GRP Procedure

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No.
1
Contractor Comments on Rev.04

Construction/ Engieering Comments at Page
No. 6, 7 & 17.
Comments Resonse Sheet

(120476/Jl-02022/27-06-01/MMS-04
AHEC Response
Rev. 5)
AHEC
'
Method Statement revised as per Construction/

Engieering Comments at Page No. 6, 7 & 17.
M s.
DAU trofac 1
DPJV
Signature
=- "
al Hassan
Remarks
3
4
6
7
CRS Page 1
DAELIM Petrofac
CONTRACT NO. - 21297
DAELIM-Petrofac SRIP JV
.:, ,,, -. II
al Hassan
JOB NO :120476 / Jl-2022
AHEC JOB NO.:B-212
SOHAR REFINERY IMPROVEMENT PROJECT
METHOD STATEMENT
FOR
UNDER GROUND GRP PIPING
PACKAGE - 3 & 4
-
Revised as per
comments
As per comme.nts
JHA Revised & MHDS
I
attached
07-July-2015
27-May-2015
14-May-2015
03-Jan-2015
09-Nov-2014
8-0ct-2014
For Review
Rev.
Date
Descriptior
As per HSE'
comments JHA
Revised
FPI Documents
Attached for
Approval
Comments
incorporated & re
issued for Approval
AHEC JOB NO.:B-212
Owais
Kareem
Deepak
Pawar
Kameshwar
Rao
Prepared
Checked
by
Approved by
by
PROJ. ENG.
SIGN
DP - JV APPROVAL
DOCUMENT TYPE :
DOCUMENT NO.
Page
Mechanical Method
Statement
120476 / JI -02022 /
27-06-01 / MMS - 04
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Section
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1
Method Statement For Under Ground

GRP Piping
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al Hassan
INDEX
CONTENTS
PURPOSE
Page
No.
3
SCOPE
REFERENCES
DEFINITIONS / ABBREVIATIONS
MANPOWER
RESPONSIBILITIES
EQUIPMENTS &INTRUMENTS
HANDLING & STORAGE
8.1
LOADING & UNLOADING
8.2
STORAGE OF MATERIAL
I NSTALLATION OF UNDERGROUND PIPE SYSTEM
9.1
THE TRENCH CONSTRUCTION
9.2
SPOOLS LAYING
9.3
BACKFILLING
ADHESIVE BONDED JOINT
10
10.1
SURFACE PREPARATION PRIOR TO ADHESIVE BONDING
11
10.2
SEQUENCE OF WORK
13
10.3
REPAIR
19
LAMINATION JOINT
19
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
10
11
11.1
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,) .,JQi Method Statement For Under Ground

GRP Piping
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1111-1 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

S-000-5360-106
Issued by GRP Supplier.

Technical specification
components.
for
FRP
piping
and
ISO 14692 - 4
Petroleum and natural gas industries GRP piping

- Fabrication,installation and maintenance.
ISO 14692 - 2

- Qualification & manufacture.
ISO 14692 - 1

- 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.
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"' .,JQI Method Statement For Under Ground
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DIEIIHetrolac
GRP Piping
DEFINITIONS / ABBREVIATIONS
The word shall indicate a requirement.
The word should indicate a recommendation.
The word may indicate a possible course of action.
OWNER
Oman Oil Refineries

Company SAOC
MAIN CONTRACTOR
Daelim and Petrofac
DPJV
Daelim - Petrofac Joint Venture
SUB
CONTRACTOR
(AHEC)
Al Hassan Engineering Company SAOG
QP
GRP SUPPLIER
AFC
ASTM
BPS
BPQR
cs
CSR
GRP I GRE
HSE
ISO
ITP
MEK
MIBK
BA
SA
TS
TB
QA
QC
ID
OD
FLG
BOP
STD
STHP
and
Petroleum Industries
Sub Contractors Quality Plan

Future PipeIndustries (FPI)
Approved For Construction
American Standard for Testing Materials
Bonding Procedure Specification
Bonding Procedure Qualification Record
Carbon Steel
Company Site Representative
Glass Reinforced Polyester
I Glass Reinforced Epoxy
Health, Safety and Environment

