REFINERY TANK FARM

PACKAGE 6

Document No. Doc. Type Discipline System JOB No.

SA-JER-TFAAA-PSCL-508008 PRC CNS 3000235438

SEWER LINE WORKS

Revision
Remarks Issued Date Return Date
No.
00 Issued For Review 21-APR-2010 29-APR-2010
01 Issued For Acceptance 11-MAY-2010 31-MAY-2010
02 Issued For construction 31-MAY-2010

RAJ JOSEPH GILBERT HO

Prepared By Checked By Approved By Issued By

IMPORTANT:

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by means of electronic,
mechanical, photocopying, recording, or otherwise, without the written permission of Rotary Engineering Limited.
 REFINERY TANK FARM
PACKAGE 6

Revision History

Revision Revision date Page Scope of Revision

00 21-APR-2010 ALL Submitted for Review

01 11-MAY-2010 ALL Submitted for Acceptance
01 11-MAY-2010 3 AS CLOUDED
01 11-MAY-2010 4 AS CLOUDED
01 11-MAY-2010 5 AS CLOUDED
01 11-MAY-2010 6 AS CLOUDED
01 11-MAY-2010 7 AS CLOUDED
01 11-MAY-2010 9 AS CLOUDED
01 11-MAY-2010 10 AS CLOUDED
01 11-MAY-2010 11 AS CLOUDED
01 11-MAY-2010 12 AS CLOUDED
01 11-MAY-2010 15 AS CLOUDED
01 11-MAY-2010 16 AS CLOUDED
02 31-MAY-2010 ALL Issued for construction

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TABLE OF CONTENTS

1. SCOPE………………………………………………………………………………………….4
2. REFERENCE DOCUMENTS..……………………………………………………………..4-5
3. DEFINITIONS…………………………………………………………………………………..5
4. RESPONSILITIES…………………………………………………………………………..5-6

5. METHODOLOGY…………………………………………………………………………..6-11
6. QUALITY CONTROL AND QUALITY ASSURANCE……………………………………12

7. MACHINERY AND RESOURCES………………………………………………………...12

8. SAFETY EQUIPMENTS……………………………………………………………………12

9. HEALTH, SAFETY AND RISK ASSESSMENT………………………………………13-16

10. ATTACHMENT (Inspection Forms)………………………………………………………16

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1. SCOPE

This Scope is to derive the methodology for the sewer line to be performed for the
construction of tank farms for SAUDI ARAMCO TOTAL REFINING &
PETROCHEMICAL COMPANY (SATORP) in package 6 at Al-Jubail, Kingdom of
Saudi Arabia, in order to qualify and comply with all the company standards.

The following service lines:

1. WSS Pipes
2. OSW Pipes
3. RWS Pipes
4. RTR Pipes
5. RC Pipes
6. Others

01
2. REFERENCE DOCUMENTS
1.1. Approved IFC Drawings
1.2. Project Quality plan
1.3. Project ITP
1.4. Safety and Medical plan
1.5. Schedule “D” & Sec. 11-2 & 11-14 of JER Construction Safety Manual
1.6. Project Specifications & Standards
1.6.1. JERES-Q-005 Concrete foundations
1.6.2. JERES-Q-006 Asphalt concrete paving
1.6.3. JERES-Q-009 Concrete retaining walls
1.7 Company material specifications
1.7.1 JERMS-H-9016 Epoxy Coating of Steel Reinforcing Bars.
1.7.2 JERMS-M-2007 Fabrication of Structural and Miscellaneous Steel
1.7.3 JERMS-M-2008 Erection of Structural and Miscellaneous Steel
1.7.4 JERMS-Q-9016 Concrete Masonry units and Concrete Building
1.8 American Welding Society (AWS)
1.8.1 AWS D1.1 Structural Welding Code - Steel
1.8.2 AWS D1.4 Structural Welding Code – Reinforcing Steel
1.9 American society for testing and materials

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1.9.1 ASTM A 775/ASTM A 775M-97 Standard Specification for Epoxy

Coated Reinforcing Bars.
1.10 Company Inspection Requirements
1.10.1 Form 175-092000 Company Inspection requirements.
1.11 Other references (Saudi Arabian standard organization)
1.11.1 SASO SSA 2 Steel bars for the reinforcement of concrete
1.11.2 SASO SSA 224 Steel fabric for reinforcement of concrete

3. DEFINITIONS
All the definitions mentioned in the JER Documents have priority over other
standards and any deviation of these standards shall be brought to attention of the
COMPANY. It means to the company representative for resolution.

