Method Statement for Tie-Ins During Shutdown
Short Description
Method statement...
Description
JANUARY, 2016
DOCUMENT NUMBER: [K2S-NG01007551-SOKG1-MX6180-00003]
Shell Petroleum Development Company of Nigeria Classification Status: [Restricted]
FABRICATION AND INSTALLATION OF END FACILITIES AT THE SOKU GAS PLANT [METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN]
Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Petroleum Development Company The Process Manager for this procedure is the Major Projects General Manager, the Process Owner is the Major Projects Project Services Manager Revision
Date
Description
R01
14.01.2016
Issue for Internal Review
Originator
FELIX ANYANELE
Checker
Approver
T.S. PACURARIU
IKENNA ONYEKONWU
ADDITIONAL AGREEMENT/APPROVAL RECORD PARTY
REF IND.
NAME
SIGN
DATE
Revision Philosophy All revisions for review will be issued at R01, with subsequent R02, R03, etc as required. All revisions approved for issue or design will be issued at A01, with subsequent A02, A03, etc as required. Documents approved for Construction will be issued at C01, C02, and C03 respectively. Documents or drawings revised as “As built” will be issued as Z01, Z02 Z03 etc. Narrative sections revised from previous approved issues are to be noted in the table below and/or highlighted in the RH margin (using the appropriate revision status) thus: | A02 Previous revision highlighting to be removed at subsequent issues. Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas and by the use of a triangle containing the revision status.
Revision History REVISION NO.
DATE OF ISSUE
REASON FOR CHANGE
K2S-NG01007551-SOKG1-MX6180-00003
METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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TABLE OF CONTENT
S. NO.
DESCRIPTION
PAGE NOS.
1.
INTRODUCTION
4
2.
SCOPE
4
3.
REFERENCES
4
4.
RESPONSIBILITIES
5
5.
MANPOWER, MACHINERY AND EQUIPMENT
6
6.
HSE REQUIREMENTS
7
7.
PROCEDURE
7
8.
ATTACHMENT
17
K2S-NG01007551-SOKG1-MX6180-00003
METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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1.0 INTRODUCTION This method statement provides operational guidance and methods to be adopted in carrying out Tie-in activities during shutdown for the EPC FOR KOLO CREEK TO SOKU GAS EXPORT PIPELINE Project as per the technical specification and standards applying best industrial practice and applicable technical specifications and standards.
2.0 SCOPE The scope is to define the detailed activities for the identified tie-ins during plant shutdown of SOKU Plant. This shall include the installation of connecting piping works for the shutdown.
3.0 REFERENCES
Project Quality Plan
K2S-NG01007551-SOKG1-AA5759-00001
Project HSSE Management plan
K2S-NG01007551-SOKG1-HX5798-00001
Construction Plan
K2S-NG01007551-SOKG1-BA5736-00002
Procedure for Radiographic Examination
K2S-NG01007551-SOKG1-MX6180-00005
Procedure for Ultrasonic testing
K2S-NG01007551-SOKG1-MX6180-00009
Procedure for Magnetic Particle Inspection K2S-NG01007551-SOKG1-MX6180-00006 Procedure for Tie-in
K2S-NG01007551-SOKG1-MX6180-00001
Approved WPS
Piping – General Requirements
DEP 31.38.01.11-Gen.
Piping Classes - Refining and Chemicals
DEP 31.38.01.12-Gen.
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METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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4. RESPONSIBILITIES
CONSTRUCTION MANAGER Shall be responsible for:
The construction team by coordinating the various tie-in activities involved during construction.
The implementation of the Work Procedure and the Inspection and Test Plan during the shutdown window.
LEAD FIELD SUPERVISOR Shall be responsible for:
Managing all the resources, developing and managing procedures and processes.
Ensuring that the construction works is sufficiently supported and conducted in accordance with approved procedures, documents and drawings.
Shall report to the Construction Manager.
Shall be responsible for all raw data quality checks and coordinate with the QA/QC Inspector in the implementation of the checks as mentioned in the Inspection and Test plan (ITP).
