GL1 COOLING WATER LINE COOLING

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Hydro Jetting
Method Statement
Document Details
TAPS Document No.: TAPS‐DPE‐MS

Client Reference No.:

Client: Dubai Petroleum

Project: Cooling Water Line Cleaning

Location: Dubai Off Shore at SWF GL1

Scope: Hydro Jetting

Document Number: TAPS-DPE-MS Content Owner: TAPS

0 27/11/2019 Issue for Review Aaron

Rev. Date Description Prepared By Reviewed By Approved By

Document Revision History

Rev. Date Description Originator TAPS TAPS Client Approval

Review Approval
0 27/11/2019 Initial Draft
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Method statement & Safety Procedure for GL1 Cooling water line Cleaning

1. Introduction

This document outlines the safe working practices for the execution of hydro jetting for the Cleaning
of Cooling Water lines. It is the responsibility of the TAPS project execution team and shall be adhered
to by all personnel involved with the work

2. Pipeline cleaning procedure

Cleaning is accomplished by passing a jet lance completely through the pipe. A lance of adequate
length (Lance length of 60 meters) is then attached to the pressure discharged hose, and at the same
time the foot pedal is repositioned, and a hose catcher is equipped to restraint the unplanned
movement of the flex lance.

The prime reason for positioning the foot pedal is for the protection of the operator, since he is
required to be in close proximity to the nozzle when feeding the lance. Thus, he will only approach
the nozzle when he has himself released the pressure at the foot pedal. Safety considerations
associated with high pressure jetting are very important.

A suitable nozzle is then fitted to the lance and positioned just inside the line, and pressure is applied
by closure of the foot pedal and adjusted by manipulation of throttle and gears on the pump drive.
When an adequate pressure has been reached, the lance is advanced steadily through the pipe until
it emerges at the far end. The pressure will be gradually increased from 3500 PSI upto 5000PSI
based on the pipeline cleanliness conditions. More debris inside the pipeline will be requiring higher
pressure for cleaning. The nozzle is then withdrawn releasing pressure at the foot pedal before the
nozzle is at the far end. The pipe may then be examined to establish the degree of cleaning
accomplished and further experimental runs made at different pressure and speeds and with different
nozzle.

A safety device(Anti retrieval device) will be placed from where the nozzle will be inserted to prevent
the nozzle from reverting outwards. A proper flange will be required to place the device on the
pipeline opening. There should be ample clear space of 1 meter near the pipeline opening to insert
the nozzle without any obstructions.

3. Responsibility of blasting Crew

 Obtain a Safe Work Permit for all jetting work.

 Ensure that all equipment complies with the equipment specifications, including inspection
and testing requirements.
 Provide training on proper equipment use to jetting equipment operators.
 Ensure that hoses are not placed where they could become tripping hazards or be damaged
and that they are secured. Also, ensure that all those connections are connected with safety
connectors (whip checks) and that hoses are shrouded as appropriate
 Ensure that the use of all jetting equipment is in compliance with the manufacturer's
recommendations.
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 Ensure that all required Personal Protective Equipment is properly used while inside the
barricaded area.
 Ensure that the area in which jetting work is being done is adequately barricaded and has
adequate lighting and for elevated jetting work that a fixed, stable work platform is available.
 Ensure that a line of sight or other continuous, two-way communication method is established
and maintained among the operator, the safety attendant and/or the operator of the pumping
unit.

4. Process Operations General Requirements

 Persons operating jetting systems will ensure compliance with the following general
recommendations
 The various pieces of equipment will only be used in accordance with the manufacturer’s
recommendations
 Attachments such as extensions will be fitted and used in accordance with the manufacturer’s
instructions and in a manner that will not adversely affect the safety features or the safe
operation of the system
 Jetting equipment and its attachments will not be modified without written approval from the
manufacturer
 Jetting systems will not be used unless the operator is satisfied that: They have been
inspected or serviced in accordance with the manufacturer’s recommendations and They are
free from any fault that has been identified at the last inspection or service which may
adversely affect the performance and safe operation of the equipment.

