CLIENT : QATALUM

PROJECT TITLE:

WET SCRUBBER QUENCH REINFORCEMENT AND RELINING

DOCUMENT TITLE :

Method Statement for Reinforcement and Relining of the internal body of

wet scrubber quench duct and pipes.

Petrol & Gas Construction Co.

PGCC Document No PGCC-MS-0705-19

QATALUM Document No -

07-05-2019 A For Approval MJR BD MA

PREPARED CHECKED APPROVED APPROVED

REV. REASON FOR REVISION
DATE
NO. PGCC QATALUM
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DOCUMENT TITLE: Method Statement for Reinforcement and Relining of the internal body of wet scrubber quench duct and pipes.

TABLE OF CONTENTS

1. Purpose:.................................................................................................................................................................3

2. Scope: ....................................................................................................................................................................3

3. References: ............................................................................................................................................................3

4. Responsibilities: .....................................................................................................................................................4

5. Materials & tools:...................................................................................................................................................4

6. Material storage:....................................................................................................................................................5

7. Repair methodology ..............................................................................................................................................5

8. Test: .......................................................................................................................................................................7

9. Safety precaution ...................................................................................................................................................7

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DOCUMENT TITLE: Method Statement for Reinforcement and Relining of the internal body of wet scrubber quench duct and pipes.

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1. Purpose:

The purpose of this method statement is to establish a uniform procedure to carry out GRP Relining and
Reinforcement on Scrubber, It aims to ensure that the work force involves to perform the operations have a
complete understanding of the operating standards and safety practice associated with the use of tools/materials.

2. Scope:

This Method Statement shall describe the procedure and sequence of GRP Relining and
Reinforcement on Scrubber
Execution of GRP lining will be performed by skilled & expert PGCC technicians

PGCC shall ensure the safety of personnel and equipment in the work area were work is being
performed, PGCC shall provide all the safety and protective equipment.

3. References:

Standard Practice for Classifying Visual

ASTM D2563 Defects in Glass-Reinforced Plastic Laminate
Parts

Standard for GRP Fabrication, Installation

ISO 14692
and operation.

Standard Test Method for Indentation

ASTM D2583 Hardness of Rigid Plastics by Means of a
Barcol Impressor

Vendor Method statement, procedure

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DOCUMENT TITLE: Method Statement for Reinforcement and Relining of the internal body of wet scrubber quench duct and pipes.

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4. Responsibilities:
4.1 Project Engineer has the overall responsibility for the implementation of this method
statement and shall well ensure that team members are aware of the requirements of
the Method Statement.
4.2 The overall responsibility lies with the Site supervisor/Engineer who will be supported
by qualified technicians, QA/QC and safety personnel to ensure that the activities
incorporated in this method statement & all quality aspects are followed.
4.3 QA/QC Engineer and QA/QC Inspector are responsible to all QA/QC related documents
and implementation.
4.4 Qualified Technicians will be responsible for lamination activities as per this method
statement.

5. Materials & tools:

Lining Materials /tools include but not limited to the following.

A. Materials

a) Derakane 470-300 or Equivalent Resin & Hardener

b) Chopped Strand Mat (CSM)

B. Tools and consumables

a) Barcol Hardness tester, Measuring tape, pipe fitter’s wrap-around, marker pen
b) Cleaning rags
c) Pair of scissors
d) Angle Grinder and Sand disc
e) Mixing tongue/stick and buckets
f) Brushes, rollers
g) Styrene for cleaning tool
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DOCUMENT TITLE: Method Statement for Reinforcement and Relining of the internal body of wet scrubber quench duct and pipes.

6. Material storage:
Lining materials shall be stored in proper places as recommended by manufacturer.

Inspection shall be conducted on all materials issued for job execution as per the
requirements stated on Clause 5.1, Sec. 5 of ISO 14692-4

Resin, catalyst & styrene shall be stored in stored in cool maintained room at 20-25°C
and segregated from any other materials.

Glass fibre CSM shall be stored in a close room to avoid dust, damp & direct sunlight.

Store GRP materials in covered sheds and take precautions to ensure that the
workmen and the work area are adequately protected from the fire hazards and
health hazards resulting from handling, mixing, and application of GRP systems.

7. Repair Methodology

A. Site Preparation

a) Prior to repair activities line shall isolated and flushed by operation.

b) Take necessary safety precautions to ensure a safe working environment.
c) Provide adequate manpower to execute the job
d) Qatalum should provide confined space and gas testing apparatus.
e) Ensure full time ventilation while work in confined space.

