,.c> .

,JQI Comments Resonse Sheet

Orp1c (120476/Jl-02022/27-06-01/MMS-04 Rev. 5)
DAU trofac 1 d ••• =- "
al Hassan
SI.
Contractor Comments on Rev.04 AHEC Response AHEC DPJV Signature Remarks

M s.
No.

1
Construction/ Engieering Comments at Page
No. 6, 7 & 17. , '
Method Statement revised as per Construction/
Engieering Comments at Page No. 6, 7 & 17.

CRS Page 1
 DAELIM Petrofac
DAELIM-Petrofac SRIP JV
.:, ,,, -. II
al Hassan
CONTRACT NO. - 21297 JOB NO :120476 / Jl-2022 AHEC JOB NO.:B-212

SOHAR REFINERY IMPROVEMENT PROJECT

METHOD STATEMENT

FOR

UNDER GROUND GRP PIPING

PACKAGE - 3 & 4

- A

Revised as per
5 07-July-2015
comments
As per comme.nts
4 27-May-2015 JHA Revised & MHDS
I
attached
As per HSE'
3 14-May-2015 comments JHA
Revised
FPI Documents
2 03-Jan-2015 Attached for
Approval
Comments
1 09-Nov-2014 incorporated & re
issued for Approval
Owais Deepak Kameshwar
0 8-0ct-2014 For Review
Kareem Pawar Rao
Prepared Checked PROJ. ENG. SIGN
Rev. Date Descriptior Approved by
by by DP - JV APPROVAL

DOCUMENT TYPE : DOCUMENT NO. Page

AHEC JOB NO.:B-212
Mechanical Method 120476 / JI -02022 /
1of 27
Statement 27-06-01 / MMS - 04
,).,Jq Method Statement For Under Ground
i GRP Piping - rol&: 1 1.
al Hassan
Orp1c
INDEX
Section Page
CONTENTS
No: No.
1 PURPOSE 3
2 SCOPE 3
3 REFERENCES 3
4 DEFINITIONS / ABBREVIATIONS 4
5 MANPOWER 5
6 RESPONSIBILITIES 5
7 EQUIPMENTS &INTRUMENTS 6
8 HANDLING & STORAGE 6
8.1 LOADING & UNLOADING 6
8.2 STORAGE OF MATERIAL 7
9 I NSTALLATION OF UNDERGROUND PIPE SYSTEM 8
9.1 THE TRENCH CONSTRUCTION 8
9.2 SPOOLS LAYING 9
9.3 BACKFILLING 9
10 ADHESIVE BONDED JOINT 10
10.1 SURFACE PREPARATION PRIOR TO ADHESIVE BONDING 11
10.2 SEQUENCE OF WORK 13
10.3 REPAIR 19
11 LAMINATION JOINT 19
11.1 REPAIR 22
12 FLANGED JOINT 23
13 FLANGE TIGHTENING 23
14 TIE-IN JOINTING, FITTINGS, BENDS 24
15 REPAIRS 25
16 HYDRO TESTING 26
17 HSE REQUIREMENTS 26
17.1 SUPERVISION 26
17.2 HSE REQUIREMENTS 26
17.3 PTW REQUIREMENTS 27
18 DOCUMENTS 27
19 ATIACHMENTS 27

l Doc. No: 120476 / Jl-02022 / 27-06-01 I MMS-04 j Rev. No: 5 j Date: 07-July-2015 Page 2 of 27
 ,) .,JQi Method Statement For Under Ground
Orp1c GRP Piping 1111-1 1 .
1 PURPOSE
.
The purpose of this Method Statement is to define the Scope of Work and sequence
of performing Bell & Spigot Jointing (Adhesive Bonded Joints), Lamination jointing and
Flange Joints of various diameters for the installation of underground GRP piping work for
Sohar RefineryImprovement Project.
This Method Statement is as complete as possible, it is not possible to describe all circumstances
that may be encountered in the field. For this reason FPI experienced supervisor may vary the
described procedure in order to achieve an optimum solution using the latest techniques and
processing method.

2 SCOPE
This Method Statement covers the minimum requirement for the installation of GRP
underground piping work for Sohar RefineryImprovement Project
3 REFERENCES

GRP nstallation Manual Issued by GRP Supplier.

S-000-5360-106 Technical specification for FRP piping and

components.
ISO 14692 - 4 Petroleum and natural gas industries GRP piping
- Fabrication,installation and maintenance.

ISO 14692 - 2 Petroleum and natural gas industries GRP piping

- Qualification & manufacture.

ISO 14692 - 1 Petroleum and natural gas industries GRP piping

- Vocabulary, symbols, applications & materials.

D-000-5311-003 Geotechnical nvestigation (soil report).

ASTM D 1599 Standard Test Method for Resistance to Short

Time Hydraulic Pressure of Plastic Pipe,
Tubing, and Fittings.

ASME B 31.3 Process Piping.

Applicable "Approved For Construction"

Drawings.

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 Page 3 of 27
 "' .,JQI Method Statement For Under Ground
Orp1c GRP Piping DIEIIHetrolac al Hassan
.
4 DEFINITIONS / ABBREVIATIONS
The word shall indicate a requirement.
The word should indicate a recommendation.
The word may indicate a possible course of action.

Oman Oil Refineries and Petroleum Industries

OWNER
Company SAOC

MAIN CONTRACTOR Daelim and Petrofac

DPJV Daelim - Petrofac Joint Venture

SUB
CONTRACTOR Al Hassan Engineering Company SAOG
(AHEC)
Sub Contractors Quality Plan
QP
Future PipeIndustries (FPI)
GRP SUPPLIER
Approved For Construction
AFC
American Standard for Testing Materials
ASTM
Bonding Procedure Specification
BPS
Bonding Procedure Qualification Record
BPQR
Carbon Steel
cs Company Site Representative
CSR
Glass Reinforced Polyester I Glass Reinforced Epoxy
GRP I GRE
Health, Safety and Environment
HSE
International Organization for Standardization
ISO
Inspection and Test Plan
ITP
Methyl Ethyl Ketone
MEK
Methyl sobutyl Ketone
MIBK
Bell Area
BA
Spigot Area
SA
Tapered Spigot
TS
Tapered Bell
TB
Quality Assurance
QA
Quality Control
QC
Inside Diameter
ID
Outside Diameter
OD
Finished Level Ground
FLG
Bottom of Pipe
BOP
Standard
STD
Short-Time Hydraulic Pressure
STHP

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 Page 4 of 27
 ,"' _ ,Jqi Method Statement For Under Ground
Orp1c GRP Piping - ac 1 1 .
al Hassan

S MANPOWER

Allocation of Manpower shall be in line with the Site Organization Chart appended as Annexure to
QP. As a minimum the following personnel shall be available Depending on the activity:
• Construction Manager.
• QA/QC Manager.
• HSE Manager.
• QCInspector.
• Discipline Supervisor / Foreman.
• GRP Supervisor.
• Bonder / Lamination Technician
• Riggers and Helpers.
• Crane Operators.
Personnel involved in these activities shall follow the necessary safety precautions during
preparation, assembly, erection, installation and jointing of GRP piping work.

6 RESPONSIBILITIES

• Construction Manager

Responsible for all site GRE activities and provides assurance that all related activities like
preparation, execution, testing of joints in site fabrication yard as well as job site are
performed in accordance with project specifications, safety and quality requirements.

• QA/ QC Manager

Responsible for a ll quality activities during installation and fina l inspection.

• HSE Manager

Responsible for safety matters and safety monitoring of all activities relating to the
transportation, placement and installation of the unit.

• QC inspector
Shall ensure and monitor the implementation of this Method statement during installation
works.

• Discipline Supervisor / Foreman

Responsible for overall implementation of this Method statement.

Responsible for coordination of lifting activities and communication with others.
Responsible for all installation works including the GRE jointing with qualified technicians.

! Doc. No: 120476 / Jl-02022 / 27-06-01 I MMS-04 ! Rev. No: 5 ! Date: 07-July-2015 ! Page 5 of 27
 ,..) . Method Statement For Under Ground
,JQi GRP Piping Dllll ac l I al Hassan
.
Orp1c
• GRP Supervisor
Shall be responsible for implementation of this Method statement during jointing works.

• Bonder / Lamination Technician

shall have qualification certificate Issued by Vendor for jointing of GRP Pipe / Fitting.

• Riggers & Helpers

directly
Lifting plan is coordinated and communicated to all involved and to communicate
with crane operator during lift.

Ensures the area being barricaded before commencement of any lifting activity with crane.
Identifies the type of lifting arrangement with respect to material.
Ensures tools & tackles used for lifting are inspected and have valid certification.
Helpers shall be equipped with mandatory and work related PPE'S.
Helpers shall follow the instruction of the respective discipline rigger/foremen/engineer.

