil, Mr. Seyfettin Bayrak ITE M

1

ACTIVITY Using of Manlift

HAZARD / POTENTIAL CONSEQUENCES

1,1

Initial Risk

P C

CURRENT CONTROLS

RISK RANK

Mechanical Breakdown

Equipment shall be serviced 1.1.1.1 maintained and inspected as per set maintenance and inspection program.

Ensure equipment to be provided with controls of the dead man type, which only allow movement of the machine to take place whilst they are actually being operated.

1.1.2

Ensure E-Stop is in place through the 1.1.1.2 control system. Perform equipment daily check prior 1.1.1.3 to use. Supervisor shall ensure that work will be properly supervised as per work method statement.

Dead man controls automatically return to the neutral position. Appropriate trained & certified persons only to use equipment.

1.1.4

1.1.5 Improper use of equipment

1.2.1

B

3 #####

ADDITIONAL CONTROLS

1.1.1

## 3 ##### 1.1.3

1,2

SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, CRYOGENIC VAPORIZER

1.2.2 1.2.3

Ensure an emergency stop should be provided on the platform control panel. Manlift shall not be used as cranes or 1.2.1.1 jacks unless they have specifically been designed for this purpose by their manufacturers. Leaning out of the platform will not be 1.2.1.2 allowed. Colour code sticker to be available on 1.2.1.3 the equipment.

Residual Risk

P C

R

A

3 #####

A

3 #####

Ensure equipment is inspected, approved & colour coded as per colour code chart. Current inspection sticker must be in place.

JOB SAFETY ANALYSIS / RISK ASSESSMENT T-4.305.139

JSA Number: QT- 4.xxx.yyy A T A

Q A T A R

Job Performers: Mr. Osman Davaslıgil, Mr. Seyfettin Bayrak ITE M

ACTIVITY

HAZARD / POTENTIAL CONSEQUENCES

1,3

Initial Risk

P C

CURRENT CONTROLS

RISK RANK

Untrained personnel

1.3.1

1.3.2 B

3 #####

## 3 ##### 1.3.3 1.3.4

1,4

Fall of personnel

1.4.1

B

SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, CRYOGENIC VAPORIZER

5 ##### 1.4.2

Ensure platforms must only be used by authorized personnel who have been trained in the operation of the type of platform in use. Initial training should cover operating principles, machine controls and environmental conditions, which are likely to be encountered. Training and practice in this type of work undertaken is essential. Ensure that equipment operator is certified by third party, valid certificates. Safety harness shall be provided for the use of all personnel working from mobile work platforms so that in the event of any advertent movement of the platform they are working from, they will not be thrown from it.

ADDITIONAL CONTROLS 1.3.1.1

1.4.1.1

Boxes, hop-ups or ladders will not be 1.4.1.2 used to gain additional height or reach from the platform of manlift machine work platform.

Residual Risk

P C

R

Ensure supervisor/foreman who will be using the manlift should be particularly aware of the hazards which may be encountered whilst using these machines and of the precautions which may be taken to eliminate or minimize the hazards. A

3 #####

A

3 #####

A

4 #####

Discuss working at height hazards in TSTI.

Supervisor shall ensure that work will be properly supervised at all times as per work method statement.

JOB SAFETY ANALYSIS / RISK ASSESSMENT T-4.305.139

JSA Number: QT- 4.xxx.yyy A T A

Q A T A R

Job Performers: Mr. Osman Davaslıgil, Mr. Seyfettin Bayrak ITE M

ACTIVITY

HAZARD / POTENTIAL CONSEQUENCES

1,5

Initial Risk

P C

CURRENT CONTROLS

RISK RANK

Overturning of Machine

Ensure no excessive force by the operator on the platform by introducing an element of side load.

1.5.2

The outriggers or stabilizers, when 1.5.1.2 fitted, shall be fully extended and in position, before the platform or boom is raised. The platform shall not be overloaded 1.5.1.3 exceeding the regulated safe working load. Ensure the machine will be located to the most suitable position for the job to be carried out before any slewing takes place. Slewing of the boom to the extent that causes the machine to overturn shall be avoided. Ensure all vehicle movement to be guided by competent banks men with high visibility vests. Ensure that each piece of equipment is fitted with an automatic reverse alarm and beacon or strobe light.

4 ##### 1.5.3

1.5.4

1.5.5

1,6

Vehicle Movement

1.6.1

B

ADDITIONAL CONTROLS

1.5.1

## 3 ##### B

SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, CRYOGENIC VAPORIZER

3 ##### 1.6.2

1.5.1.1

When a manlift needs work in a congested area, an approval for the operation shall be obtained from HSSE dept of Gama/Linde authorized personnel's. Considering the effects of the acceleration and deceleration of the manlift. Discuss in TSTI.

Residual Risk

P C

R

A

3 #####

A

4 #####

A

3 #####

JOB SAFETY ANALYSIS / RISK ASSESSMENT T-4.305.139

JSA Number: QT- 4.xxx.yyy A T A

Q A T A R

Job Performers: Mr. Osman Davaslıgil, Mr. Seyfettin Bayrak ITE M

2

ACTIVITY Transportation of nitrogen bottle

HAZARD / POTENTIAL CONSEQUENCES

2,1

Initial Risk

P C

Moving of the nitrogen bottle to the "filling position" via man-lift

RANK

2.1.1 A

3

CURRENT CONTROLS

RISK

Damaging of cylinder 4 #####

3,1 Dropped bottle

3.1.1 ## C 3 5 ##### ##### 3.1.2

4

Nitrogen filling

4,1

Dropped tools

4,2

Gas Leakage

4,3

Inhaling nitrogen

4.1.1 A

4 #####

A

4 #####

B 4,3

Handling pressurized equipment

B

ADDITIONAL CONTROLS

Ensure the bottle is securly tied to the 2.1.1.1 vehicle. 2.1.1.2

Ensure that the nitrogen bottle is tied 3.1.1.1 to the basket rails of the man-lift using metal or plastic clamps. Barricade and secure the working area with sign boards to prevent unauthorized entry. Ensure that all hand tools are carried in a tool box or attached to the personnel.

Perform Gas Testing prior to start of operation. 4,3,1 Ensure that the operation is carried 5 ##### out in a well ventilated area or out doors. 4,4,1 Ensure that valve protection cap is in place.

2 #####

SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, CRYOGENIC VAPORIZER

Ensure the driver is warned to avoid abrubt manouvers. Ensure that the people are instructed to avoid to drop the bottle while carrying. Discuss in TSTI.

4.1.1.1

Install barricades "exclusion zone" with sign boards indicating nitrogen filling works in progress to prevent unauthorized entry.

4.3.1.1

Install "INERT GAS WARNING" signs, as necessary.

4.4.1.1

Remove protection cap only to connect the bottle to the filling point. Use a check-valve.

Residual Risk

P C

R

A

4 #####

A A

3 4 ##### #####

A

3 #####

4,2,1

Ensure the regulator is connected to 4.4.1.2 the bottle and operational. Ensure that the bottle is kept under 50 4.4.1.3 degrees Celcius and not in elongated direct contact with sunlight. Ensure that the bottle valve is opened slowly to avoid pressure shock. Ensure backfeed is not allowed into the bottle.

Isolate cylider (bottle) at cylinder valve when not in use.

Doc. Title

:

Q A T A R Date/Rev. No :

GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer