- SCOPE
- DEFINITIONS
- REFERENCES
- RESPONSIBILITY
- TOOLS AND EQUIPMENT
- WORK PROCEDURE
- INSPECTION
- HYDRO TEST
- SAFETY ACTION PLAN
- EMERGENCY RESPONSE PLAN
- SAFETY HAZARDS
PLUMBING, DRAINAGE & VENT PIPING WORK PROCEDURE | METHOD STATEMENT
1.0 Scope
This method statement defines the method of various work activities involved in plumbing system for Jazan refinery and terminal project. This method statement is applicable only for the plumbing work of following building in this project.
• Process Interface Building
• Substation Building
Materials
• Copper pipe and fittings ASTM 888 shall be used for plumbing work.
• Method Statement :
A Written document that explain the procedure and safe execution Method at various stages.
3.0 References
3.1 Codes and standards.
• ANSI American National Standards Institute
• ASTM American Society for Testing & Materials
• IBC International Building Code. 2003
• NFPA National Fire Protection Association
• SASO Saudi Arabian Standards by Saudi Arabian Standards Organization
• UMC Uniform Mechanical Code
• UPC Uniform Plumbing Code
3.2 SAUDI ARAMCO Standards and Specification
• SAES Saudi Aramco Engineering Standards.
• SAES-A-004 General Requirements for Pressure Testing.
• SAES-A-005 Safety Instruction Sheets.
• SAES-A-112 Meteorological and Seismic Design Data.
• SAES-B-008 Restriction to use of Cellars, Pits and Trenches.
• SAES-B-014 Safety requirements for Plant and Operations Support Buildings.
• SAES-B-069 Emergency Eye Washers and Showers.
• SAES-K-100 Saudi Aramco Mechanical(HVAC) Code.
• SAES-L-105 Piping Material Specification.
• SAES-M-100 Saudi Aramco Building Code.
• SAES-O-100 General Requirements Safety and Security.
• SAES-S-010 Sanitary Sewers.
• SAES-S-040 Saudi Aramco Water Systems.
• SAES-S-060 Saudi Aramco Plumbing Code.
• SAES-S-070 Installation Of Utility Piping Systems.
• SAEP Saudi Aramco Engineering Procedures.
• SAEP-322 Performance Qualification Testing and Certification of Saudi Aramco Brazers.
• SAEP-323 Performance Qualification testing of Contract Welders & Brazers.
• SAEP-324 Certification Review and Registration of Project Welders and Brazers.
• SAMMS Saudi Aramco Material System Specification.
• 01-SAMMS-024 Pipe Handling and Testing.
• Saudi Aramco Safety Handbook.
• Saudi Aramco Construction Safety Manual.
4.0 Responsibility
4.1 Site Manager
He is responsible to provide his site teams with appropriate resources to ensure that works are done in accordance with the project quality requirements.
4.2 Civil/Building Superintendent
He is responsible to ensure the full implementation of this Method Statement and identify the requirements and maintain sufficient resources for the effective accomplishment of the scope of work for Installation of civil/ Building work.
4.3 HVAC Supervisor
He shall take the whole responsibility for the activities of HVAC & Plumbing Works to be executed.
1. Making plan and reporting daily, weekly and monthly to his superintendent.
2. Supervising and monitoring his works for safe execution and for good and quality
production as per the approved drawings and specification.
3. Reporting any incidentals and emergencies arising during the course of the works to site Manager and taking first aid at field.
4.4 QC Manager/ Supervisor.
He is responsible to ensure the full implementation of the required minimum quality requirements, procedures and maintain the required documentation as per applicable Saudi Aramco Inspection and test plan for the final acceptance and handover of document.
4.5 QC Inspector
He is responsible to conduct daily surveillance and inspection as necessary in accordance with this procedure and project quality requirement. Prepare quality control records and secure readiness of completed activity for final acceptance, secure the QC documentation which is required for final handover.
4.6 HSE Manager/ Supervisor
Ensure that the working area is in safe working condition and minor properly from time to time the implementation of safety procedures, requirements and ensure that all safety equipment’s and tools are present at working site and in proper or good condition. Verify that equipment and tools inspected for Saudi Aramco minimum requirements.
4.7 Work Permit Coordinator
The work permit coordinator shall be authorized for all the work permit related activities concern and he shall be responsible channel. If necessary trial can be conducted to read the scenario of the work and obtain permits. The issuer and receiver both are the key personnel for complete execution of the work. As well as internal work permit coordinator shall be the responsible senior person for guiding and granting work permit through Saudi Aramco for all site activities. The other internal premises Work Permit shall be issued.
5.0 Tools and Equipment’s
All Equipment and tools being mobilized on site will be certified and in good and running condition. It shall be double checked and inspected by the concerned personnel prior to use of them. Equipment operators and drivers shall have a current Saudi Arabia license with a valid Saudi Aramco certificate (GI 7.025 Table I). The tools and Equipment’s are listed as below.
• Transit
• Grinder
• Chipping tools with Hammer
• Grout mixer
• Lifting tackles (Sling belt, wire, shackles)
• Chain blocks
• Wire puller
• Generator
• Pump for water pressure test
• Boom Truck
6.0 Work Procedure
6.1 General
1. This instruction encompasses all the work activities associated with installation of plumbing work. Subcontractor safety together with safety Department shall inspect the site prior to starting the work. The safety departments shall ensure that all the requirements, in relation to protection.
2. No work is to start prior to a complete safety clearance and work permits to proceed being issued.
3. For Employee working more than 1.8 Meters above any adjacent working surfaces, proper work platforms with a guardrail system shall be provided. When the work is to
be accomplished outside a work platform, a ANSI complaint full body harness with double shock absorbing lanyard shall be worn that is securely fixed to a dropline or anchor.
4. Employee shall not be permitted to work above vertically protruding reinforcing steel unless it has been bent over or capped.
5. Critical crane lifts are required for certain conditions and activities, except as approved during a turnaround and inspection (T & I) or shut down.
6. When working at night, spotlights or portable lights for emergency lighting shall be provided as needed to perform the work safely.
7. At night, Flagman shall wear light-reflecting vests and gloves, and use reflective signs or flags.
6.2 Work Permits
1. Secure work permit required prior to start of any activities.
6.3 Personal Protective Equipment
1. Proper PPE such as hard hat, Safety goggles, cover-all, safety shoes, hand gloves, harness, etc. shall be arranged and implemented with the personnel engaged in the working area.
6.4 Drinking Water System
1. All Drinking water piping shall be designed, fabricated and installed in accordance with project specifications specified on section 3.
2. Drinking water pipe shall be water supply for all systems including a humidifier and emergency eye-washers.
3. Drinking water pipe shall be copper tube confirming to ASTM B88. Copper tube below ground shall be Type” K”. Copper tube for water piping shall have a weight of not less than Type “L”.
4. All fittings shall be wrought copper with solder or brazed joints of ASTM B88. Pipe fittings shall be approved for installation with piping material and shall conform to the pipe standards.
5. All joints surfaces shall be cleaned.
6. All piping shall be provided by labels made of rugged plastic with permanent adhesive according to Project Specification.
7. All drinking water piping shall be insulated with fire-retardant insulation in accordance with design drawings and Project Specification.
8. Brazing and Welding.
a. Welding procedures shall be qualified in accordance with either one of the following standards;
– ASME BPV SEC IX
– AWS D10.9, using either Level AR-1 or AR-3.
b. Standard welding procedures specification (WPS) in accordance with AWS B2.1 or the Saudi Aramco Welding Manual may be used without additional qualification, provided that the contractor accepts full responsibility for the use of the WPS. And the WPS is used without modification.
c. Brazing shall be performed in accordance with the procedures and techniques specified in either the copper tube Handbook of the copper development association, or IAPMO IS 3-93. For other materials and applications, procedures shall be qualified in accordance with ASME BPV SEC IX. Standard brazing procedure specifications in accordance with Saudi Aramco Welding manual may be used without additional qualification, provided that the subcontractors accept full responsibility for the use of WPS, and WPS is used without modification.
d. Welder and Braziers shall be certified in accordance with SAEP-321, SAEP 322. SAEP-323 0r SAEP-324 as applicable.
e. All surface to be welding / Brazing shall be dry and free of mill scale, oil, grease, dirt, paint, galvanizing and other contaminants that may harm the completed weld(s).
f. Each layer shall be complete prior to starting of the next one (no block welding).
g. Proper supporting & locking is required to prevent distortion.
9. Drinking water shall be purged of deleterious matter and disinfected prior to utilization. The pipe system shall be flushed with clean, drinking water until dirty water does not appear at the point of outlet.
10. Testing (Portable water system inside Building)
a. Potable water piping inside building shall be tested in accordance with the requirements of the Uniform plumbing code (UPC). Exceptions to UPC requirements are listed in SAES-S-060. (Para. 6.8 of SAES-S-004)
b. Upon completion of a section or of the entire hot and cold water supply system, it shall be tested and proved tight under a water pressure not less than the working pressure under which it is to be used. The eater used for tests shall be obtained from a portable source of supply.
c. Except of plastic piping, a fifty (SO) pound per square inch (344.S kPa) air pressure may be substituted for the water test, in either method of test, the piping shall withstand the test without leaking for a period of not less than fifteen (15) minutes.
6.5 Drainage waste and Vent piping system
1. The drainage and vent piping system shall be designed, fabricated and installed in accordance with SAES-S-060 and uniform plumbing code.
2. All drainage, waste and underground vent piping shall be PVC of schedule-40 pipe conforming to project specification.
3. The vent piping of above ground shall be galvanized carbon steel confirming to project specification.
4. All fitting shall be socket type, suitable for solvent welding. All joints shall be clean and from moisture.
5. Primer and solvent shall confirm to ASTM Specification, Solvent cements joints shall be permitted above and below ground.
6. All solvent welds shall be in accordance with solvent cement manufacturer’s instruction.
7. Drainage piping for future fixture shall terminate with an approved cap or plug.
8. Piping labels shall be provided for each piping which is made of rugged plastic with permanent adhesive.
9. Indicate the direction of flow and service at least once in each space, at least once in every 6M.
10. Floor drain or similar traps directly connected to the drainage system and subjected to infrequent use shall be provided with an approved (Acceptable to the
Authority Having Jurisdiction) automatic means of maintaining their water seal. Except where not deemed necessary by Chairman of plumbing and utilities Standard committee.
11. Galvanized steel pipe of 80CG0D1, with galvanized malleable iron fittings shall be provided for vent piping above grade.
12. Transition from nonmetallic to metallic piping shall be done in a manner that the weight of metallic piping shall not be transferred to nonmetallic piping (PVC female threaded fittings are prohibited by UPC Section 6.2.2). And flexibility requirements shall be taken into account separately for both piping materials. The transitions from nonmetallic to metallic piping shall be flanges installed in horizontal line considering the above requirements.
13. The below ground metallic piping not less than 150 mm above the finish surface shall be externally coated with APCS-113C as described in SAES-H-002.
14. Building Drainage and vent piping Hydro-test
a. The piping of the plumbing, drainage and venting system shall be tested with water.
b. The Authority having jurisdiction may require the removal of any cleanouts, etc. To ascertain if the pressure has reached all parts of the systems. After the plumbing fixtures have been set and their traps filled with water, they shall be submitted to a final test.
c. The water test shall be applied to the drainage and vent systems either in its entirety or in sections.
d. If applied to the entire system, all openings in the piping shall be tightly closed. Except the highest opening, and the system filled with water to point of overflow.
e. If the system is tested in sections, each opening shall be tightly plugged except the highest opening of the section under test, and each section shall be filled with water, but no section shall be tested with less than a ten (10) feet (3048mm) head of water. In testing successive sections, at least the upper (10) feet (3048mm) of next preceding section shall be tested, so that no joint or pipe in the building (Except the uppermost ten (10) feet (3048mm) shall have been submitted to a test of less than a ten (10) fool (3048mm) head of water.
f. The system (Joints or exposed) shall be tight at all points for a period of 4 hours.
g. Lines whose joints have been backfilled (Joints not exposed) shall be tested (Kept under pressure) for twenty-four (24) hours.
7.0 Inspection
The QC inspectors of subcontractor, Saudi Aramco representative shall carry out the necessary tests and inspection throughout the plumbing works. Saudi Aramco QC. Representatives shall witness the test or inspection in the plumbing piping installation. Inspection shall be according to Saudi Aramco Inspection & test Procedures, and also based with latest issued for Construction drawings. All reports prior to installation are to be submitted to Daewoo/ Saudi Aramco.
8.0 Hydro test
• Water test is conducted to ensure and prove the tightness of the joints and ensure there are no leaks in the piping system.
• The water pressure test can be applied to the system in its entirely or in sections.
• All openings in the piping will be tightly closed by special cast iron pipe plugs or by another suitable means and the system filled with water to the point of overflow from the highest point.
• The plugs can be temporarily opened to make sure that all air has been vented and that water has reached all parts of the system.
• Ensure the pressure gauges used have current calibration stickers.
• Remove all persons not directly involved with the test from the test area.
• Install the calibrated test gauge so it is visible at all the time.
• Ensure that water used for the test at not less than ambient temperature, but in no case less than 70 F.
• Pressurizes the system, raising the pressure in the system gradually until the designed test pressure is achieved.
• Ensure the metal pipe temperature at the time of the hydrostatic test does not exceed 120 F.
• If the test is above maximum allowable working pressure (MAWP), reduce the MAWP while making a full through inspection for leaks.
• No section of the pipe shall be tested to less than 3-meter head of water. In testing successive of piping, at least the upper 3 meters of the next proceeding section will be tested. Except the upper most 3 meters, the whole system shall have been subjected to a height of less than 3 meters ahead of water.
• The water shall be kept in the system or in the portion under test for at least 30 minutes before inspection starts.
• While the system is under pressure, a careful inspection shall be made on all pipes and joints. If any leaks in joints or evidence of defective pipe or fittings is revealed, the defective pipe/fitting should be immediately replace with new joints and materials.
• After the correction is made the test pressure will be maintained for minimum of 30 minute.
• Duration of test period will be 4. hours.
• Testing will be inspected by Aramco PID to their satisfaction and document for correct test will be maintained by getting approval in test certificate from PID representative.
10.0 Safety Action Plan
The safety officer shall carry out the safety site inspection to ensure that safety requirements laid out in the safe work plan are followed during. Subcontractor Safety Inspector / Supervisor shall review Safety Action Plan and secure required Work Permit if necessary prior to start of any activities.
10.1 Job safety analysis and work execution risk assessment must be secured for various activities Covered in erection of plumbing piping.
10.2 According to nature of job work execution risk analysis talk (WERAT) shall be used and fill in every day WERAT be filled in daily together with tool box meeting and shall be attached to the PTW and be available in PTW Box.
10.3 Acquire appropriate work permit for all associated works within the project specific work scope and working area.
10.4 Ensure tools and equipment’s calibrated as necessary, inspected/ accepted within Saudi Aramco minimum requirements.
10.5 Safe working condition and sufficient safety tools and equipment at working area.
10.6 Personnel responsible for execution of work activities must wear minimum personal protective equipment’s (PPE). I.e. hard hat, foot protection, safety goggles.
10.7 Plant and equipment operators shall possess license and certification asper G. I. 7.025 and personal performing at working area shall have enough experience/knowledge for the specific activity.
10.8 Conduct tool box meeting related to the work activities. Safety personnel shall monitor the activity to ensure that optimum level of safety is carried out.
10.9 Competent Persons Qualified competent persons as Standards shall be assigned and thereafter be responsibilities regarding safety. List of competent personnel will be provided by Contrator and submitted to Client/Company.
11.0 Emergency Response Plan
11.1 Fire Prevention: storage of flammable and explosive materials shall be kept to minimum quantities. Ignition sources shall be kept away from flammable and combustible materials, this include:
a. Smoking (Permitted only in the designated area)
b. Electrical cords that are damaged.
c. Welding, torch cutting and brazing.
d. Vehicle engine and electric motors.
e. Hot plates.
f. Minimize flammables at the work site to the daily supply that is needed.
g. Metal solvent containers shall have a label.
h. Gasoline and diesel engine shall be operated only in well ventilated areas.
11.2 Adequate numbers and easily accessible fire extinguishers shall be provided and maintained on the job site and the specified fire hazards.
11.3 Injury and Damages Reporting; Subcontractors shall ensure that all accident report will be reported immediately to HSE representative.
a. Fatality.
b. Injuries requiring medical attention, which result the loss, time injuries.
c. Damages over SR. 10,000.00 to contractor plant equipment’s.
d. Damages in any amount of Saudi Aramco.
e. Fires.
f. Damages or near misses report for crane and equipment. In addition to the report above, subcontractor must keep records for all the injuries and damages.