QA/QC MANAGER Shall be responsible for:
Preparation of quality plans to ensure the required quality of WORK is attained in accordance with applicable DEPs, and project specifications.
Verification of activities to ensure shutdown work is in compliance with the procedures or method statement.
Preparation, monitoring and execution of the Quality Audit Programme.
Liaison with COMPANY representative on all matters relating to the shutdown work and the planned quality delivery.
QA/QC INSPECTOR Shall be responsible for:
Reporting to the QA/QC Manager.
Carrying out all field inspections and checking as specified in the ITP in addition to coordinating with the Company representative.
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METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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HSE COORDINATOR He shall be responsible for:
Coordinating safety programs regarding the work.
Enforcing safety regulation and maintains safety records
Developing and maintaining the Project Safety Plan.
Verifying program and implementation of HSE procedure by conducting audits.
5.0 PERSONNEL, MACHINERY & EQUIPMENT 5.1 Personnel S. NO.
Personnel
1.
Qualified Welders (Structural & Piping)
2.
Supervisors (Structural & Piping)
3.
Fitters
4.
Welder Mates
5.
HSE Officers
6.
QC Inspectors
7.
Hydrotest Team
8.
Torquing Team
9.
Scaffolders
10.
Approved NDT Party
11.
Painters (where applicable)
12.
Operators (crane, manlift)
5.2 MACHINERY & EQUIPMENT: S. NO.
DESCRIPTION
1.
Crane
2.
Welding Machines
3.
Baking Ovens
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METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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4.
PPE’s
5.
Loader Truck
6.
Man Lift
7.
Hydrotest equipment e.g. pressure pump, chart recorder, gauges, hose, manifold etc)
8.
Torque Wrench
6.0 HSE REQUIREMENTS Prior to commencing the works a detailed Job Hazard Analysis shall be carried out. After all known, suspected or potential hazards and risks have been identified, the work force shall be informed of the hazard and control measures that must be put in place to eliminate or control the hazard and potential risk. All personnel involved in the shutdown activity shall receive safety training induction All personnel to be engaged in this work shall be properly mobilized and inducted. This is to enable them to appreciate the risk hazards involved in the operations. All workers shall be medically fit to work. The health, safety and environment of all personnel shall be safeguarded to avoid injuries and illness. There shall be a qualified first aider, fully equipped with first aid drugs required in the first aid administration. Dedicated site HSE officers shall man all work sites. An authorized Gas Tester shall carry out Gas Monitoring tests before any isolation work is carried out, and will then continuously monitor the work atmosphere, he shall ensure that gas monitoring records are kept. Warning signs and barriers shall be positioned around all work areas. All personnel shall wear the appropriate PPE reference Job Specific JHA. All the work force shall comply with the Contractor’s Health, Safety and Environment requirements as per the HSE plan. Only authorized personnel shall be allowed into the work area. All necessary measures as per Client’s requirements or manufacturer’s recommendations shall be adhered to. K2S-NG01007551-SOKG1-MX6180-00003
METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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PTW and the JHA shall be signed off.
7.0 PROCEDURE Before beginning any shutdown activities Client and Contractor shall agree the programme for the shutdown work and all the Tie-in area has been verified and checked by the SPDC Operation Representative. 7.1 Flanged Tie -In: 7.1.1
Production Manifold Tie-in No.
From
To existing
TP-006A
12”-P-11901-153451
20”-P-10502-15350X
TP-006B
12”-P-11902-153461
20”-P-11902-K2S153834
The mode of operation for the above mentioned tie-in is as indicated in the below table: S/No
TASK STEPS
STEP DESCRIPTION
1
Work area Inspection
2
Position the equipment & pipes
3
Operation
REMARKS
Ensure that the lines to be tied into are well isolated and free of hydrocarbon. Conduct Gas test prior to the commencement of the operation. Ensure that hot work permit is obtained prior to start of work.
SPDC/ Nestoil responsible for purging of hydrocarbon if necessary. Use of appropriate PPE Personnel to work carefully at all times.