All terms used in the development of this procedure are defined below:

 COMPANY - SATORP
 CONTRACTOR - Petrol Steel Company Ltd / Rotary Engineering Ltd
 PSCL - Petrol Steel Company Ltd.
 Shall - Indicates a mandatory requirement
 Should - Indicates a recommended practice

4. RESPONSIBILITIES:
4.1 The project manager shall ensure that all operations related to sewer line
works have been risk assessed and necessary control measures have been
implemented to carry out the task in a safely manner.

4.2 Contractor shall engage their own surveyor for all the related surveying works.
Contractor shall follow IFC Drawings Coordinates and data, which will be
approved by the company. Contractor shall check and verify the BM before
execution of the works. Any changes and deviation found shall be
01
immediately notified to the company for resolution.

4.3 Contractor’s construction engineer shall review and confirm that all sewer line
works being implemented as per the activities stated in the method statement
and in compliance with the (SATORP) codes, standards and project
specifications.

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4.4 Contactor’s supervisor shall supervise all sewer line activities as required by
the project drawings and specifications. He shall prepare all the necessary
permits in advance and get it approved from the company designated
representative for the execution.

4.5 Contractor’s QA/QC Engineer shall closely monitor and assure all sewer line
activities are carried out as per (SATORP) QA/QC requirements and conduct
frequent inspections and maintain all records as required by project QA/QC
Program.

4.6 HSE officer shall monitor the sewer lines works and strictly enforce safety PPE
requirements and HSE plan.

‘5. METHODOLOGY

01
5.1 SETTING OUT

All survey coordinates and datum references shall be based on the JERES –
A –100 specification.

 Prior to start the work, contractor should obtain work permit.

 Establish benchmark (BM) near on sewer line or at construction
site. BM to be protected properly to avoid from destruction or
accidentally remove by others.
 Locate the actual coordinates of the trench to be excavated for
sewer line and mark it with permanent marker using rebar or timber
and barricade it properly to avoid for destruction by others.
 Ensure that all site survey report are properly documented and
witness or signed by SATORP representative according to
approved ITP or survey report.
 Execution of survey works shall witnesses by both parties for
ensuring the correctness and accuracy of the survey readings.

5.2 EXCAVATION WORKS

 Determine the width of trench to be excavated and place a mark on the

ground for driving of timber shoring or sheet piling. Shoring system
shall be designed by a qualified person and shall meet the standard
specification by SATORP.

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 Wherever underground services are crossing the trench, contractor will

provide enough distance at least 3 to 5 meters bothways from the
facility, use a barricade and then apply a manual excavation.

 Where necessary, edges of cut surface will be sloped to meet natural

sloping ground and wherever existing facilities along the trench using a
shoring system to be provided.

 Driving of timber shoring or sheet piling shall use the approved

mechanical machines. All materials used shall be in good serviceable
condition, and timber shall be sound, free from large or loose knots,
01
and proper dimensions.

 Placing of timber shoring or sheet piling and drive through to the

proposed elevation. Sequence has to repeat until complete with timber
shoring or sheet piling on both side of the area where need to excavate
the trench for sewer line.

 Excavation shall start after inspection and verification of the timber

shoring and sheet piling, if it is ready. Excavation permit as per
JERES–O-119 specification to be obtain an approval from SATORP
before commencing of excavation work. SATORP representative shall
be notified prior commencement of excavation works.

 Excavation works as per JERES-A-114 specification standard

requirements. All safety precautions (eg. Advance warning signs,
barricades, blinker lights) shall be in-place and displayed correctly.

5.3 DEWATERING

 Dewatering is needed when the water level is high on the excavated

trench. No construction shall start until the design of the de watering
system has been approved by the SATORP representative.

 Trench dewatering system shall be in accordance with the JERES-A-

114. Dewatering system shall not discharge into existing sewers or
completed sections of new sewers without the approval of the
authorities having jurisdiction on the maintenance of the sewer
systems.

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 Dewatering shall not discharge into open areas without the approval of
the authorities having jurisdiction on the maintenance of the area.

 The bottom of the trench shall be dry or sufficient drained so that there
is no standing water before the support and bedding layers are placed
and compacted. The bedding layer must be sufficiently drained so that
there is no standing water on the bedding layer before the pipe is
installed.