5. Safeguards

 Persons using jetting equipment will ensure compliance with the following safeguards:
 Where necessary all equipment in close proximity to the area where water jetting is being
performed will be adequately shielded or protected from debris and ingress of water resulting
from the operation of the water jetting equipment. Any essential electrical installation will
meet the required protection levels against the ingress of water fumes or overspray
 Whenever possible all persons other than the operating team will be excluded from barricaded
areas
 Operators will ensure there is no interruption or interference to the release mechanism of
hand or foot controls which will prevent the equipment operating in a manner consistent with
the manufacturers’ specifications

6. Water jetting operations will cease when:

 Unauthorized or inadequately protected persons enter the barricaded area

 Any recommended practices are violated or immediately a malfunction occurs
 Systems will be depressurized when:
 Not in use and left unattended or Replacement of components or repairs is being made to the
system.
 Operators of water jetting systems will not carry out repairs or maintenance other than simple
adjustments or the replacement of parts which are specifically listed in the manufacturer’s
instructions for use and periodic service or maintenance. Repairs or maintenance will be
carried out by the manufacturer or qualified persons.
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7. Emergency Arrangements (Client scope) General

 The Site HSE department shall be responsible to arrange and coordinate with site execution
teams in arranging Day & Night emergency procedures
 Site Clinic shall be established to carry on first aid on site in case of any injuries.
 Contact numbers of site safety officer, safety manger and other emergency services shall be
displayed at site during all times.
 In case of any emergency the Client will be informed about the emergency
 Emergency assembly point shall be allotted and communicated to all the operatives in involved
in the job
 Ensure clear access to the emergency assembly area with signage’s in place.
 No construction activity shall block the access leading to the emergency assembly point. In
case of any deviation the access has to divert and the same shall be communicated to all the
operatives on site.

8. Fire Precautions

 Fire extinguishers shall be put in place in each working zone and a clear access shall be
provided to the location
 All the operatives shall be trained for fire precautions on site
 A fire warden is appointed and trained from each team of operatives

9. Training
 Necessary safety/Site induction shall be provided to the operatives involved in the activities
by the client.

10. Supervision
 Adequate supervision shall be provided for the executing each activity
 Client Operations Manager & Site Engineer shall monitor the progress of the works

11. Housekeeping
 The work areas shall be clean and tidy.
 No debris from construction activities is allowed to accumulate in the work area.
 Work areas shall be cleaned on daily basis at the end of the shift or on completion of the
activity
 Sufficient Waste collection bins shall be provided at each working zone
 Waste segregation area (where recyclable / landfill materials are segregated, usually as Steel,
Wood, Plastic, Concrete and Debris) shall be established to control the waste generated on
site due to construction.

12. Hydro jetting

Hydro jetting machine is a high-pressure [10000 psi (690 bar) to 15000 psi (1034 bar)] plunger
type water pump driven by diesel engine.
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13. Hazard

If proper precautions are not taken, there are various hazards one may be exposed to while doing
hydro jetting with high pressure water jets.

The major hazards include:

 Injury due to high pressure water jet

 High-velocity impact
 Machinery and equipment
Other possible hazards are:

 Fall from height while hydro jetting at height

 Opaque vision due to misty atmosphere
 Electric shock
 Source of ignition for a fire
 Working in confined space e.g. Sewer.

14. High-pressure water jetting set up:

A high-pressure pump, high pressure hoses, a Foot Pedal and nozzle assembly.

Filtration:
Adequate filtration of the pump supply water is to reduce wear on the pump components and reduce
the risk of a nozzle becoming blocked with dirt or debris. Filters must be selected, used, and
maintained daily as per TAPS instructions. Check the condition of filters daily and replace them when
dirty

Pressure gauge:
TAPS equipment will be equipped with a pressure gauge to indicate the system pressure.

The gauge shall be mounted in a position so that the pressure reading is clearly visible to the pump
operator when “setting the pressure.”

Pressure relief device:

TAPS high-pressure pump must be equipped with at least one and preferably two pressure relief
devices (as for following figure). The primary relief device should be set for 1.2 times the maximum
operating pressure, with the secondary device set for 1.4 times the maximum operating pressure of
the high-pressure pump.
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High pressure hoses:

High pressure hoses used for high pressure jetting are specifically designed and manufactured for
this application. They are typically composed of a plastic liner reinforced with multiple layers of steel.
The outer covering of high-pressure hoses can be rubber or plastic. High pressure hoses are rated
for maximum allowable working pressure (MAWP) and for burst pressure. The burst pressure is the
pressure at which the hose will fail. The difference between the MAWP and the burst pressure is the
design factor.

It is safe to select a hose with a design factor of at least 2.5 times the maximum allowable working
pressure. High pressure hoses must not be operated above their maximum allowable working
pressure. The service life of any high-pressure hose can be influenced by many factors, such as age,
storage conditions, pressure and heat cycles, chemical exposure, bend radius, vibration, axial and
torsional loading, and so on. Ensure that any hose inspections include inspection of the hose end
fitting for damage or signs of excessive wear. Protective coverings should be used wherever possible
to reduce wear and to help prevent damage to high pressure hoses.

Fittings and couplers:

When assembling the high-pressure fittings and couplers, all connections must be inspected for
damage and assembled using proper tools

Dump valve:
The term “dump valve” can refer to two different devices: a hand (trigger) or a foot (pedal) operated
dump valve. Essentially, they work the same way, with a lever to actuate the position of a small,
cartridge-type valve that directs the water through the high-pressure circuit (when engaged) or
through the low-pressure diffuser (when released). The primary difference is that a jetting gun is
operated by hand and a foot dump by foot. In either case, it is essential that the control lever be
operated only as designed—by the operator, and without the use of tools, levers, or other devices
(rope, wire, plastic zip ties, etc.) to hold the lever in the ON position. The control lever must be of
the type that requires the operator to hold the control in the ON position (continuous pressure type)
and that will immediately dump the pressure when released.
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Jetting gun:
Jetting guns are available in a variety of types, styles, and configurations.

The example shown in the figure is a dry shut-off style jetting gun It must be used with an auxiliary
Pressure regulating valve to discharge the water when the trigger is released

Foot dumps:

Foot dumps are available in a variety of styles and are generally operated with the foot. When
operating mechanized systems, an air actuated foot dump is commonly employed. When attaching
a discharge hose to the diffuser, ensure that there is unrestricted flow from the diffuser valve to
avoid creating back pressure within the foot dump, which could hinder the function of the control.

Nozzles:

Nozzles are available for many applications in a variety of types, designs, and sizes. It is important
to select and use the right nozzle for each task to ensure the safe application and productive use of
high pressure washing Equipment.

There are three primary applications of nozzles for use with high pressure washing equipment.

 Jetting gun nozzles

 Flex-lance nozzles
 Mechanized tool nozzles
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Jetting gun nozzles:

Jetting gun nozzles are configured to provide a straight-ahead jet or fan jet pattern. Each type will
provide efficiencies for conducting different types of cleaning tasks (following figure). A straight-
ahead jet will deliver the maximum force to the surface and is best used for cutting or breaking hard
materials. A fan jet will deliver a wide spray pattern and is best used for cleaning large surfaces of
soft coatings or contaminants. Self-rotating nozzles offer the option of combining the attributes of
both types of standard jetting gun nozzles by providing two or more straight ahead jets offset to
create rotational reaction forces and provide a wide spray pattern.

Flex-lance nozzles:
Flex-lance nozzles are configured with multiple orifices to self-propel the nozzle and provide a 360°
jet pattern for cleaning the internal surfaces of pipes and tubes (as shown in following figure). The
nozzles are arranged with forward-facing, rear-facing, and side-facing orifices to provide balance and
self-propelling properties (as shown in following figure). Before installing any nozzle on a flex-lance,
ensure that the orifice pattern is designed with rear-facing orifices to provide forward thrust. Always
check the nozzle orifices before use to ensure that they are clear of debris that could block the flow
of water and cause Over pressurization of the system or an unbalanced nozzle.

Mechanized tool nozzles:

Nozzles used with mechanized tools are available for many applications and are generally designed
to deliver maximum flow at a desired pressure. With the use of mechanized tools, reaction forces to
the operator and the need for self-propelling nozzles are often not a consideration.