Carefully position required equipment Ensure the use of correct and spool on designated work space. tools and the right PPE. Lift the spool into position and align it to Ensure that all hand held the tie-in position. tools and equipment are in a good working condition. to work Slack Bolts and remove the existing blind Personnel flange on 20”-P-10502-15350X & 20”-P- carefully at all times. 10840-153832. Connect the 12” spool as well as double Ensure the use of correct block and bleed valves for TP006A (10-BV- tools and the right PPE. 132, 10-BV-133 & 10-BV-134) & TP006B (10-BV-135, 10-BV-136, 10-BV-137) in Ensure that all hand held tools and equipment are closed position to the existing flanges. Ensure bolts and blind flange are properly in a good working installed and torqued to the approved condition. values.
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METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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7.1.2
Process flow line from fiscal metering (EGGS-1) to slug catcher Tie-in No.
From
To existing
TP-015
2”-P-11904-91412
24”-P-36009-91410-H
The mode of operation for the above mentioned tie-in is as indicated in the below table: S/No
1
TASK STEPS
Work area Inspection
STEP DESCRIPTION
REMARKS
SPDC/ Nestoil responsible for purging of hydrocarbon if necessary.
Ensure that the lines to be tied into are well isolated and free of hydrocarbon. Conduct Gas test prior to the commencement of the operation. Ensure that hot work permit is obtained prior to start of work.
Use of appropriate PPE Personnel to work carefully at all times.
2
Position the equipment & pipes
3
Operation
Carefully position required equipment Ensure the use of correct and spool on designated work space. tools and the right PPE. Lift the spool into position and align it to Ensure that all hand held the tie-in position. tools and equipment are in a good working condition. Personnel to work Slack Bolts and remove the existing 2” carefully at all times. blind flange from line 24”-P-36009-91410H. Ensure the use of correct Connect new 2” spool including a double tools and the right PPE. block and bleed valves in closed position (11-BV-008, 11-BV-009, and 11-BV-010). Ensure that all hand held Ensure bolts and blind flange are properly tools and equipment are installed and torqued to the approved in a good working values. condition.
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METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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7.1.3
Chemical line Tie-in No.
From
To existing
TP-001
2”-C-64319-151412
2”-C-64564-151410
The mode of operation for the above mentioned tie-in is as indicated in the below table: S/No
1
TASK STEPS
Work area Inspection
STEP DESCRIPTION
REMARKS
SPDC/ Nestoil responsible for freeing the system of methanol if necessary.
Ensure that the lines to be tied into are well isolated and free of methanol. Conduct Gas test prior to the commencement of the operation. Ensure that hot work permit is obtained prior to start of work.
Use of appropriate PPE Personnel to work carefully at all times.
2
Position the equipment & pipes
3
Operation
Carefully position required equipment Ensure the use of correct and spool on designated work space. tools and the right PPE. Lift the spool into position and align it to Ensure that all hand held the tie-in position. tools and equipment are in a good working condition. Personnel to work carefully at all times. Loosen blind on line 2”-C-64564-151410. Install 2” spool with double block and Ensure the use of correct bleed valves (64-BV-001, 64-BV-002, and tools and the right PPE. 64-BV-023). Ensure bolts and blind flange are properly Ensure that all hand held installed and torqued to the approved tools and equipment are values. in a good working condition.
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METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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7.1.4
Blow down line to HP Flare Tie-in No.
From
TP-007
20”-B-11905-13451
To existing 24”-B-66001-1149
The mode of operation for the above mentioned tie-in is as indicated in the below table: S/No
1
TASK STEPS
Work area Inspection
STEP DESCRIPTION
REMARKS
SPDC/ Nestoil responsible for purging of hydrocarbon if necessary.
Ensure that the lines to be tied into are well isolated and free of hydrocarbon. Conduct Gas test prior to the commencement of the operation. Ensure that hot work permit is obtained prior to start of work.
Use of appropriate PPE Personnel to work carefully at all times.