• Crane Operators
Shall follow the instructions & signals given by Rigger and Banks man.
Shall have Valid Third Party Certification for the respective crane.

7 EQUIPMENTS & INSTRUMENTS

• Appropriate tools & equipment in safe working condition shall be used. The same shall
be monitored by the Discipline Foreman and QCInspector. All inspection instruments shall
have valid calibration at the time of use.

• Equipment shall be handled and operated by the trained or authorized personnel as instructed
by Discipline Foreman and Supervisor only.

• All the equipment shall have valid Third PartyInspection Certificates (Wherever required).

8 HANDUNG & STORAGE

8.1 LOADING & UNLOADING

The GRP pipes, spools, fittings and jointing materials (stored in controlled temperature), etc.
received will be off loaded and stored in suitable designated location.
End protection of piping components shall remain in place during handling & transport.
Chains, wire ropes or clamps will not be used during lifting.
For loading / unloading Suitable Third party certified Nylon or Canvas hoisting belts with a width
of 10cm & 20 cm shall be used.

! Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 ! Rev. No: 5 ! Date: 07-July-2015 Page 6 of 27
 DIEUI "'ac .
,..,,_ , Method Statement For Under Ground
Jqi GRP Piping
al
Hassan
Orp1c
Standard pipe lengths shall be picked up at two or more supporting points. Hoisting belts shall
always be placed around the widest part.
During transportation, all components shall be firmly secured to prevent excessive movement.

8.2 STORAGE OF MATERIAL

In order to avoid damage to the stocked pipes, fittings and bends the following rules must
be observed:

a) Do not lay the pipes directly on the ground, onto rails or concrete floors. Provide a flat
surface, i.e. compacted sand.
b) Pipes shall be stacked in heights up to 1.5 meters with side supports provided.
c) Suitable supports / Spacer stripping shall be used for example Plastic or wooden,
(approximately 10 x 5 cm), as supports for the pipes and as separators between pipe layers.
d) Pipes of small diameter may be stored inside pipe of large diameter and spacers provided to
prevent contact between pipes.
e) Manufacturer instruction should also be followed for storage of pipe, fittings, etc.
f) The distance between supports shall not be more than 3 m. To avoid damage to pipe ends,
stocking shall be undertaken with care. (See Figure below).
g) Pipe stacks shall have side supports or blocks to prevent rolling or slipping of the stack.
h) Unprotected flange-faces shall never be placed directly on the ground or on concrete floors.
i) All pipe ends to be covered.
j) All pipes / flanges / elbows etc. shall be properly covered (if required as per
manufacturer instruction) with suitable / applicable covering.
k) The site storage of cement kits should be maintained under an ambient temperature of
20=25 C under a shaded area or as per manufacturer recommendation, to achieve the
optimum performance of the product.

·-·-·- -·-·-·-·-·-·-·-·-·----- L._

- ' :r
m.
mcx. 3;r. max. 3m. -l ..I
-·-·-·-·-·-·-·-·-·-·-·-·-·-·-i - -
l Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 l Rev. No: 5 l Date: 07-July-2015 Page 7 of 27
 ,) .
,JQi
Orp1c
Method Statement For Under Ground
GRP Piping - al
Hassan

9 INSTALLATION OF UNDERGROUND PIPE SYSTEM

Special attention needs to be given to the bedding (minimum 150mm), side filling and
backfilling of the trench, this provides the necessary support of the pipe, and hence
manufacturer instruction shall be followed.
It also prevents settlement and possible damage by the soil and / or traffic. Resistance to
horizontal movement of the pipe depends on the soil type, its density and moisture content. The
greater the soil resistance, the less the pipe will deform or move, when fully buried and
compacted.

9.1 THE TRENCH CONSTRUCTION

The Civil Contractor will open the trenches as per the approved issued for construction drawings.

Depth of trench should be 3.800 Mtrs as per approved drawing.

Proper side slopes protection must to be maintained due to deeper excavation of trench .

The trench dimensions should comply with the requirements specified in pipe manufacturer's

installation manual and those mentioned in the procedure.

Details of local soil conditions and water table should be obtained from Geotechnical

Investigation (soil report) prior to trench excavation.

The minimum width of the bottom of the trench for a single pipe should be at least 1.5 times the

pipe diameter or as per GRP supplier instruction manual or as suitable space required for

Lamination joint.

For multiple pipes, the distance between pipes should be at least 0.5 times the larger pipe
diameter and the gap between the outer pipe and the trench wall should be at least the same
width as for a single pipe.

The pipe trench shall be smooth, regular and free from stones or any other hard objects, which

may damage the pipe or cause stress concentrations.

The surface of the bedding layer should be at the same elevation as the pipe invert level.

The trench should be over-excavated under the joints as mentioned in "Requirements from Civil

Contractor" to allow for space required for the jointing activity, as well as inspection for

monitoring leaks during hydro test.

Pipe laying will be started only after the Trench is accepted.

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 ! Rev. No: 5 ! Date: 07-Juiy-2015 Page 8 of 27
 ,.., .,JQi Method Statement For Under Ground
Orp1c GRP Piping 1111 dac & .
.
9.2 spools Lavina
The spools will be laid in the trench by Mechanical Contractor under according to the coordinates
and the elevations specified in the approved isometrics, or otherwise as directed by Client.

Ideally water should be removed from the trench prior to pipe laying & backfilling.

All pipes shall be carefully inspected for damage during loading, unloading and or laying before
installation.

Each pipe/spool shall be cleaned inside and maintain cleanliness.

Open ends of the installed line shall be covered with caps at end of each day to avoid
contamination and entry of animals.

Pipes can be double-jointed beside the trench in order to reduce the installation time.

The pipes can be lowered into the trench after curing of the joint. This must be done with
reasonable care in order to prevent overstressing of the pipe. Do not move the joint during
curing.

Following are the methods, which will be used for the installation and adjusting of pipe systems
in the field:

a) Adhesive Bonded Joint ( Bell & Spigot ).

b) Lamination Joint.
c) Flanged Joint.

9.3 BACKFILLING

After the spools are jointed and inspected and if the "Line and Elevation" is approved i.e. (BOP,
survey report verified by Construction & QA/QC prior to backfill), only then will the Civil
Contractor start the backfilling.

The Backfill material should be worked into the underside of the pipe before backfilling the
trench.
The lines will first be released for partial backfilling.

The spools will be covered with the compacted backfill soil up to minimum one diameter above
the crown level with a minimum of 300mm and a maximum of m. At this stage, the joints will
be kept exposed to allow a proper inspection during the hydro test. t is important that partial
backfilling follows closely the pipe installation as covered pipes will not expand due to thermal
variations.

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 ! Rev. No: 5 ! Date: 07-July-2015 Page 9 of 27
"' - ,JQI Method Statement For Under Ground
Orp1c GRP Piping - &: I I .
al Hassan

In the same form, the Civil Contractor will be also given the approval to pour concrete
around the installed pipes as specified in the approved isometrics, e.g. at wall insert
in the valve/discharge pits.

After the successful hydro test, Mechanical Contractor will release the tested lines for complete
backfill up to the grade level. The same release note used for the partial backfill release will be
used at this stage.

Backfilling shall be carried out in accordance with the procedures mentioned in pipe
manufacturer's installation manual. During Backfilling care should be taken regarding top
elevation (FLG) with respect to above ground piping.

10 ADH ESIVE BONDED JOINTS

Before adhesive bonding, all safety precautions shall be checked. Ensuring that all necessary
tools and materials are available.

No person may produce an adhesive-bonded connection unless that person has passed the
bonding qualification test as per FPI Training procedure.

The adhesive-bonded joint consists of a tapered socket end and a tapered spigot end
bonded with an adhesive/hardener mixture. See figures 1and 2 below.

Tapered Spigot End - Figure 1.

(SA)

O•.S x4
, 59 .
Taper Angle
• rt
r
I ..... ... • • •I

-\ !
I
. I

-·-·-·-·-·-·-·-·-·-·-·-1 0
0
•f
. .
.
l

0-/.-.././. / . . . . .
.