International Organization for Standardization
Inspection and Test Plan
Methyl Ethyl Ketone
Methyl sobutyl Ketone
Bell Area
Spigot Area
Tapered Spigot
Tapered Bell
Quality Assurance
Quality Control
Inside Diameter
Outside Diameter
Finished Level Ground
Bottom of Pipe
Standard
Short-Time Hydraulic Pressure
al Hassan
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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.
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! Rev. No: 5 ! Date: 07-July-2015 !
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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).
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.
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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
8.2
STORAGE OF
movement.
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
mcx.
3;r.
max. 3m.
m.
-l
..I
---------------i - -
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INSTALLATION OF UNDERGROUND PIPE SYSTEM

Special attention needs to be given to
the
bedding
(minimum
backfilling of the trench, this provides the necessary support of
150mm), side
the
pipe,
filling
and
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.
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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.
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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
manufacturer's installation manual. During Backfilling care should be taken
regarding
pipe
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.
O.S x4
Taper Angle
rt
59
r
-\
.
I
(SA)
..... ...
------------1
f
l
. .
0-/.-.././. / . . . . .
.
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Tapered Bell End - Figure

2.
,i
i
-- --
spigot
funit
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.
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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.
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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
'
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _tI _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
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
Joint Bonding / Curing
---------------------T----------------
1
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _tI _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
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
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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
Clean the calibrated spigot with a clean and dry cloth or use a dust
assembly.
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
thickness gauge.
calibrated
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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.
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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
Setting Time
20C
25C
30C
35C
40-55C
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
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GRP Piping
Orp1c
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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
20-25C & 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
!
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Orp1c

GRP Piping
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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.
Page 18 of 27
- ac &
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,..).,JQI Method Statement For Under Ground

GRP Piping
Orp1c
10.3
REPAIR
al
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....
l.
-E-...,
{i
'.. .
Laakage
l
l
E
E
II ...
l I Insert
_ ...,
Cut
....
-----
neT,
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
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GRP Piping
Orp1c
- ac
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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
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Method Statement For Under

Ground GRP Piping
DIEll ac &
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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

GRP Piping
Orp1c
IEUI
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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
Page 22 of 27
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GRP Piping
Orp1c
The Lamination will harden at ambient
IEUl at . .
al Hassan
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
,;") .,
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Orp1c

GRP Piping
IIUl ac &
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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
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GRP Piping
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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
14
Combination spanner of required size.
Calibrated Torque Wrench of required capacity with wrench sockets.
PPE.
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
27
Page 25 of
tl _ ,
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Orp1c
16

GRP Piping
rolac l I .
al Hassan
Hydro-testing
Sectional / Final hydro testing shall be carried out as per approved hydro testing
17
procedure.
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.
Page 26 of 27
, tl . ,
JQI

GRP Piping
llll aw
Orp1c
al Hassan
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
IIAE t1etr
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PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC

JOB NO.:Jl-2022
JOB
HAZAR
D ANALYSI S
I RISK
ASSESSMEN
T
Sohar, Sultanate of Oman
Jqi
Orp1c
Sohar Refinery
Improvement Project
JV Job No. 120476
JHA Title:
Work Location:
SRIP Site
1.0 Permit(s) Required:
./ Confined
Space
N.
CAING
lHV IHat
_....U .J
os
,,, ./Hard
rnav.ire
Name
PPE Required:
REV
2.0
.
Please t1ck
3.0
Potential
Environmental
Hazards
6.0
Hazardous Materials
(attach SHOC
Cards)
Other Potential
Hazards
7.0
Additional
Instructions
5.0
Risk Rating Matrix
0
1
Severity
Date
./Ear Plugs
2
3
4
Entry
- ,
09
D,
r'\
I O Energy Isolation
./Clear Safety Glasses
lf2A/,I
OtAJAd.
.//' r - Name
./oust Mask
./FaceShield
Ocotton
Prepare d By:
Gloves
(.I') appropnate
boxes
Special Tools and

Equipment Required:
4.0
JHA No.:
Under Ground GRP/GRE Piping
Company: AHEC
I O Non-Destructive Test I O.Night W

./Dark Safety
Ochem
KameshwarRao M WJ-.-Name
Glasses Owelding
Oweld
I
Signature
Signature
Date
./Earmuffs
Mask
0Esca
Reviewed
By:
Approved
By:
0Leather Gloves (rigging)
./Cartridge Respirator
0Rubb
./Disposable Coverall
0Leather Gloves
./Hi-vi
0Gas Badge
Ooosimeter
0Multi-Gas Monitor
0Thermometer
(welding)
0Gas Detective
./Ventilation Fans
Ough
./Air B
Oufeline
ORetrieval Line
DPadlock, Hasp, Tags
Ought
0Air Horn
OWhistle
./Traffic Flags
./Traffi
ONoise
Osofl erosion
./Air Pollution (dust)
0Air P
Ocarcinogen
Olrritant
0Air Pollution
(smoke) Ospills
(wadi)
./Highly Flammable
0Toxi
./Electrical
0Pressure (air, water, gas)
0Mechanical (crush
./Ergo
Ought I Dark
OIgnition Sources
points) Ooust I Vapor
Osuffo
./Spills (to ground)
"Eye wash" to be provided.