2
3
Position the equipment & pipes
Operation
Carefully position required equipment Ensure the use of correct and spool on designated work space. tools and the right PPE. Lift the spool into position and align it to Ensure that all hand held the tie-in position. tools and equipment are in a good working condition. No AFC drawing from Nestoil Loosen 14” blind on line and remove. Install 14” valve and blind. Ensure bolts and blind flange are properly installed and torqued to the approved values.
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METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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7.1.6
Condensate from slug catcher to condensate drum Tie-in No.
From
To existing
TP-005
8”-P-11905-91432
12”-P-51020-9143
The mode of operation for the above mentioned tie-in is as indicated in the below table: S/No
1
TASK STEPS
Work area Inspection
STEP DESCRIPTION
REMARKS
SPDC/ Nestoil responsible for purging of hydrocarbon if necessary.
Ensure that the lines to be tied into are well isolated and free of hydrocarbon. Conduct Gas test prior to the commencement of the operation. Ensure that hot work permit is obtained prior to start of work.
Use of appropriate PPE Personnel to work carefully at all times.
2
Position the equipment & pipes
3.
Operation
Carefully position required equipment Ensure the use of correct and spool on designated work space. tools and the right PPE. Lift the spool into position and align it to Ensure that all hand held the tie-in position. tools and equipment are in a good working condition. Nestoil to provide AFC. Loosen blind on line 12”-P-51020-9143. Install 8” spool with double bock and Isometric to confirm exact bleed valves (11-BV-024, 11-BV-025, and tie-in position. 11-BV-026) in closed position. Ensure bolts and blind flange are properly Ensure the use of correct installed and torqued to the approved tools and the right PPE. values.
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METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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7.1.7
Instrument air Tie-in No.
From
To existing
TP-017
2”-A-68600-11412
2”-A-68021-1841
The mode of operation for the above mentioned tie-in is as indicated in the below table: S/No
TASK STEPS
STEP DESCRIPTION
1
Work area Inspection
2
Position the equipment & pipes
3.
Operation
REMARKS
Ensure that the lines to be tied into are Use of appropriate PPE well isolated. Conduct Gas test prior to the commencement of the operation. Ensure that hot work permit is obtained prior to start of work. Personnel to work carefully at all times. Carefully position required equipment Ensure the use of correct and spool on designated work space. tools and the right PPE. Lift the spool into position and align it to Ensure that all hand held the tie-in position. tools and equipment are in a good working condition. Personnel to work carefully at all times. Loosen 2” blind flange on line 2”-A-680211841. Ensure the use of correct Install 2” isolation valve in closed position. tools and the right PPE. Ensure bolts and blind flange are properly installed and torqued to the approved Ensure that all hand held tools and equipment are values. in a good working condition.
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METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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7.2
Threaded Tie-In:
7.2.1
Instrument air Tie-in No.
From
To existing
TP-018
3”-A-68008-11412
3”-A-68507-18410
The mode of operation for the above mentioned tie-in is as indicated in the below table: S/No
TASK STEPS
STEP DESCRIPTION
1
Work area Inspection
2
Position the equipment & pipes
3.
4.
Qualification of Personnel and WPS
Operation
REMARKS
Ensure that the lines to be tied into are Use of appropriate PPE well isolated and free of hydrocarbon. Conduct Gas test prior to the commencement of the operation. Ensure that hot work permit is obtained prior to start of work. Personnel to work carefully at all times. Carefully position required equipment Ensure the use of correct and pipes to be welded on designated tools and the right PPE. work space. Lift the spool into position and align it to Ensure that all hand held the tie-in position. tools and equipment are in a good working condition. Ensure that the WPS to be used is Ensure the use of Qualified Personnel at all approved. Ensure that the Welders are qualified in times accordance with the approved WPS. Personnel to work Cut cap on line 3”-A-68507-18410. carefully at all times. Thread existing line with dicing machine. Install coupling on existing line. Ensure the use of correct Tie-in 3” spool on existing line. tools and the right PPE. Ensure bolts and blind flange are properly installed and torqued to the approved Ensure that all hand held values. tools and equipment are
K2S-NG01007551-SOKG1-MX6180-00003
METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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in a good condition.