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 Page 10 of 27
,··)
.,JQi
Method Statement For Under Ground
GRP Piping 1111 ac 1b1 .
Orp1c
Tapered Bell End - Figure
2.
9,,
,i
spigot
·-·- -·-· funit
i
I

Before forming the joint every precaution shall be taken to ensure that all the moisture has
been removed. f necessary, moisture, absorbed by glass fiber or subsisting on surface of the
socket and spigot, must be removed by thoroughly drying with hot air gun or Suitable localized
preheating as recommended by manufacturer.
Contamination of the spigot should be avoided. It is essential that precautions shall be taken
to avoid moisture on jointing surface when weather is highly humid, or having high density
fog.
It is also recommended not to carry out bonding activities during sand storms and sand
blown conditions.
Temperatures and Relative Humidity Requirements:

• The bonded assemblies may be performed only if the temperature of the pieces to be
assembled is 3° C above the dew point and,
•If the relative humidity is lower than 75%. Alternatively,
• Temperature of the jointing surface is not more than 40° C.

10.1 Surface Preparation Prior to Adhesive

Bonding I nspection
Before proceeding it is important to inspect all the pipes and fittings or any components, which
are to be used in system prior to assembly of the joints.

All pipes and fittings shall be visually inspected for damages that may have occurred during
shipment. One hundred percent (100%) of the interior and exterior surfaces shall be inspected
visually.

Damaged pipe/fittings shall not be used in the system.

Remove the end protectors and check these areas carefully for any possible damage. The male
end is the more fragile of the two parts of the joint, i.e., if the male of the pipe is chipped, the
edge shall be made square by cutting and re-formed taper end by machining.

l Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 l Rev. No: 5 l Date: 07-July-2015 l Page 11 of

27 !
 ,) .,JQi Method Statement For Under Ground
Orp1c GRP Piping - ac 1 1 .
al Hassan

Visual inspection of all pipes and fittings including corrective actions shall be in accordance
with Annexure-D of 150-14692-4.

Each pipe spool shall be internally blown out with air or otherwise, cleaned to ensure that it is
free from dust, dirt, sand, etc. prior to lowering into the trench/support.
Adhesive bond kits shall be inspected prior to use to ensure that the expiration date has not
elapsed.

If any doubts or any clarifications are needed before the use of pipe, the subcontractor's
personnel shall contact FPI and Contractor Site Supervisor.
Roughening and Cleaning of the Surfaces

The grade of roughening and cleaning of the surfaces are directly proportional to the high
quality strength of the joint.
Roughening is by the use of flapper wheel or emery to remove the smooth shiny finish from the
surface of either the spigot or socket, which subsequently make the adhesive bond between the
two roughen structures.

Cleaning Is essential to remove any contamination of the spigot & socket and any created dust
during the roughening process.

Preparation of the socket & Spigot

Each bonding surface shall be checked visually and cleaned using acetone to remove any
grease or dust.

Factory-formed spigot & socket ends have to be roughened using a flapper wheel or Emery
Caps (40:60 grit) mounted on a 13 mm hand drill, at 2500-3000 rpm and by hand with emery
sheet/ paper (40:60 grit).

Also the control of roughening of the spigot end surfaces is very important. Over abrading of the
spigot and socket will cause a loose fit of the joint during trial fit (dry fit).

After roughening, the surfaces to be bonded should show a dull fresh finish, not a polished
appearance.

Dust removal from ends to be jointed shall be carried out using a clean dry brush or
compressed air that is dry and free from oil.
The surface of the spigot & socket shall be cleaned by swabbing with acetone or Methylene or
other suitable solvent prior to the bonding using clean cloth.

The cleaned surfaces shall not be touched or contaminated by oil, moisture or bare hands
prior to bonding.If surfaces become wet or contaminated they must be cleaned /
dried, re roughened made dust free using brush or clean cloth.
Note that the bonding shall be executed immediately (Within 1 hour) after the surface
preparation to avoid any dust and humidity that will contaminate the spigot and socket.

! Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 l Rev. No: 5 l Date: 07-July-2015 Page 12 of 27
 ,) .,Jqi Method Statement For Under Ground
Orp1c GRP Piping DIUl ac l 1 al Hassan
.
Trial Assembly
A trial assembly is required for each joint prior to bonding, to check the machining of the pipes
and to determine the length of spigot penetration.
There must be a gap between the stub of the socket and the spigot end that shall not be more
than the dimensions as recommended by manufacturer.
Measure and note the length of socket prior to trial fit.
Align and engage the end of the spigot into the socket without turning the pipe, push it until
the tapered surfaces are touching.

10.2 SEQUENCE OF WORK

CONSTRUCTION FLOW CHART

I - ----- - --- -- ---- ---..,

: Pipe CUtting :
I - - - - - - - - - - - r - - - - - - - _1
I
I
I

------------ -----------'
calibration cl Pipe Ends :
I------------, -------------I
'I

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _tI _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
I
I
I Preparation of Factory Shaved Spigot
I I
•-----------------------L -------------------
I
I

I
______________y ________________
I
I
I Preparation of Socket
I---------------, - - - - - -I
'
I
I

1---------------------t -------I
:
I
Joint Bonding / Curing I
l ---------------------T----------------
1
I

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _tI _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
I I
: QA/QCInspections :
·----------------------------------- ·

PREPARATORYWORKS

The preparatory work shall be completed as per the agreed project specification and
requirements shall be confirmed to all Method Statements, ITP and Job Hazard Analysis.

Following are the completion of the related works shall be detailed below.

Pipe Cutting

The pipe section to be cut shall be marked using a marker pen and a pipe fitter's wrap-a-round
guide.
Ensure that the cut end is completely square as the reliability of the joint depends on it.

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 ! Rev. No: 5 I Date: 07-July-2015 Page 13 of 27
 ...-c) . , Method Statement For Under Ground
JQi GRP Piping IIUl ac l I al Hassan
.
Orp1c
Cut the pipe using an electric grinder attached with an abrasive cutting disc or other suitable
tool.
Ensure the cut ends are square and if any adjustment is to be made, use an electric grinder
with abrasive disc.
Pipe of nominal diameter up to lOOmm should have squareness up to 1.Smm or as per
manufacturer recommendation. Cuts on larger pipes should be up to 3.0mm or as per
manufacturer recommendation.

CALIBRATION

Calibrate the pipe ends using the FPI supplied GRP shaving machine.
Make sure to Reach the spigot dimensions as specified by manufacturer specially 51.
The taper angle is achieved by using the cutting drum of the shaver machine that corresponds
to the required taper angle.

Important Notes:
a) Taking 51 as the controlling dimension, shave the spigot length SA at the required taper
angle.
b) The shaving length (SA) specified by the manufacturer is the minimum required cementing
length. Actual shaved length is always longer therefore, application of cement should be
maintained throughout the extent of the shaved length.
c) Once the required 51 dimension specified by manufacturer is achieved, a joint geometry
should be obtained or observed that allows a specified gap for different taper angle between
the nose tip and bell stopper, provided by manufacturer. These gaps depicted in figure 2
should be maintained as much as possible. However, the installer shall rely on his
judgment to determine the right position at which to stop pulling during joint assembly.

Clean the calibrated spigot with a clean and dry cloth or use a dust brush.

FACTORY SHAVED SPIGOT {TS)

The factory shaved spigots are in accordance with the required measurements within the
specified tolerance. The spigot (TS) shall be sanded off using emery paper of suitable grade.

SOCKET {BELL END -TB} PREPARATION

The top coat inside the bell end shall be sanded using an emery cup of suitable grade inserted
In a rubber mandrel and fixed to the drilling machine. The sanding depth should not exceed
more than that as specified by manufacturer which can be measured using a calibrated
thickness gauge.

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 I Page 14 of 27
I
 ,) .,
Jql
Method Statement For Under Ground
GRP Piping - oc . al Hassan
Orp1c
Precautions:

The prepared bond surface area should not have an influence of grease, oil, dust, moisture,
water, etc. Clean the surface with a clean and dry cotton or dust brush.
If any oil or grease is noticed on the bonding surface, soak the cloth in acetone or Methylene or
other suitable solvent and clean the surface.
Ensure that the bond surface is dry.

Do not use water, paint thinners, petrol, etc., for cleaning purpose.

Adequate precaution shall be taken in case of adverse weather conditions around the work
place. Such as high humidity, mist, rain, sandstorms, etc.

If the weather condition around the work area contain high humidity, mist, rain fall and
sandstorm, etc.,

a) Arrange makeshift tents to protect the pipe assembly directly exposed to the atmosphere.

b) The prepared assembly shall be heated up to avoid moisture content on the bonding
surface. Use the heating blanket or hot air blower to warm up the joint. Once the warming
process is completed, the joint shall be re-sanded before the cement mixture application.

JOINT BONDING

Fix the latch belts with side hooks, on both sides of the pipes.

Use wooden blocks to prevent contacts between the come along jack and the pipe.

After ensuring the pipe sections are adequately supported and aligned properly, check if the
prepared bonding surface is clean, dry and free from dust, oil, etc., if not, sand it with an
emery paper and make it fresh prior to application of the adhesive mixture.

The prepared bonding surface should not be touched with a bare hand or dirty hand gloves.

Mark a reference point on the spigot side at a length in excess of BA, as mentioned by
manufacturer. BA is the bell length up to stopper. The BA dimension will be as per manufacturer
recommendation.

Mix the adhesive containers until mixture has a uniform color. Adhesive components should not
be mixed partially.

l Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 l Rev. No: 5 l Date: 07-July-2015 Page 15 of 27
 The expiry date of the adhesive components shall be checked before using the product at all
times. Expired cement kits are not allowed to be used.

Using a spatula or putty knife, apply a thin uniform layer of adhesive, to the inner surface of the
socket.
A thick uniform layer of adhesive has to be applied to the outer surface of the Spigot.
It is important to ensure that no dust/sand or any other particles are mixed with adhesive or on
the mixture spread of the bonding surface.
The bonding process shall be completed before the setting time of the Adhesive Mixture detailed
in Table below.
Table

Temperature of adhesive 20°C 25°C 30°C 35°C 40-55°C

Setting Time 30 min. 25 min. 20 min. 15 min. 10 min.

The adhesive mixer will cure too fast if it is mixed above 40° C and the work shall be carried
out within the pot life after mixing the two components.

An important thing to be noted is that the adhesive mix should be spread on the pipe as fast as
possible.

A qualified technician shall perform the joining of adhesive bonded joints.

Pull the pipe sections together by pullers, Secure the alignment of the joint during the insertion
of spigot end in to the bell end.

The spigot shall be inserted until the bell end is away from the reference marked to a specified
distance as mentioned by the manufacturer.

The installer shall rely on his experienced judgment to determine the right position at which to
stop pulling.

Clean the excess quantities of adhesive formed around the joint and if possible clean it out
from inside.

Do not release the lever hoist until the bonded joints is self-cured. The bonded joint should not
be disturbed under any circumstances while the joint is curing.

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 ! Rev. No: 5 ! Date: 07-July-2015 Page 16 of 27
, ") .,
QI
Orp1c
Method Statement For Under Ground
GRP Piping
- a( . at

Once the cement joint is self-cured, the puller can be released (Heating blanket required before
release). The temporary supports provided for assembly or alignment proposes shall remain in
place until the joint is fully cured.

The adhesive bonded joints shall be considered accepted only after passing the hydrostatic test.

CURING
Proper curing method and curing time depends on type of adhesive used, temperature of the
pipe and conditions of the service.

Ensure the bonded joint is self-cured by ascertaining the applied cement is tack free to touch.
If additional heating is required to cure the joint, heating blankets are used as per
GRP manufacturer's instruction.

Apply the heating blanket around the joint with the required temperature as specified by the
manufacturer.

Close the ends of the pipe to prevent any air blowing into the section.

The duration of heating starts after surface of the pipe has reached the required temperature
underneath the blanket or as mentioned by manufacturer.

Once the heating process is completed allow the joint to cool down naturally and remove all
fasteners and materials from the joint.

Mark the cured joint with permanent marker to identify the uncured joint.

Each field joint shall be marked with a unique number, the joiner's identification, date of
jointing and the date and time that heat curing started and finished.

Once the process is completed the joint is ready for hydro test.

SITE STORAGE OF ADHESIVE KITS

The site storage of cement kits should be maintained under an ambient temperature of
20-25°C & under a shaded area or as per manufacturer recommendation, to achieve the
optimum performance of the product.

f INAL CLEANING AND INSPECTION

Once the bonding process has completed, the general area shall be cleaned and prepared for
inspection.
Contractor shall carryout an initial inspection to confirm the installation and general safety.
Contractor / Sub Contractor shall at all time work together to ensure a smooth and safe
working

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 I Page 17 of 27
!
 Method Statement For Under Ground
,"") _ ,
JQi GRP Piping DIELl oc . .
al
Orp1c Hassan

environment.
The processed joint will be subject to one final inspection prior to being fully operational for the
Sohar Refinery mprovement Project.

Tools for Adhesive Bonded Joints

• Crane or Side boom or boom truck.
• TS Shaver for various diameter as required.
• Heating Blankets.
• Temperature Control.
• Pi-tapes covering all pipe diameter.
• Chain Block.
• Wrap-Around tape & guide.
• Angle Grinder.
• Spirit Level.
• Latch Belt.
• Come along jack.
• Grinding disc.
• Cutting disc.
• Emery disc.
• Emery cup.
• Backing disc pad.
• Rubber mandrel.
• Brush.
• Sanding paper.
• Marker pen.
• Generator.
• Shelter / Shade.

I Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 Page 18 of 27
,..).,JQI Method Statement For Under Ground
Orp1c GRP Piping - ac & al

10.3 REPAIR .
Hassan

All the repairs shall be as per manufacturer recommendation and shall be approved by
manufacturer (its representative).

1) If any TB / TS joint is found to be leaking, cut the joint out and replace it with a
pipe piece length as specified by manufacturer. Connect this piece by two (2)
lamination joint. The repair works are illustrated below.

1.... -E-·..., {i
l. E '·.. . _ ...,
Laakage
·-----·
l E E II ...
Cut

....
l E l I Insert neT,

l E x x Perform 2.11eld
tomlnallun Joints

l
2. The same shall be done if the leak occurs on the pipe wall due to impact damage.
3. In case of a superficial damage on the pipe, the following steps to be followed. A superficial
damage is a scratch within the resin rich outer layer of the pipe.

a) Abrade the damaged area by using emery paper.

b) Use a brush to clean the area from dust.
c) Mix the Epoxy resin according to the recipe. d)If
it is necessary apply 1or 2 layers of G-glass.
e) Apply the mixed resin on the damaged surface.

Note: All joints found to be leaking and/or damaged shall be reported to the end user
(Owner) in order to give them an opportunity to inspect prior tp the repairs being made.

11 LAMINATION JOINT

Before starting a lamination joint, all safety precautions will need to be checked. Ensure that all
necessary tools and materials are available.

l Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 l Rev. No: 5 l Date: 07-July-2015 Page 19 of 27
 , ;· ) _
,JQi
Orp1c
Method Statement For Under Ground
GRP Piping - ac al
Hassan

Following notes should be taken care of:

• Lamination should be avoided in foggy conditions .

• The length of exposed pipe should be kept minimum especially during summer to avoid effect
of expansion/contraction of the pipe on the new lamination joints. This can be done either
partially backfilling the jointed section or by covering at least 2 lengths of pipe with
tarpaulins.
• Fiber glass will be kept covered till used to prevent contamination by sand, dust or gravel.
• In case of long lines, it is preferable to do erection and jointing in sections on either
side of the manhole spool, manhole spool erected and jointed last to connect the jointed
sections.

Cutting and Sanding

Mark off the pipes to be joined using a pipe fitter's wrap-a-round guide & marker pen.
Cut the pipe (sections) to the right length, with a straight cut perpendicular to the pipe axis. The
pipe can be cut using abrasive cutting disc or other suitable tool or diagrit, carborundum-slitting
disc or with a diamond edged disc.
Use a sander (Angle grinder) to remove the topcoat of the pipes when cut to the right length, in
order to give a clean and rough surface for adhesion.
Clean the sanded part with a clean cloth or brush. The pipe sections must now be clean and free
of dust.
In case of oily contamination, wash with methylene or acetone or suitable solvent.
The ends of the pipes to be connected should be chamfered back to a minimum taper of 1:6.
Lamination should be carried within one hour of grinding or as per manufacturer
recommendation / instruction.

Temperature and Relative Humidity Requirement.

The temperature of the pipe bond area should be 3° C above the dew point prior to application of
resin and,
The relative humidity should be lower than 75%. Alternatively,
No lamination should be done at site if the surface temperature of the pipe bond area is more
than 40° c.

Mixing
The hardener must be added to the container with the resin and carefully mixed. The resin and
hardener shall be mixed as per the quantities mentioned in the pipe manufacturer's lamination
recipe to maintain the right mixing ratio.
Mixing should continue until the resin mixture has a uniform colour & consistency.
I Doc. No: 120476 / Jl-02022 / 27-06-01 I MMS-04 ! Rev. No: 5 ! Date: 07-July-2015 ! Page 20 of 27
 •t ) .
,JQi
Method Statement For Under
Ground GRP Piping DIEll ac & al
.
Orp1c Hassan

The Mixing will be carried out as close as possible to lamination location.

After mixing as per the recipe, Lamination will be started immediately and the mixed quantity
will be used within the time specified as per manufacturer recommendation.

Fit Layer
The functions of the fit layer are, firstly to ensure proper positioning and secondly, to create a
seal (See Figure below).

Figura 2
No Lcrrillllm'
moisture shall be present on the pipe bond area.
The pipe bond area shall be dry prior to application of resin.
Measure fit layer bond length (mentioned in recipe) from the end of each pipe.
The surface should be uniform and free of sharp edges.
Grind the above area to remove the surface layer of the pipe and remove the dust using clean
dry cloth or brush.
Clean this area and ensure that it is fully dry.
The allowance of miss-alignment for pipe shall be as per manufacturer instruction.
Cab-o-sil can be used to fill minor misalignment.
The gap between the two pipes to be laminated shall be as per manufacturer's guidelines.
The gap (if any) shall be filled using CAB-0-SIL mixture.
Impregnate the roughened area with the resin & catalyst mixture as per the ratio specified in the
recipe.
Apply woven roving (type as per recipe) with 50% overlap between each two consecutive
windings as specified in manufacturer recipe.
Ensure that the layers are tensioned, wrinkle free, sag-free by continuously pulling the W/R
layers.
Impregnate the above layers with the resin/catalyst mixture.
Ensure the layers are bubble free, if required remove with suitable roller.
Repeat the above steps till the required number of layers is applied.
Wait one hour till the lamination is cured under ambient temperature.

l Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 Page 21 of 27
 ,t) .,JQi Method Statement For Under Ground
Orp1c GRP Piping IEUI ac 1 1 .
al Hassan

External Lamination {Main Laminate}

Measure the bond length (mentioned in recipe) on each pipe from the middle of the fit layer.
Grind the above area to remove the surface layer of the pipe and remove the dust using clean
dry cloth or brush & Ensure this area is fully dry.
Impregnate the above area with the resin/catalyst/delayer mixture as specified in recipe.
Apply two (2) layers of woven Roving (type as per recipe) with 50% overlap between each two
consecutive windings as specified in manufacturer recipe.
Ensure that the layers are tensioned, wrinkle free, sag-free by continuously pulling the W/R
layers.
Impregnate the above layers with the resin/catalyst/delayer mixture.
Ensure the layers are bubble free, if required remove with suitable roller.
Repeat above two steps till the required number of layers is applied.
Every two layers should be impregnated before applying the second two layers of the same type
or different type.
After application of required layers of woven roving as per recipe, wind 2 layers of top tape glass
around the laminate to extract the excess lamination quantity of resin and to provide smooth
surface.
Wait two (2) hours for curing to complete at ambient temperature.
The Strength of laminate should be checked by Barcol Hardness on ground flat spot in 3 evenly
spaced points (at 120 degrees) around the circumference.

Internal Lamination

For diameters up to 600mm, internal lamination will not be done.

If requiredInternal lamination be done for pipes of bigger diameter, if access is possible.
Measure a length as specified by manufacturer from the end of each pipe.
Grind the above area to remove the internal liner of the pipe and remove the dust using clean
dry cloth or brush.
Cut several pieces of roving (type as per recipe) with equal length and impregnate with the
mixed resin (as per manufacturer recipe) on a flat surface.
Wet the grinded surface with mixed resin and place the above impregnated roving on the joint .
Evenly press the surface to flush air traps and blisters using suitable roller. The number of
layers of roving is applied as mentioned in the recipe.
Cover the laminate with two layers of surface MAT to provide a smooth resin-rich laminate
surface.

Curing

! Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 ! Rev. No: 5 ! Date: 07-July-2015 Page 22 of 27
,.., _ Method Statement For Under Ground
,Jql GRP Piping IEUl at . . al Hassan

Orp1c
The Lamination will harden at ambient temperatures.

The curing method shall be same as per Adhesive joint or as per GRP manufacturer instructions.

The joint is ready and can be tested next day.

1. Inspection Report.

11.1REPAIR

All the repairs shall be as per manufacturer recommendation and shall be approved by
manufacturer (its representative) and shall be carried as above mentioned for Adhesive bonded
joints.
Tools for Lamination joi nt

• Measuring tape, pipe fitter's wrap-around, marker pen.

• Cleaning rags.
• Angle grinder.
• Angle grinder + sanding disc + flexible support disc.
• Pair of scissors.
• Gloves, brushes, rollers, buckets, dust masks, safety glasses.
• Weighing scale.
• Heating blanket/hot blower/halogen light.
• Shelter / Shade.
• Scaffolding depending on size.
• Generator.

12 FLANGED JOINT

All The fiberglass flanges shall be joined to the fiberglass pipes with Lamination joint as
described above as per manufacturer recommendation with respect to lamination recipe for the
respective diameter.

The fiberglass flanges must always be installed tension free, therefore flanges must be
accurately aligned. f possible, flanges should be jointed to pipe only after bolting the flange to
the required torque value.

Before assembling flanges, inside surface of the flange will be cleaned and checked for any
defects or irregularities on the flange's gasket face.

Steel blind flanges to be used during the hydro test and/or if connected to the fiberglass
manufacturer or
Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04Rev. No: 5 Page 23 of 27
 ,;") .,
JQI
Method Statement For Under Ground
GRP Piping IIUl ac &
Orp1c
_9,,
alternatively should have adequate steel reinforcement bracing for blind flanges of lower plate
thickness.

Gasket shall be checked for any defects and will be cleaned on both sides. Permanent gaskets
used should be as per the project specification or as recommended by pipe manufacturer.

Gasket will then be fixed in position using masking tape.

Make sure that the mating flange is properly supported to avoid load being transmitted to the
fiberglass flange.

Insert flange bolts, washers and apply nut until it is hand tight.

Number each bolt starting at the top in a clock-wise direction as per the torque sequence.

Once all the bolts are hand tight, bolts will then be tightened in sequence using a
calibrated torque wrench up to the 30% of the max. torque value provided for that
particular gasket, diameter and pressure rating {Torque values to be provided by Pipe
manufacturer).In case of leak, bolts will be again tightened in sequence using the torque
wrench up to the 60% of the max. torque value

Tightening will be done as per the torque sequence provided in the Pipe manufacturer manual.

After all bolts have been tightened to recommended torque, recheck the torque on each bolt in
the same torque sequence.

1. Inspection Report.

13 FLANGE TIGHTENING

For tightening GRP flanges with a flat-faced surface, the flange will be provided with kroll &
Ziller gasket to seal the connection.

The flange faces, holes, gaskets shall be properly cleaned with acetone, MIBK or MEK.

Inspect the gasket for any defect prior to installation.

Place the gasket in position and make sure that the holes of gasket and flanges are aligned.

Position the other flange to be assembled to the GRP flange in the right place. Make sure the
holes of the two flanges are aligned and leveled.

Insert the stud bolts in the holes. Bolt threads shall be cleaned and lubricated to attain
the proper torque.

l Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 Page 24 of 27
 ,"' . ,
JQi
Orp1c
Method Statement For Under Ground
GRP Piping - . al
Hassan

Number each thread bolt starting from the top and following a clock wise sequence.

Hand tight all the nuts.

Tighten all the nuts using torque wrench. The nuts shall be tightened as per the sequence
describe in the drawing. The torque wrench setting in Nm shall be 4 times of the Design
pressure.

After completing one round of tightening repeat the tightening sequence one more time. The
bolts on the one side tend to get loose while tightening the bolts on the opposite side.

Tools for Flanged joint

• Spirit level, Square angle, Marker pen, measuring tape.

• Cleaning rags, Masking Tape
• Combination spanner of required size.
• Calibrated Torque Wrench of required capacity with wrench sockets.
• PPE.
14 TIE-IN JOINTING, FITTINGS, BENDS

The trench width for tie-in inside trench shall be as AFC drawings or as per manufacturer
recommendation.

Tie-ins of spools shall take by means of Lamination Joint.

All tie-in connections to metallic systems shall be by means of flanged connections.

Tie-ins to other GRP pipe systems may be made by flanged connections or by means of bonded
couplings as stated in the AFC drawings or as per manufacturer recommendation.

The Jointing of GRP Pipe to GRP fitting and GRP fitting to GRP fitting as required shall be
carried out as per the same procedures as that of pipe to pipe.

15 REPAIRS

Minor repairs to pipe & fittings may be repaired on site.

Any damaged outer layer shall be ground and cleaned and resin / hardener mix applied as
recommended by the manufacturer.

Minor cracks in flanges can be repaired by grinding & filling with resin.

All The Repair Methods shall be approved by the client and confirmed by the Manufacturer.

I Doc. No: 120476 / Jl-02022 / 27-06-01 I MMS-04 ! Rev. No: 5 ! Date: 07-July-2015 ! Page 25 of
27
 •tl _ , Method Statement For Under Ground
JQI GRP Piping - rolac l I .
al Hassan
Orp1c
16 Hydro-testing

Sectional / Final hydro testing shall be carried out as per approved hydro testing procedure.

17 HSE REQUIREMENTS

17.1 Supervision

Site Representative shall be responsible for execution of all activities at site.

Supervisor shall be responsible for execution of the job and present at site according to the
activity.

11.2 HSE Requirements

• Proper communications are available during working in remote area.

• All personnel shall complete safety induction and receive training as required by Contractor /
Owner.
• Prior to start of any work activity special attention shall be given to identifying the work area
and providing fit for purpose barriers and applicable signboards.
• Refueling of any equipment is strictly forbidden while the equipment is running.
• Refueling of vehicles must be planned in safe manner and carried out in a designated area.
• Adequate quantity of water available at site.
• Smoking, eating & drinking prohibited during handling & storage of resin, paste, adhesives or
other chemicals.
• Use of rubber gloves, barrier creams, dust mask, protective clothing etc., as per MSDS.
• Use of oxygen or fresh air masks in confined spaces such as in trench depth below 1.2 meter
or inside pipe of bigger diameter.
• All involving employees are wearing proper P.P.E as per manufacturer MSDS.
• All lifting operations must be carried out by competent trained personnel.
• All equipment are fit and third party certified and safe to use.
• Lifting will be done by properly tested, approved and third party certified equipment only.
• Lifting gears are functional and third party certified suitable for hoisting operations.
• Transportation and lifting activities will only be carried out during day light hours.
• Transportation and lifting activities to be carried during night shall have valid permits.
• Pipes are located on support and secured properly.
• Fire extinguisher available at workplace.
• All electrical tools & equipment are in good conditions.

! Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 ! Rev. No: 5 ! Date: 07-July-2015 Page 26 of 27
 , tl . ,
JQI
Method Statement For Under Ground
GRP Piping llll aw .
al Hassan
Orp1c
• Safe distance is maintained between the machine & overhead lines & above/underground
services.
• MSDS available with this Method Statement and understood.
• Chemical/Hazardous Material Storage to be provided separately according with the HSE
compliance and with Coolant/Exhaust system installed.
• Good housekeeping is to be implemented after job completed.
• Environmental policy adhered.
• Site kept clean & tidy after completion the work.
• An approved Job Hazard Analysis for this operation will be attached to the Method
Statement.
• All accidents will be reported immediately to the Site Engineer and then as soon as possible
to Senior Project Engineer and/or appointed Health and Safety Officer.
• Any First Aid treatment will be provided by the trained First Aider.
• Tool Box Talks will be carried out daily before start of work and shall be Activity specific.
• All electrical & power tools are to be in good condition inspected prior to use.
• Color coding system to be implemented and shall be inspected by DPJV HSSE representative.

17.3 PJW Requirements

Hot Work Permit.

18 DOCUMENTS

1) GRP instruction manupl.

2)Incoming MaterialInspection report.
3)Inspection report.
4)Release note.

19 Attachments

1) JHA - JOB HAZARD ANALYSIS.

2) Handling & Storage Procedure (V-616G-462-J01-A01-N01-001)
3) MS Lamination Procedure (V-616G-462-J01-B01-H99-001)
4) FPI Doc. No. 010054-MPI-GRP-DPJV
5) FPI Doc. No. 010054-RP-GRP-DPJV
6) FPI Doc. No. 010054-ABJ-GRE-DPJV
7) FPI Doc. No. 010054-MFJ-GRP-DPJV

l Doc. No: 120476 / Jl-02022 / 27-06-01 / MMS-04 I Rev. No: 5 I Date: 07-July-2015 Page 27 of
27
PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC

IIAE•• t1etr JOB NO.:Jl-2022

JOB
otac GI
HAZAR
 D ANALYSI S Sohar, Sultanate of Oman
I RISK Jqi
ASSESSMEN Orp1c
T
Sohar Refinery

Improvement Project

JV Job No. 120476

JHA Title: Under Ground GRP/GRE Piping JHA No.: 09

D,
Work Location: Company: AHEC
SRIP Site
1.0 Permit(s) Required: ./ Confined
•
I O Energy Isolation
Entry r'\ I O Non-Destructive Test I O.Night W I

Space
I

os N. CAING _....U .J
,,, ./Hard
lHV IHat
rnav.ire lf2A/,I .//' r - -
./Clear Safety Glasses
OtAJAd. - ,
KameshwarRao M WJ-.--
./Dark Safety Ochem

REV
2.0
Name
PPE Required:
c ./oust Mask
./Ear Plugs
Name
./FaceShield
Date
./Earmuffs
Signature
Date
Mask
Name
Glasses Owelding
Signature
0Esca
Oweld

Reviewed By: Approved By:

.
Please t1ck
.
Ocotton
Prepare d By:
(.I') appropnate boxes
Gloves
0Leather Gloves (rigging)
./Disposable Coverall
./Cartridge Respirator
0Leather Gloves
0Rubb
./Hi-vi
0Gas Badge 0Multi-Gas Monitor (welding)
0Gas Detective Ough
Special Tools and Ooosimeter 0Thermometer ./Ventilation Fans ./Air B
3.0 Equipment Required: Oufeline ORetrieval Line DPadlock, Hasp, Tags Ought
0Air Horn OWhistle ./Traffic Flags ./Traffi
Potential ONoise ./Air Pollution (dust) 0Air Pollution 0Air P
4.0 Environmental
Hazards Osofl erosion ./Spills (to ground) (smoke) Ospills ./Haz
Hazardous Materials (wadi)
5.0 (attach SHOC Ocarcinogen Olrritant ./Highly Flammable 0Toxi
Cards)
Other Potential ./Electrical 0Pressure (air, water, gas) 0Mechanical (crush ./Ergo
6.0 Hazards Ought I Dark OIgnition Sources points) Ooust I Vapor Osuffo
Additional
7.0 Instructions
"Eye wash" to be provided.

Risk Rating Matrix People Asset Environment

0 No injury or health effect No damage No effect
1 Slightinjury or health effect Slight damage Slight effect
2 Minor injury or health effect Minor damage Minor effect
Severity
3 Major injury or health effect Moderate damage Moderate effect
4 PTO or up to 3 fatalities Major damage Major effect
5 More than 3 fatalities Massive damage Massive effect

Page 1 of 14
DA.LIM
t'etrorac GI
JOB HAZARD ANALYSIS I
Sohar Refinery ,1
RISK ASSESSMENT Improveme
PETROFAC
INTERNATIO
nt Project
Sohar,
.,JQi
NAL LTD.
JOB
HAZARD
Sultanate
of Oman Orp
1c
ANALYSIS JV Job No.
PETROFAC 120476
JOB NO.:Jl-
2022

JHA Title: I Under Ground GRP/GRE Piping

 Risk
Step Activity Hazards Control Measu
Rating
1. Handling & Storage • Transportation P4 • TBT to be conducted fo
• Falling materials designated task and re
• Ensure the transportat
• Improper lifting of GRP pipes in inspected, approve
• Improper storage certifiedVehicles.
• Slips & Trips • Ensure the drivers are
and adheres the safe
• Suspendedload requirements.
• Ensure the pipes arelo
lashed as per the man
instruction.
• Ensure the no chains
or clamps to lift the G
Ensure proper housekeepin
• Ensure the pipes are s
the manufacture instr
• Ensure no persons und
suspended load.
• Ensure signboards are

2 Lowering & installation of • Heavy (elevated) loads P4 TBT to be conducted for the
pipes Bad lifting equipment designated task and re
Existing facilities • Ensure the PTW requir
• Communication are met.
Ensure theloads are within
Dust & debris
• Trained, certified & co
Incompetent banks man I riggers operators.
• Defective • Ensure the lifting equ
• Lifting equipment are inspected and fit f
purpose.
• Poor procedure Ensure the existing facilitie
• Hitting identified and taken i
• Falling prior to lifting I strin
• Use of chemicals (adhesive) • Clear unobstructed vis
through all windows
• Over stressing of pipes • Ensure proper houseke
• Avoid the sharp edges
• Ensure the riggers I b
are certified

Page 2 of 14
• ••u• JOB HAZARD ANALYSIS I Sohar Refinery J
Petrotac c.,
RISK ASSESSMENT Improvement Project
Sohar, q
PETROFAC
Sultanate
INTERNATIO
NAL LTD. of Oman
JV
i
Orp
JOB
HAZARD Job
ANALYSIS No.
PETROFAC
JOB
NO.:Jl-
120
476 1c
2022