People
No injury or health effect
Slightinjury or health effect
Minor injury or health effect
Major injury or health effect
PTO or up to 3 fatalities
More than 3 fatalities
Asset
No damage
Slight damage
Minor damage
Moderate damage
Major damage
Massive damage
Environment
No effect
Slight effect
Minor effect
Moderate effect
Major effect
Massive effect
Page 1 of 14
DA.LIM
t'etrorac GI
PETROFAC
INTERNATIO
NAL LTD.
JOB
HAZARD
ANALYSIS
PETROFAC
JOB NO.:Jl2022
JHA Title:
./Haz
JOB HAZARD ANALYSIS I

RISK ASSESSMENT
I Under Ground GRP/GRE Piping
Sohar Refinery
Improveme
nt Project
Sohar,
Sultanate
of Oman
JV Job No.
120476
,1
.,JQi
Orp
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Activity
Step
1.
Handling & Storage
Lowering & installation of

pipes
Hazards
Transportation
Falling materials
Improper lifting of GRP pipes
Improper storage
Slips & Trips
Suspendedload
Heavy (elevated) loads

Bad lifting equipment
Existing facilities
Communication
Dust & debris
Incompetent banks man I riggers
Defective
Lifting equipment
Poor procedure
Hitting
Falling
Use of chemicals (adhesive)
Over stressing of pipes
Risk
Rating
P4
P4
Control Measu
TBT to be conducted fo
designated task and re
Ensure the transportat
in inspected, approve
certifiedVehicles.
Ensure the drivers are
and adheres the safe
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
TBT to be conducted for the

Ensure the PTW requir
are met.
Ensure theloads are within
Trained, certified & co
operators.
Ensure the lifting equ
are inspected and fit f
purpose.
Ensure the existing facilitie
identified and taken i
prior to lifting I strin
Clear unobstructed vis
through all windows
Ensure proper houseke
Avoid the sharp edges
Ensure the riggers I b
are certified
Page 2 of 14
JOB HAZARD ANALYSIS I

RISK ASSESSMENT
u
Petrotac c.,
PETROFAC
INTERNATIO
NAL LTD.
JOB
HAZARD
ANALYSIS
PETROFAC
JOB
NO.:Jl2022
JHA Title:
Step
Sohar Refinery
Improvement Project
Sohar,
Sultanate
of Oman
JV
Job
No.
120
476
J
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Orp
1c

Activity
Hazards
Risk
Rating
Control Measu
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

tightening
Rotating parts
Exposure to chemicals
Fine particles while cutting
GRP pipes
Fire
Chemical spill
Power tools
Electrocution
P4

Ensure the painting and
is done at designated y
Deploy trained personn
Ensure the MSDS requ
are met.
Wear appropriate PPE a
& filin of
g
Page 3 of 14
JOB HAZARD ANALYSIS I RISK

ASSESSMENT
t1etrorac t11
PETROFAC
INTERNATIO
NAL LTD.
JOB
HAZARD
ANALYSIS
PETROFAC
JOB NO.:
Jl-2022
JHA Title:
Step
,..l.,
Sohar Refinery Improvement
DAIII.IM

JV Job No. 120476
JQi
Orp
1c
Under Ground GRP/GRE Piping

Activity
Hazards
Risk
Rating
Control Measu
MSDS.
MSDS to be discussed during
Working near excavations

Homemade I damaged tools
Pinch point
Manual Handling
Ensure barrier creams

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

ASSESSMENT
t'etrotac ...,
PETROFAC
INTERNATIO
NAL LTD.
JOB
HAZARD
ANALYSIS
PETROFAC
JOB NO.:
Jl-2022
JHA Title:
Step
Sohar Refinery Improvement Project