5.4 BEDDING

 Ground bed shall provide uniform and adequate support and drainage
along the entire length of the piping. Base support layer of crushed
stone base materials 150mm deep is required.

 The crushed stone base shall meet the requirements of class B base
materials as defined in JERES-Q-006 Table A, and shall be compacted
to at least 95% of ASTM D698.

 A non-woven geotextile with a unit weight of at least 100 g/m2 must be

placed between the crushed stone and the sand bedding layer to
prevent filtration of the sand bedding into the crushed stone matrix.

 Alternatively, a double layer of sand bags may be used for a base

support layer, with approval from the SATORP representative.
5.5 INSTALLATION OF PIPES
RC PIPES

 Surveyor has to determine the center line of the sewer line for
positioning of RC pipe. Reduce and invert level shall confirm for
achieving the gradient or contour of the sewer line.

 From storage yard, RC pipe shall deliver to work site using lorry crane
and unload directly into the trench and laid over to the prepared
bedding for actual positioning.

 Placing of RC pipes shall start from downstream end manhole to

upstream end manhole.

 Unloading and placing of RC pipe over the prepared bedding and

aligned it to the center line. Secure the RC pipe with sand bag at both
sides to prevent from minor movement and maintain the accuracy of
the center line.

 Sealed the joint gap from inside to outside with approved material and
request with SATORP representative to inspect and get approval for
partial backfilling of sewer lines.
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RTR PIPES
RTR PIPE SCHEDULE

 The RTR pipe shall be constructed as per project design and the
approved drawing for construction. Based on the approved drawing,
RTR pipe schedule shall be prepared. The RTR pipe schedule contains
the following details:
The size of RTR pipe, length required, number of pipes (male &
female), number of adhesive kits.
RTR PIPE INSPECTION BEFORE ASSEMBLY

 AFC isometric drawings of RTR pipe to be issued for reference prior to

assembly.

 All RTR pipe and fittings shall be visually inspected for scratches,
damage ends, cracks, de-lamination, crushing, weathering and
cracked. Damaged pipe and fittings shall not be installed.

 RTR pipes (male & female) shall be cleaned and dried before
installation.

 Installation for jointing RTR pipe shall be accordance with the

manufacturer recommendation.

 Training shall include familiarization and proper handling of the

materials use of the equipment and the manufacturer installation
instruction.

 Training certificate for installing RTR piping system must be obtained

from the RTR piping manufacturer.
LAYING RTR PIPING AND ASSEMBLY IN THE TRENCH

 RTR pipe joints shall be restrained or unrestrained, these joint shall be

assembled in accordance with the manufacturer procedure for specific
application. Heating blankets shall be used to cure adhesive bonded
joints maximum from 30 minutes to 45 minutes.

 For trenches 2 m deep or less, pipe assembled next to the trench shall
not be moved within three pipe lengths of an uncured joint. The
pipeline shall be lowered into the trench progressively to avoid
excessive joint angular deflection.

 Site engineer/supervisor shall double check the bottom of the trench

shall be dry or sufficient drained so that there is no standing water
before the support and bedding layers are placed and compacted.
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 Site engineer/supervisor shall double check the trench width
requirement for RTR pipe size 300-600 the minimum width is 2 x O.D,
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for over 600 O.D + 600. The depth of the trench shall be dug deep
enough to provide minimum ground cover above the top of pipe, for
RTR pipe sized under 150mm sized minimum cover is 600mm RTR
pipe sized 150mm and larger is 900.

 Alternatively, a double layer of sand bags may be used for base

support layer, with approval from the Company Representative.

 A bedding layer of clean sand 150mm depth is required for all

trenches. The sand shall be free of debris and rocks and compacted to
at least 70% relative density. Compaction by water flooding is allowed
for clean, freely draining sand provided the excess water is
continuously collected in sumps and pumped out of the trench. The
bedding layer is placed and compacted, the pipe laid, and the trench
backfilled up to 150 above the pipe.

 Piping shall have steel sleeves at road crossing and railroad crossing
in accordance with the Company Standard Drawing.

 If it is impossible to achieve the minimum cover as specified in this

standard, the piping shall be protected by a reinforced concrete slab, or
metallic casing in accordance with JERES-460 prior to approval from
the Company Representative.
BACKFILLING and REMOVAL of SHORING

 Backfilling and compaction shall be constructed in accordance with

JERES-A-114 and JERES-Q-006. Ensure that the backfilling area is
cleaned, free from unwanted material and has been inspected and
approved by SATORP representative prior back filling commencement.