B. Scaffolding

a) Scaffold platform shall be erected on the area where the relining/repair has to be executed with
considering the design of wet scrubber.
b) Prepare/arrange all the materials, tools, equipment required for scaffolding
c) Every component must be inspected prior to erection, by an experienced employee and defective
parts will be replace immediately
d) Evaluate the task required and inspect the location & confirm the best comfort choice by
qualified/experienced employees.
e) Ensure that components are uniform. This means, components are of the same type and from
the same manufacturer
f) Erect the best comfortable scaffolding with the aid of experienced employees.
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DOCUMENT TITLE: Method Statement for Reinforcement and Relining of the internal body of wet scrubber quench duct and pipes.

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g) Once the desired dimension/design is reached, check squareness, alignment, and levelness of the
newly erected scaffold.
h) keep the work platform clean and free of obstacles and slipping or tripping hazards at all times
i) Dismantle scaffolds using the exact reverse process to setting it up.

C. Cleaning

a) Ensure that all personnel working has hold confined space training prior for cleaning.
b) Prepare/Arrange all the materials required for cleaning.
c) Place experience employees prior for cleaning of the wet scrubber.
d) The sludge needs to be removed at regular intervals in order to maintain a smooth running
operation.
e) Our technical team/experts will inspect inside the wet scrubber prior for commencing the
cleaning activities
f) Any liquid or residual sludge is possible to pump out is removed using pumps and collected in
storage drums.
g) Continue the above process until liquid waste is drained completely.
h) Residue sludge should remove manually by experienced technicians.
i) Once the surface is free from sludge proceed for washing with low pressure washer.
j) Pressure washer will strip away all the dirt’s/dusts on the surface.
k) Pump out all the residue liquid stuff using pumps and collected in storage drums prior for
disposal.
l) Once the surface is prepared well proceed for relining.

D. Execution of GRP Lining

a) Prepare/Arrange all the materials, tools, equipment required for the relining
b) Remove all surface glazes, paint, oil, grease, scale, moisture, or other foreign material to
ensure proper lining to the surface
c) Commence with grinding/sanding the existing lining until a fresh dry surface is present (Until
obtain a rough surface prior for relining).
d) Wipe the ground areas with clean solvent / cloth to remove the collected dust and any surface
moisture
e) Remove all dust & loose particles from the sanded area using a soft bristled brush
f) Ensure the surface is visibly dry, and free of moisture and other foreign/contaminant materials.
g) Mix the resin and catalyst as recommended by Manufacturer.
h) A prime coat of above mixture is applied to the freshly prepared surface to cover all pores and
undulations to form a good binder using a roller. Care is taken to obtain an even surface.
i) Place one layer of CSM (Chopped Strand Matt) 450gms/m2 density and impregnate with above
mixture.
j) Evenly press the layer of CSM by lamp wool roller to flush/remove air traps & white marks.
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DOCUMENT TITLE: Method Statement for Reinforcement and Relining of the internal body of wet scrubber quench duct and pipes.

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k) Impregnate by lamb wool roller the above layer with the resin/catalyst mixture.
l) Repeat the above procedure i, j, k, l until 2-3 mm thickness is achieving on entire surface of
scrubber
m) Number of layers shall be determined by surface condition
n) Roll out and consolidate, so that all entrapped air goes out and that no air pockets or bubbles
occur
o) Make sure that the lining is undisturbed until it cures under ambient temperature. The curing
time varies between 16 to 24 hours depending on the sunlight exposure and temperature
p) Once the curing of the lining is completed, visual inspection and the Barcol hardness test of the
lining shall be carried out.

8. Test:
After completion of all activities following test shall be carry out,

a) Visual Inspection
b) Hardness Test

9. Safety precaution

a. The chemical components required for lining present certain safety health hazards if not
handled well.
b. Resin: Liquid resin contains styrene which is flammable. Its vapors may cause irritation of
the eyes, nose and throat. Excessive inhalation may cause dizziness or loss of consciousness.
c. Utmost importance shall be given safety of personnel and protection of services. It will be
ensured that the personnel involved are thoroughly aware of all safety regulations.
d. Tool box Meetings will be conducted before starting the works
e. All personnel will be provide with suitable Personal Protective Equipment
f. Proper and safe access will be provided for workmen to reach the work spot and carry out
their works safely.
g. Necessary and essential lighting and ventilation with blower fans will be provided during
the course work.
h. All the requirements for work at height shall be followed by all crew members throughout
the execution and inspection activities.
i. If scaffolding and working platforms are to be provided to facilitate the work, the same will
be checked for its safety.
j. All materials and chemicals shall be away from heat source, sparks and open flames.
k. First Aid for Inhalation: move victim to fresh air.
l. First Aid for Eyes: Flush exposed eyes with large amount of water. In case of severity,
immediately obtain medical aid from nearest hospital.
m. First Aid for Skin: Wash with soap using enough volume of water.