JV Job No. 120476
d.:-,J
Qi
Orp
1c

Activity
Hazards
Risk
Rating
Control Measu
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

Joints
Electrocution
Fire
Exposure to chemicals
Falls from height
Slip, trip &. fall
Falling/flying objects
Hazardous GRE fiber dust
and related hazards pri

the work every day.
PTW requirements to be me
Ensure all the electrica
cable &. connectors use
condition and to be colo
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,
JHA Title:

Activity
Step
Hazards
Risk
Rating
Confined space entry
Lack of oxygen
Presence of poisonous gas like H2S,
CO etc.
Improper access and egress
Lack of emergency evacuation system
Unqualified/inexperience work force
Lack of supervision
Slip,trip and fall
Lack of illumination
P4
JHA No.:
Control Measures
4.

JV Job No. 120476
JOB HAZARD ANALYSIS I RISK ASSESSMENT
PETROFAC INTERNATIONAL LTD.

JOB HAZARD ANALYSIS
PETROFAC JOB NO.:Jl-2022
,") .,JQi
Orp1c
09
Residual
Risk
Responsible Person
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).

designated task and related hazards.
Permit to work system to be followed
and full fill all PTW requirements
prior commencing the work at
confined
space area.
Conduct gas test prior starting the
work and repeat the gas test
depending up on the nature of work
Proper access and egress to provided
P2
Page 6 of 14
DAIII.IM
Petrorac tJ,
PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022
JHA Title:
Step

Activity
Hazards
Presence of explosive gases/fumes
Standard
operation
Absence
of
procedures
DA.LIM
..-etrotac I-'

JV Job No. 120476
Risk
Rating
JHA No.:
Control Measures
Forced ventilation fan to be provided.
Sufficient illumination to be provided.
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
PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.:Jl-2022
,") .,JQi
Orp1c
09
Residual
Risk
Responsible Person
Page 7 of 14
JV Job No. 120476

JOB HAZARD ANALYSIS

I RISK ASSESSMENT
Orp1c
JHA Title:
Step
,) .,JQi

Hazards
Activity
Risk
Rating
JHA No.:
Control Measures
09
Residual
Risk
Responsible Person
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
Cave in
Fall ng Objects
Use of defective hand tools for hand
excavation
Slip, trip, Fall
Working near Plant equipments
Existing services (if any)
Terrain Condition
Unauthorized entry
Improper access
Noise
Dust
Vibration
Adverse weather condition
Spillage
Personal Injury
P4

Obtain valid PTW from DPJV
before starting the work.
Ensure the equipments used are
inspected approved and fit for
purpose.
P3
Only experienced operators/

drivers to be deployed.
Ensure qualified banks men
are deployed along with all
the
equipments.
Ensure Reverse horns/
Revolvinglights of equipments are
working prior to job.
Keep safe distance from moving
equipments I Bucket Swing radius.
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

ASSESSMENT
JHA Title:
Step

Activity
Hazards

Sohar, Sultanate of
Oman JV Job No.
120476
Risk
Rating
JHA No.:
Control Measures
cl..:-,JQi
Orp1c
09
Residual
Risk
Responsible Person
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

JV Job No. 120476
JHA Title:
Step

Activity
Hazards
Risk
Rating
Control Measures
6.
Filling Water into the

Pipe(Using by diesel driven
pump)
Pressurized water
Noise
Water Spillage
Bad weather condition (General for all
activities)
P3
JHA No.:
,.c) .,Jqi
Orp1c
09
Residual
Risk
Responsible Person
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.
Follow the PTW System.

Ensure filling water should be prior
approved by QC
Using certified diesel pump
Securing hoses and connections safely
P2
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
ANALYSIS I RISK
ASSESSMENT
JHA Title:
Step

JV Job No. 120476
I
Hazards
Activity
Risk
Rating
JHA No.:
Control Measures
d.:-,JQi
Orp1c
09
Residual
Risk
Responsible Person
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
7.
Hydro test activity(Develop

pressure in section)
Spillage of diesel &. water

Pressurized water
Noise
Inferior quality hoses
Substandard hose connection
chemicals
P3
Follow the work permit system

Using certified diesel pump
Securing hoses and all connections
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
8.
Discharging of Hydro test

water
High pressurized water

Noise
Impactinglocal environments
P2
P3
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
Release the pressure as per the
procedure.
Identify the area for disposal and
mange as per the approved
procedure.
Water discharging under DPJV
instruction
P2
Page 11 of 14
DAIIUM Petrotac G
PETROFAC INTERNATIONAL LTD. JOB HAZARD ANALYSIS PETROFAC JOB NO.: Jl-2022