 Backfilling and removal of trench support shall be accomplished first by

backfilling up to a level allowing for the removal of the lower braces.

 Layer of backfill shall be positioned in the trench to the next layer of

braces to be removed.

 Fill up of thickness approved fine sand bedding on the trench. After lay-
out / install the pipe and fill with approved soft sand as padding around
the pipes by 200mm.

 The remaining excavated depth of trench, contractor might use

selected material for filling and apply compaction by layers of 200mm
according to relevant method statement.
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 Removal of trench supports shall progress together with the backfill

from the bottom of the trench. In unsuitable soil, ropes shall be used to
pull out jacks or braces from above after cleared the trench.

 All excavations shall be backfilled and consolidated, and the surface be

left in good condition as soon as is practicable.

 Reinstate the area as per existing or required ground level.

 Pulling up of all timber shoring or sheet piling and transfer it to the next
01 location where sewer line is needed to installed.

 Pulling up to all timber shoring or sheet piling and transfer it to the next
location where sewer line is needed to installed.

5.6 GRAVITY TEST (NON PRESSURISED PIPE)

 Gravitational Test or Flow Water Test to the top of upper cleanout is

mandatory. All gravity flow sewer piping networks shall be designed to
be free flowing and self draining to ensure that no effluents remain in
the piping no flow conditions.

 Gravity flow piping shall be sized to maintain a minimum flow velocity

of 0.9 meters per second (3 feet per second) at the peak flow rate
under full below condition.

 Forced main sizing shall be based on a minimum flow velocity of 0.9

meter per second (3fps), and a maximum velocity as listed in JERES-
L-132 under “Water Sea/Saline” for different piping materials

 Effluent velocity within the sewer piping networks shall comply with the
requirements specification. JERES-S-020 Section 5.4.

 Sanitary sewer systems shall not be combined with oily water system.

 Sewer shall be flushed with water to remove foreign matter before

putting it into service.

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6. QUALITY ASSURANCE AND QUALITY CONTROL

The quality of the works shall be on line with the SATORP standards.
Required tests shall be performed on each stage of sewer line works and the
report shall be prepared and submitted to the company representative for prior
approval.

7. MACHINERY AND RESOURCES

Bar Cutting Machine
Bar Bending Machine
Hand Tools
Lorry Crane
Markers
Welding Machine
Generator
Grinders
Blowers
Air-compressors
Concrete trucks
Excavator/Grader Profiler
Water Pump
Chain Puller

Man Power
Civil Engineer
Civil Supervisor
Surveyor
Safety Supervisor
Foreman
Lorry / Truck Driver
Operators
Labourer 01

8. SAFETY EQUIPMENTS
Fire extinguisher
Hand-held-sirens
PPE
Warning Signs

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9. HEALTH, SAFETY AND RISK ASSESSMENT

The health and safety shall perform a splendid role in all construction activities
to ensure that all the works are being carried out in a safe manner and
creating a healthy environment at site. All works performed by individuals shall
comply with the SATORP health and safety standards

Contractor’s site supervisor shall conduct regular toolbox meetings and

explain the requirements of PPE and other special needs to create a safe
working environment. He is responsible for achieving the target and the
project milestones.
Appropriate work permit shall be applied in accordance to the requirements of
Schedule “D” and Section II-14 of the JER Construction Safety Manual.

Contractor’s Safety Inspector shall closely monitor and assure that all works
are carried out in highly safe manner, gearing the workers with full strength of
safety protective equipment, preparation of safety barricading and dust control
screening wherever applicable in safe manner, safe workability of equipment
to be used and fulfilling any other additional safety needs as required during
work executions. He shall also check and ensure that only qualified personals
are carrying out the equipment & machinery related works.

Contractors shall appoint their own safety manager and he shall conduct
safety walk around the site in weekly basis and prepare and submit a report to
the company .Any accidents occurred shall be informed immediately to the
company and recorded accordingly.

All excavation/backfilling works shall be done safely in accordance to the

requirements of Schedule “D” and Section II-2 of the JER Construction Safety
Manual.

9.1 A safety officer or a safety coordinator shall be present at site full time
during the execution of works and also to clarify the safety related issues.

9.2 Daily toolbox meetings shall be conducted as mandatory requirements

to describe and discuss the safety related issues.

9.3 The works shall be risk assessed and proper guidance should be
managed before implementation of every individual activities.

9.4 Following safety requirements shall be fulfilled

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9.4.1 Safety barricade shall be provided wherever necessary.