7.2
Weld Tie-In:
7.2.2
Closed drain from NAG slug catcher & Pig receiver Tie-in No.
From
To existing
TP-015A/B
4”-D-11904-11482
4”-D-45092-91481
working
The mode of operation for the above mentioned tie-in is as indicated in the below table: S/No
TASK STEPS
STEP DESCRIPTION
1
Work area Inspection
2
Position the equipment & pipes
3.
Qualification of Personnel and WPS
4.
Operation
REMARKS
Ensure that the lines to be tied into are Use of appropriate PPE well isolated and free of hydrocarbon. Conduct Gas test prior to the commencement of the operation. Ensure that hot work permit is obtained prior to start of work. Personnel to work carefully at all times. Carefully position required equipment Ensure the use of correct and pipes to be welded on designated tools and the right PPE. work space. Lift the spool into position and align it to Ensure that all hand held the tie-in position. tools and equipment are in a good working condition. Ensure that the WPS to be used is Ensure the use of Qualified Personnel at all approved. Ensure that the Welders are qualified in times accordance with the approved WPS. to work Carry out probing for underground Personnel facilities prior to the commencement of carefully at all times. the excavation. Excavate and expose the existing Ensure the use of correct tools and the right PPE. underground close drain piping. Cold cut the existing 4” portion of the pipe where the new connection is to be welded Ensure that all hand held and block the opening using clay in order tools and equipment are
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7.2.3
to prevent the gas from the line from in a good escaping. condition. Connect the new line and execute the field weld. Flush the clay plug with water under pressure. Ensure that NDT is carried out as per the inspection class and in accordance with the project DEP. Ensure bolts and blind flange are properly installed and torqued to the approved values.
working
Open drain from NAG slug catcher & Pig receiver Tie-in No.
From
To existing
TP-016A/B
4”-D-10310-11432
4”-D-46101-11481
The mode of operation for the above mentioned tie-in is as indicated in the below table: S/No
TASK STEPS
STEP DESCRIPTION
1
Work area Inspection
2
Position the equipment & pipes
3.
Qualification of Personnel and WPS
REMARKS
Ensure that the lines to be tied into are Use of appropriate PPE well isolated and free of hydrocarbon. Conduct Gas test prior to the commencement of the operation. Ensure that hot work permit is obtained prior to start of work. Personnel to work carefully at all times. Carefully position required equipment Ensure the use of correct and pipes to be welded on designated tools and the right PPE. work space. Lift the spool into position and align it to Ensure that all hand held the tie-in position. tools and equipment are in a good working condition. Ensure that the WPS to be used is Ensure the use of Qualified Personnel at all approved. Ensure that the Welders are qualified in times accordance with the approved WPS.
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4.
Operation
Carry out probing for underground facilities prior to the commencement of the excavation. Excavate and expose the existing underground close drain piping. Cold cut the existing 4” portion of the pipe where the new connection is to be welded. Connect the new line and execute the field weld. Ensure that NDT is carried out as per the inspection class and in accordance with the project DEP. Ensure bolts and blind flange are properly installed and torqued to the approved values.
Personnel to work carefully at all times. Ensure the use of correct tools and the right PPE. Ensure that all hand held tools and equipment are in a good working condition.
8.0 ATTACHMENT Document No.
a) b) c) d) e) f) g) h) i)
Tie-in No.
K2S-NG01007551-SOKG1-MP2343-00002-001 K2S-NG01007551-SOKG1-MP2343-00002-001 K2S-NG01007551-SOKG1-MP2343-00002-001 K2S-NG01007551-SOKG1-MP2343-00002-001 K2S-NG01007551-SOKG1-MP2343-00002-001 K2S-NG01007551-SOKG1-MP2343-00002-001 K2S-NG01007551-SOKG1-MP2343-00002-001 K2S-NG01007551-SOKG1-MP2343-00025-001 K2S-NG01007551-SOKG1-MP2343-00027-001
K2S-NG01007551-SOKG1-MX6180-00003
TP-001 TP-005 TP-006A TP-006B TP-015 TP-017 TP-018 TP-016A/B TP-015A/B
METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN
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