JV Job No. 120476
,)
.,Jqi
Orp1c
JHA Title:
Step

Hazards
Activity
Risk
Rating
JHA No.:
Control Measures
09
Residual
Risk
Responsible Person
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
Traffic incident
Incident, near miss etc.
P3
DPJV HSSE and Medical

numbers posted at work site
Numbers informed to AHEC supervisor
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.
P1
10.
Weather /Climate Conditions
Bad weather
P3
Resting shelter to be available on site
Take rest when feel tired.

Drink water as much as oossible
P1
condition
Same as Above
Page 12 of 14
DAL11111 t1etrorac o,

JV Job No. 120476

JOB HAZARD ANALYSIS
PETROFAC JOB NO.: Jl-2022
JHA Title:
Step

Activity
Hazards
Risk
Rating
,..) .,JQi
Orp1c
09
JHA No.:
Control Measures
Residual
Risk
Responsible Person
P2
Same as Above
In dusty &. stormy weather job to be

stopped.
Use dust mask during

dusty environment
11.
Health and Welfare
Personal hygiene
Personnel welfare
P4
Provide
portable
bathroom
washroom faci ity at work location
Consumption of food is not

permitted at working.
Page 13 of 14

JV Job No. 120476
DAEI.IM Petrorac
JOB HAZARD ANALYSIS
PETROFAC JOB NO.:Jl-2022
JHA Title:
JHA NO.:
d:,,JQi
Orp1c
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.
No.
Name
Company
Date
Signature
1.
2.
3.
4.
5.
6.
7.
8.
'
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Page 14 of 14

GRP Procedure

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GRP Procedure

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,.c> .

Contractor Comments on Rev.04

Comments Resonse Sheet

Method Statement revised as per Construction/

JOB NO :120476 / Jl-2022

AHEC JOB NO.:B-212

SOHAR REFINERY IMPROVEMENT PROJECT

AHEC JOB NO.:B-212

Method Statement For Under Ground

HANDLING & STORAGE

LOADING & UNLOADING

I NSTALLATION OF UNDERGROUND PIPE SYSTEM

THE TRENCH CONSTRUCTION

ADHESIVE BONDED JOINT

SURFACE PREPARATION PRIOR TO ADHESIVE BONDING

TIE-IN JOINTING, FITTINGS, BENDS

,) .,JQi Method Statement For Under Ground

(Adhesive Bonded Joints), Lamination jointing

minimum requirement for the installation of GRP

underground piping work for Sohar RefineryImprovement Project

GRP nstallation Manual

Issued by GRP Supplier.

Petroleum and natural gas industries GRP piping

Petroleum and natural gas industries GRP piping

Petroleum and natural gas industries GRP piping

Geotechnical nvestigation (soil report).

Standard Test Method for Resistance to Short

Applicable "Approved For Construction"

"' .,JQI Method Statement For Under Ground

Oman Oil Refineries

Daelim and Petrofac

Daelim - Petrofac Joint Venture

Al Hassan Engineering Company SAOG

Sub Contractors Quality Plan

I Glass Reinforced Epoxy

Health, Safety and Environment

Method Statement For Under Ground

Discipline Supervisor / Foreman

! Doc. No: 120476 / Jl-02022 / 27-06-01 I MMS-04

! Rev. No: 5 ! Date: 07-July-2015 !

Method Statement For Under Ground

Bonder / Lamination Technician

Lifting plan is coordinated and communicated to all involved and to communicate

EQUIPMENTS & INSTRUMENTS

HANDUNG & STORAGE

8.1 LOADING & UNLOADING

Method Statement For Under Ground

All pipe ends to be covered.

--- -------------- L._

Method Statement For Under Ground

INSTALLATION OF UNDERGROUND PIPE SYSTEM

backfilling of the trench, this provides the necessary support of

manufacturer instruction shall be followed.

THE TRENCH CONSTRUCTION

monitoring leaks during hydro test.

,.., .,JQi Method Statement For Under Ground

1111 dac & .

9.2 spools Lavina

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

Contractor start the backfilling.

"' - ,JQI Method Statement For Under Ground

elevation (FLG) with respect to above ground piping.

ADH ESIVE BONDED JOINTS