9.4.2 Necessary safety signboards shall be provided at work places

as required by safety standards.

9.4.3 All workers shall be provided with job specific Personal

Protective Equipment.

9.4.4 Safety flickering lights shall be provided for vehicles working on

longtime hours especially on night hours.

9.4.5 The approving authority shall inspect all equipment checklists

for machineries related to the activities prior before
commencing the works.

9.4.6 Working equipment shall be equipped with amber lights, horns,

safety guards etc. as required and mentioned in safety
manuals.

9.4.7 Any incident at site shall be immediately reported to company

and recorded.

9.5 Weekly safety statistics reports and safety performance reports

etc. shall be prepared and recorded.

9.6 Daily safety task assignment to be prepared.

9.7 Man shelters shall be provided to protect the workers from adverse
climatic condition, i.e. sand storm, high temperature.

9.8 Potable water source shall be provided for adequate numbers for
workers.

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RISK ASSESSMENT AND SAFETY MEASURES

Possible Accident / Health & Existing Risk Additional
No Work Activity Hazard
Person at Risk Control (if any) Risk Control
Personal protective
SWP for
High Noise Level Noise induce hearing lost equipment (eg ear
excavation
plug)
Mechanic to
Regular
Exposure to Carbon dioxide Asphxiation, affects Central Nervous monitor the
maintenance of
and carbon monoxide System, blood and lungs maintenance
Excavator
Excavation and schedule
1 SWP for
backfilling Soil collapse Serious injury or death Shoring
excavation
Trained Excavator SWP for
Excavator swing onto workers Serious injury or death to workers
Operator excavation

Effective Safety Put warning

Falling into excavated trench Serious injury or death
Barricade sign
Lifting Supervisor,
Signal/Rigger man
to oversee the
SWP for lifting
lifting operation/
Falling materials Serious injury or death to workers equipment
Competent Crane
and operation
Operator Barricade
2 Formworks
the erection of
formwork area
Remove or
Personal protective
Hit by protrusions objects eg bend the
Injuries to eyes and body equipment (eg
Rebar, nails etc protruding
safety goggles)
nails.
Mechanic
regular check
Personal protective
and
Sharp noise cutting of equipment (eg ear
NIHL (Noise Induce Hearing Loss) maintaining to
reinforcement bars plugs, safety
cut and
goggles)
bending
machine
Personal protective
equipment (eg Provide
Cut from rusty reinforcement Demin gloves) workers with
Lock Jaw (Tetanus)
bars Provide Machine anti tetanus
guard to paddle vaccination
Reinforcement step
3
Bar Mechanic
Personal protective
regular check
equipment (eg
and
Demin gloves)
Expose to cut/bend machine Finger Crush or amputated maintaining to
Provide Machine
cut and
guard to paddle
bending
step
machine
Personal protective Barricade
equipment (eg working areas
Hit by reinforcement bar during Demin gloves) and workers
Injury/concussion
the bending process Provide Machine must be
guard to paddle trained to do
step the job
4 Site supervisor and
lifting supervisor SWP for lifting
Cranes equipment fails or Serious injury or death to workers
supervision / equipment
collapse and property lost
Permit to work for and operation
lifting operation
Site supervisor and SWP for lifting
lifting supervisor equipment
Falling of concrete bucket Serious injury or death to workers
Hoisting of supervision and operation
during hoisting and property lost
concrete using Barricade the
cranes hoisting area.
Personal protective SWP for lifting
equipment (eg equipment
safety helmet, and operation
01 Workers knock by concrete
Physical injuries safety belt etc)
from bucket during movement
Banks man to
direct the
movement of
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bucket Barricade
the hoisting area
Personal protective
equipment (eg
Dropping of concrete from
Physical injuries and body irritation safety helmet) NIL
bucket
Barricade the
hoisting
Personal protective
Rotating shift
Pumping Noise from pumping Noise induce hearing lost (NIHL) equipment (eg ear
of workers
5 concrete using plug)
concrete pump Manual handling of concrete Rotating shift
Ergonomics, musculoskeletal NIL
hose of shifting of steel pipes of workers
Personal protective
Noise induce hearing lost (NIHL), Rotating shift
Process of Continuous noise generated equipment (eg ear
NID of workers
6 vibration of plug)
cocnrete Proper
Trip and fall Physical injuries and irritation NIL
housekeeping

10. ATTACHMENT (Inspection Forms)

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