Flex-lancing safety devices Backout preventers:

An effective means of restraint must be used on a flex-lance where the unplanned movement of the
hose or nozzle could endanger a worker. The device must be able to withstand the forces that it will
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be subjected to, and capable of safely performing the functions for which it is used. A backout
preventer (V Lock Hose catcher) is such a means of restraint in flex-lancing operations.

When used in accordance with its design, a backout preventer:

 Helps prevent the flex-lance from backing out of the pipe due to gravity, a plugged nozzle
orifice, an obstruction in the pipe, or hydraulicing. (Hydraulicing occurs when there is not
enough room between the nozzle and the wall of the tube or pipe to allow water or debris to
pass. Pressure builds up, and the flex-lance is forced backward, toward the operator.)
 Helps prevent the pressurized flex-lance from being inadvertently pulled out of the open end
of the pipe.
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15. Appendix-1 P&ID Diagram of the Pipeline

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16. Datasheet of the Pipe

 SPEC : DP-P-20-M1

REV : 05 DATE : 07/09

BY : TL/SA APP : RD

TITLE : PIPING MATERIAL SPECIFICATION – CLASS M-1

DUBAI PETROLEUM
STANDARD SPECIFICATIONS

PIPING MATERIAL SPECIFICATION

CLASS M-1

REV DATE BY REMARKS

05 07/09 Tl/SA General Revision

04 09/05 BLK Revised to address temperatures above 130F

03 09/92 JNC Revised to incorporate all Fiberglass Applications

02 12/91 JNC Delete details of gaskets

01 10/90 LDT Added 3000 # to fittings description.

0 08/86 JAD Issued on Word Processor

E&E\SPEC\P20M1 PAGE 1 OF 3
 SPEC : DP-P-20-M1

REV : 05 DATE : 07/09

BY : TL/SA APP : RD

TITLE : PIPING MATERIAL SPECIFICATION – CLASS M-1

 SPEC : DP-P-20-M1

REV : 05 DATE : 07/09

BY : TL/SA APP : RD

TITLE : PIPING MATERIAL SPECIFICATION – CLASS M-1

NOTES:

1) For Fiberglass Pipe Selection See DP-P-11. In areas where high loading exists, such as
nozzles and fire monitors, the following alternatives may be used:
Piping 1" to 2" : Use galvanized pipe and fittings as per DP-P20.
Piping 3" and larger: Use carbon steel pipe as per DP-P2-A5 with glass flake reinforced
polyester in accordance with Section 10.3.1 of DP-PC-1
Stainless Steel (304 or 316) is not recommended for seawater service.
2) DP Engr. approval is required for use of alt. valves in ( ).
3) Rubber seal lock joints can be used as an alternate joint for pipe runs on bridges (up to
within 35' of a platform). A flanged spool piece, ~3' long, should be provided to allow
disassembly of lock joints. These joints provide some flexibility for linear expansion.
4) Where fiberglass pipe is used in a non-pressurized fire water system (dry), then an
external coating of Fav-U-Seal shall be applied in accordance with manufacturer’s
recommendations.
5) Fiberglass pipe has a higher coefficient of linear thermal expansion than steel. Consult
manufacturers for anchor and expansion loop requirements (see Wavistrong Engineering
Guide).
6) Pipe supports are required more frequently than steel piping. See Wavistrong
Engineering Guide for recommended spacing.
7) R.F. flanges (such as a connection to a steel valve or piping system) can be bolted directly
to F.F. GRE flanges by using the standard neoprene full face gasket with a second
neoprene gasket which fills the area outside of the raised portion of the RF flange. Bolt
torque must be applied in accordance with manufacturer’s recommendations.
8) Asbestos (or equivalent) gasket material shall be used for flanges in firewater service.
9) Spool pieces should be prefabricated at the manufacturer’s facility whenever possible.
Flanges are not required at all field joints because field splices can be made without hot
work.
10) Care must be exercised when filling with water for hydrotest to ensure that all air is
removed before pressurizing pipe to prevent water hammer.
11) The adhesive used at the joints of M1 piping is rated to a maximum temperature of 140F.
130F is 93% of the maximum operating temperature. M1 piping should not be used at a
temperature greater than 130F.