JHA Title: I Under Ground GRP/GRE Piping

Risk
Step Activity Hazards Control Measu
Rating
 • Banks man to control a
movements
• Ensure proper commun
between the operators
• Unauthorized entry to
• No other vehicle permi
in the area.
• Ensure belts & slings ar
and certified
• Ensure all the lifting ge
good condition
Ensure use of "tagline"
• Ensure the procedure
• Barricade thelift area
no works or persons un
load.
Provide enough warning sign
• Maintain safe distance
trenches.
• Ensure hard barricadin
ever possible.
• Ensure Pinch points a
• All pipes to be choked
to avoid slippage.
• Ensure the MSDS requ
met while handling the
• Due care to be provide
lowering the double jo
avoid overstressing of

3. Spool jointing/ Flange Rotating parts P4 TBT to be conducted for the

tightening • Exposure to chemicals designated task and re
• Fine particles while cutting & filin of • Ensure the painting and
GRP pipes g is done at designated y
• Fire • Deploy trained personn
Chemical spill • Ensure the MSDS requ
are met.
• Power tools
• Wear appropriate PPE a
• Electrocution

Page 3 of 14

,..l.,
DAIII.IM Sohar Refinery Improvement
t1etrorac t11
JOB HAZARD ANALYSIS I RISK
ASSESSMENT
PETROFAC
INTERNATIO
JQi
NAL LTD.
JOB
HAZARD
Sohar, Sultanate of Oman
JV Job No. 120476 Orp
ANALYSIS
PETROFAC
JOB NO.:
1c
Jl-2022

JHA Title: J Under Ground GRP/GRE Piping

Risk
Step Activity Hazards Control Measu
Rating
 • Working near excavations MSDS.
• Homemade I damaged tools MSDS to be discussed during
• Pinch point • Ensure barrier creams
• Manual Handling per the requirements.
• Ensure the Dust masks a
cutting and filing the
• Ensure the competency
who are involved in c
machining, bonding an
mixing activity.
• Balance chemicals to b
according to Waste ma
procedure
• No open flame/ smoki
of storage Iichemical m
• Ensure adequate firefig
are available.
• Ensure spill control me
• Ensure the power tools
inspected and color co
• Any damages to the po
reported and replaced
• All the electrical conn
verified by competent
• No make shift arrangem
made for power supply
• Ensure hard barricadin
open trenches
• Ensure safe distance fr
trenches
• Never store materials n
shores.
• Do not use homemad
damaged tools.
• Always use plastic ham
working on GRP pipes.
• Avoid pinch points
• Ensure proper lifting t

Page 4 of 14
DAIIUM
t'etrotac ...,
JOB HAZARD ANALYSIS I RISK d.:-,J
Sohar, Sultanate of Oman
ASSESSMENT
PETROFAC
INTERNATIO Sohar Refinery Improvement Project Qi
NAL LTD.
JOB JV Job No. 120476 Orp
1c
HAZARD
ANALYSIS
PETROFAC
JOB NO.:
Jl-2022

JHA Title: I Under Ground GRP/GRE Piping

Risk
Step Activity Hazards Control Measu
Rating
adhered to avoid man
handling Injuries.
• Avoid I Minimize
repetitive movements.
• Consider TILE ( time,
individual,load, envir
handling the loads
• Always spare the load
• Ensure the mechanical

. . Conduct TBT for the de

4. Bonding &. Curing of GRE • Electrocution
Joints • Fire and related hazards pri
• Exposure to chemicals the work every day.
• Falls from height PTW requirements to be me
• Slip, trip &. fall • Ensure all the electrica
cable &. connectors use
• Falling/flying objects condition and to be colo
• Hazardous GRE fiber dust competent electrician.
• Only competent peopl
be allowed to operate
equipment.
• People should be aware
involved while working
equipment.
Do not work alone.
• All should be aware of
procedures in case of e
• Maintain a good cable m
avoid trip hazard.
• Ensure fire extinguishe
nearby during the hot w
• Remove all inflammab
from the vicinity of the
activity prior commenc
always maintain a good
around the area.
• Must wear appropriate
allthe time at site.
• Must wear aoorooriate

Page 5 of 14
DAIII.IM t1etrotac u,
,") .,JQi
Orp1c
Sohar Refinery Improvement Project
PETROFAC INTERNATIONAL LTD.
JOB HAZARD ANALYSIS JOB HAZARD ANALYSIS I RISK ASSESSMENT Sohar, Sultanate of Oman
PETROFAC JOB NO.:Jl-2022 JV Job No. 120476

JHA Title: I Under Ground GRP/GRE Piping I JHA No.: 09

Risk Residual
Step Activity Hazards Control Measures Responsible Person
Rating Risk
inhalation of GRE fiber dust.
• MSDS requirements shall be met and
MSDS copy shall be made available at
the work location.
• Portable eye wash station shall be
provided at the work location.
• Adequate and suitable platforms with
proper access and egress shall be
provided.
• Scaffolding platforms to be
inspected by competent personnel
and should
hold a valid 'scaff tag' .
• Equipment and tools to be secured
properly in designated area only.
• Ensure fall protection is
available before commencing the
work at height activity.
• Ensure scaffolds used are meeting
with the standards and erected by
competent person.
• Allpersons performing work at height
activity should attend 'WAH' training
by DPJV.
• Ensure the warning signs are posted
as per the requirement.
• Area to be barricaded
• Carry out 'housekeeping' every day
(prior and post job).

4. Confined space entry Lack of oxygen P4 • TBT to be conducted for the P2

• Presence of poisonous gas like H2S, designated task and related hazards.
CO etc. • Permit to work system to be followed
Improper access and egress and full fill all PTW requirements
prior commencing the work at
• Lack of emergency evacuation system confined
• Unqualified/inexperience work force space area.
• Lack of supervision • Conduct gas test prior starting the
• Slip,trip and fall work and repeat the gas test
depending up on the nature of work
• Lack of illumination
• Proper access and egress to provided

Page 6 of 14
DAIII.IM Petrorac tJ, PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022
 JOB HAZARD ANALYSIS I RISK ASSESSMENT Sohar Refinery Improvement
Sohar, Sultanate of Oman ,") .,JQi
JV Job No. 120476

Orp1c
JHA Title: I Under Ground GRP/GRE Piping I JHA No.: 09
Risk Residual
Step Activity Hazards Control Measures Responsible Person
Rating Risk
Presence of explosive gases/fumes Forced ventilation fan to be provided.
• Absence of Standard operation Sufficient illumination to be provided.
procedures • Hole watcher to be positioned and
confined space entry log sheet to
be
maintained.
• Allpersonnel workingin confined
space must have under gone confined
space entry training by DPJV.
• Follow SOPs.
• Maintain good housekeeping inside
the pipes to avoid slip, trip and fall.
• Ensure continuous supervision
while confined space activity is
going on.
• Emergency evacuation arrangement
should be in place and procedure
for
workinginside the is as follows.
a) The person entering in confined
space should wear the safety
harness with life line attached
to the back of the harness
b) The other end of the life line
should be with the hole
watch.
c) In case of any emergency the
person inside the confined space
shall communicate the emergency
to the hole watch by
continuously pulling the life
line.
d) The hole watcher should
immediately arrange for
the rescue.
e) If person inside is not
responding further he can be pul
ed out by the help of life line.
f) A stand by vehicle should be
available at the location at all
the time when the activity is
going on.
• Mock drill shall be conducted at the
Page 7 of 14
DA.LIM ..-etrotac I-' PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022
 JV Job No. 120476
JOB HAZARD ANALYSIS Sohar, Sultanate of Oman ,) .,JQi
I RISK ASSESSMENT
Sohar Refinery Improvement Project Orp1c
JHA Title: I Under Ground GRP/GRE Piping I JHA No.: 09
Risk Residual
Step Activity Hazards Control Measures Responsible Person
Rating Risk
of the emergency preparedness.
• All the emergency contact number to
be posted at the work location.
Use approved type of respirator (FFP3)

5. Excavation &: Backfill ng Moving Equipments P4 • TBT to be conducted for the P3

designated task and related hazards.
Cave in • Obtain valid PTW from DPJV
• Fall ng Objects before starting the work.
• Use of defective hand tools for hand • Ensure the equipments used are
excavation inspected approved and fit for
• Slip, trip, Fall purpose.
Working near Plant equipments • Only experienced operators/
drivers to be deployed.
• Existing services (if any)
Terrain Condition • Ensure qualified banks men
are deployed along with all
• Unauthorized entry the
Improper access equipments.
• Noise • Ensure Reverse horns/
• Dust Revolvinglights of equipments are
• Vibration working prior to job.
• Adverse weather condition • Keep safe distance from moving
equipments I Bucket Swing radius.
• Spillage
• Personal Injury
• Ensure the excavations are done
as per the engineering standards.
• Provide necessary shoring to avoid
any cave
• Ensure the excavation spoils are kept
away from the shores and are
transported to dump area in
regular intervals.
• Ensure the hand tools are fit
for purpose.
• Random inspections of the hand
tools to be conducted.
• Ensure proper housekeeping in
and around
• the excavations to avoid Slip &: trip
• Ensure the area is hard barricaded and

Page 8 of 14
DAIILIM t1etrorac t» PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC
JOB NO.: Jl-2022
 JOB HAZARD ANALYSIS I RISK Sohar Refinery Improvement Project cl..:-,JQi
ASSESSMENT
Orp1c
Sohar, Sultanate of
Oman JV Job No.
120476

JHA Title: I Under Ground GRP/GRE Piping I JHA No.: 09

Risk Residual
Step Activity Hazards Control Measures Responsible Person
Rating Risk
• warning signs to be placed to
alert about
• the hazard.
• Ensure safe distance from the movihg
• Never rest under or near the
equipments.
• Always wear Hi visibility vests
while working near the
equipments.
Ensure all existing services are
identified and taken care before
starting the activity.
• Ensure the terrain conditions prior
to the deployment of plant
equipments to avoid any capsize.
• Barricade the area and post sign
boards to avoid accidental entry
by
third party.
• Ensure the access and exits to the
excavations are clearly marked and
kept free of obstructions.
• Ensure ear protection requirements
are adhered.( Banks man, Operators,
Etc)
• Ensure preventive maintenance of the
plant equipments.
• Ensure proper dust control
measures are adhered. (Sprinkling
water)
• Share the job to avoid Hand arm
vibration syndrome.
• Ensure the equipments used are
designed I maintained to reduce
the Vibration effects
• Ensure Appropriate the PPE's
are used.
• Ensure the works are suspended
during adverse weather condition.
• Welfare facilities like shades I
shelters, drinking water and rest

Page 9 of 14
D,UU.IM t'etrorac G PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.: Jl-2022
 ,.c) .,Jqi
Sohar Refinery Improvement Project
JOB HAZARD ANALYSIS I RISK ASSESSMENT Sohar, Sultanate of Oman
JV Job No. 120476
Orp1c
JHA Title: I Under Ground GRP/GRE Piping I JHA No.: 09
Risk Residual
Step Activity Hazards Control Measures Responsible Person
Rating Risk
breaks to be ensure during extreme
temperatures.
• Regular inspection by the operators to
find theleakage from the equipments.
• Spillages to be contained and
disposed properly.
• Ensure 100% PPE compliance prior &
during the job.
• Ensure the proper TBT is conducted
and confirm the control measures are
in place.
• Proper toilet facility to be provided.

Pressurized water P3 Follow the PTW System. P2

6. Filling Water into the Noise • TBT to be conducted for the
Pipe(Using by diesel driven • Water Spillage designated task and related hazards.
pump) • Bad weather condition (General for all • Ensure filling water should be prior
activities) approved by QC
• Using certified diesel pump
• Securing hoses and connections safely
• Use PPE such as Safety Goggles,
Face Shield, Safety boot, Ear plug Etc.
• Tool Box talk to the workmen
Proper supervision
Proper barricading of the work area
• Restriction on movement of personnel
and vehicles
Display of safety sign boards
Following work permit system
Releasing air through vent, gently by
competent person
• Maintaining good housekeeping
Use of portable fire extinguishers
• Keeping unwanted material
Iequipment away from the working
area
• Use ear plug during work.
• Resting shelter available on site.
Page 10 of 14
DAIIUM Petrotac G PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB
NO.:Jl-2022
JOB HAZARD Sohar Refinery Improvement Project d.:-,JQi
ANALYSIS I RISK
Orp1c
Sohar, Sultanate of Oman
JV Job No. 120476
ASSESSMENT
JHA Title: I Under Ground GRP/GRE Piping I JHA No.: 09
Risk Residual
Step Activity Hazards Control Measures Responsible Person
Rating Risk
Drink water as much as possible
• Take rest when feel tired
• In dusty &. stormy weather ,job to be
stopped
• Use dust mask during
dusty environment
• Spillage of diesel &. water P3 Follow the work permit system P2
7. Hydro test activity(Develop • Pressurized water • TBT to be conducted for the
pressure in section) • Noise designated task and related hazards.
• Inferior quality hoses Using certified diesel pump
• Substandard hose connection • Securing hoses and all connections
• chemicals safely
• Conducting Tool Box talk
• Proper supervision
Cordoning off the working area and
restriction on movement of personnel
and vehicles
• Pressurizing the water at a steady and
uniform rate as per the approved
method of statement
• Do not tighten any bolts while
under pressure.
• Monitoring of pressure
and temperature
constantly.
• Maintaining good housekeeping
• Use of fire extinguishers
• Use Proper PPE
• Ensure the MSDS requirements are met
during handling the chemicals
Discharging of Hydro test • High pressurized water P3 • TBT to be conducted for the P2
8. water designated task and related hazards.
• Noise • Release the pressure as per the
• Impactinglocal environments procedure.
• Identify the area for disposal and
mange as per the approved
procedure.
• Water discharging under DPJV
instruction

Page 11 of 14
DAIIUM Petrotac G PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.: Jl-2022
 ,)
Sohar Refinery Improvement Project
JOB HAZARD ANALYSIS I RISK ASSESSMENT Sohar, Sultanate of Oman
JV Job No. 120476
.,Jqi
Orp1c
JHA Title: I Under Ground GRP/GRE Piping I JHA No.: 09
Risk Residual
Step Activity Hazards Control Measures Responsible Person
Rating Risk
Avoid use of contaminated water
Ensure use of job specific PPE
• Ensure effective communication
system is placed during water
discharging activities.
• Continuous monitoring for avoid water
leakage from the hoses
• Proper supervision
• Controlling the area.
• Possible area should be barricade.
• Restriction on movement of personnel
and vehicles
• Ensure No spills and impact
onlocal environment while
discharge.
• Display of safety sign in
assigned places.

9. Emergency at worklocation Personal injury P3 • DPJV HSSE and Medical P1

numbers posted at work site
• Traffic incident
Numbers informed to AHEC supervisor
Incident, near miss etc. I HSSE
• Any incident I emergency shall be
reported to DPJV HSSE within 30
minutes or less. Initial written
notification to DPJV HSSE within 24
hours orless
• All personnel will be instructed on
procedure to take and system of
contact (AHEC I DPJV) should an
incident occur
• Reporting of incidents shall
be informed in daily TBT's
• Supervisor I engineer in charge
is responsible for leading HSE
and
compliance by workforce.

10. Weather /Climate Conditions Bad weather condition P3 Resting shelter to be available on site P1 Same as Above
• Take rest when feel tired.
Drink water as much as oossible

Page 12 of 14
DA•L11111 t1etrorac o,
PETROFAC INTERNATIONAL LTD.
JOB HAZARD ANALYSIS I RISK ASSESSMENT Sohar Refinery Improvement Project
Sohar, Sultanate of Oman
JV Job No. 120476
,..) .,JQi
JOB HAZARD ANALYSIS
PETROFAC JOB NO.: Jl-2022 Orp1c

JHA Title: I Under Ground GRP/GRE Piping I JHA No.: 09

Risk Residual
Step Activity Hazards Control Measures Responsible Person
Rating Risk
In dusty &. stormy weather job to be
stopped.
• Use dust mask during
dusty environment
11. Health and Welfare Personal hygiene P4 Provide portable bathroom I P2 Same as Above
• Personnel welfare washroom faci ity at work location
• Consumption of food is not
permitted at working.

Page 13 of 14
 d:,,JQi
Sohar Refinery Improvement
DAEI.IM Petrorac JOB HAZARD ANALYSIS I RISK ASSESSMENT Sohar, Sultanate of Oman
JV Job No. 120476
Orp1c
PETROFAC INTERNATIONAL LTD.
JOB HAZARD ANALYSIS
PETROFAC JOB NO.:Jl-2022

JHA Title: I Under Ground GRP/GRE Piping JHA NO.: I 09

PRE-START TOOLBOX TALKS
NOTE: As the worksite Supervisor, my signature (next column) confirms that I understand the hazards and control
measures on the previous page(s) and have communicated all requirements with my work crew and will abide by
all conditions and restrictions stated therein. List of names of work crew detailed below.
Company Signature Date
No. Name

1.
2.
3.
4.
5.
6.
7.
'
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Page 14 of 14