ADCOP - ABU DHABI CRUDE OIL PIPELINE PROJECT

Habshan - Fujairah

METHOD STATEMENT FOR

INSTALLATION OF DUCT INSULATION
C024-25-50-90-3938

VENDOR / SUBCONTRACTOR:
EPC CONTRACTOR: PROJECT MANAGEMENT CONSULTANT:

China Petroleum Engineering ILF Consulting Engineers China State Construction

& Construction Corporation P.O. Box 73250 Engineering Corp. M.E. L.L.C.
Abu Dhabi Branch
Abu Dhabi, UAE CONSULTING P.O. Box 63932
P.O. Box 127345
EN GI N EERS Dubai, UAE
PROJECT: ADCOP - ABU DHABI CRUDE OIL PIPELINE PROJECT-Habshan
To Fujairah
EPC Contractor Doc. No.: ADCOP/CP/ PAGE: 1 of 14
DOCUMENT No.: C024-25-50-90-3938 Rev. A Project No: E30153 DATE: 23/02/2011
 REVISION RECORD

REV DATE ORIGINATOR REVIEWED APPROVED DESCRIPTION

A 23.10.2010 Yang Weifeng Hamid Victor Zhao For Approval

© Copyright China Petroleum Engineering &Construction (Group) Corporation 2008 All rights reserved.
“This document is issued for the execution of Abu Dhabi Crude Oil Pipeline (ADCOP) project.
Copying this report without the permission of CPECC, ILF and IPIC is not permitted.

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 2 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 TABLE OF CONTENT

1. Scope …………………………………………………………………… 4
2. Definition & Abbreviation ……………………………………… 4
3. References/Standard ……………………………………………… 5
4. Equipment & Tool …………………………………………………… 5
5. Material ……………………………………………………………… 5
6. Installation Procedure …………………………………………… 5
7. Organizational Responsibilities ……………………………… 6
8. Manpower ……………………………………………………………… 7
9. Distributions ……………………………………………………… 7
10. Safety ………………………………………………………………… 7
11. Appendix A Risk Assessment ……………………………………… 8
12. Appendix B Inspection Test Plan ………………………………11
13. Appendix B Check List………………………………………………14

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 3 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 1.0 SCOPE

This Method Statement covers the insulation of G.I. ductwork. This procedure
defines the method used to ensure ductwork insulation to be carried out as per
contract requirements (Shop Drawings / Specifications / Contract Documents and
best commercial practices).

2.0 Definition & Abbreviation

2.1 Definition
International Petroleum Investment
Client
Company
Project Abu Dhabi Crude Oil Pipeline Project

Project Management
ILF Consulting Engineers
Consultant
China Petroleum Construction and
Contractor
Engineering Company
Third Party Inspector Germanischer Lloyd
China State Construction Engineering
Sub Contractor
Corporation ME LLC
MUST signifies a legal or statutory requirement
MAY signifies a feature which is discretionary

signifies a requirement made mandatory by

SHALL
this Method Statement

2.2 Abbreviation

CSCEC China State Construction Engineering Corporation ME LLC

ITP INSPECTION & TEST PLAN means the document which contains sequence
of activities in a process, highlights the applicable Quality Documents, and inspection
criticalities.

SITE means the place, designated by Company for further development, where the
construction activities shall be carried out by Sub-contractor.

PROCEDURE describes how a process is performed.

QA - QUALITY ASSURANCE is the planning and organizing of a system or program to

maintain a required level of quality or reliability. This includes auditing the system’s
operation and related controls to assure that they are being executed properly and
functioning as expected. Quality shall be assured by S u b - Contractor/ Contractor.

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 4 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 QC – QUALITY CONTROL is a part of Quality Assurance, implements the latter by
examining physical characteristics and comparing them to established and acceptable Quality
Documents as stated in the quality assurance program or plan.
Quality shall be controlled by Sub-Contractor in accordance with the Quality Documents.
TPI - Third Party Inspection

RFI Request for Inspection

3.0 REFERENCES/STANDARD

1. Project Specifications:
HVAC System for Residential Area - 30.99.24.3811

2. International Standards and References：

NFPA 90A

ASHRAE Handbook

3. Material Submittal Approval:

Material Submittal for Fibre Glass Insulation & Liner: C024-25-50-83-3961

Material Submittal for Adhesive & Vapour Barrier: C024-25-50-83-3950

4. Approved Shop Drawings.

4.0 Equipment & Tools

No heavy equipment and tools are required

5.0 Materials

5.1 Material List

1. Rigid Fibre Glass Insulation. Produced by KIMMCO, 25mm thickness for supply
air/return air duct located in air conditioning area, 50mm thickness for others.
2. Insulation Adhesive. CP-129, produced by Childers, USA.
3. Vapour Barrier. CP-45, produced by Childers, USA.

5.2 DELIVERY & STORAGE

1. Receive materials from suppliers, CSCEC site Engineer will check against the model,
quantity and ensure the received materials are as per specification.
2. Store relevant materials in a designated storage area.
3. The storage area must be well shielded and should be kept in proper manner to avoid
any damages.
4. Obtain approval from the consultant on every batch of materials delivered to site before
installation.

5.3 INSPECTION OF MATERIALS

1. CSCEC site Engineer will inspect the received material and make sure the delivered
materials are as per the approved material submittal.
2. After inspection by CSCEC, RFI will be submitted to the consultant for further checking
and approval.
DOCUMENT TITLE : Method Statement for Installation of Duct
Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 5 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 3. After consultant’s approval, the materials will be ready for installation

6.0 INSTALLATION PROCEDURE

6.1 Pre Installation Checks

1) Before installation ensure all insulation and adhesive have been inspected on site
and have been approved.
2) Inspect all materials and verify that they are undamaged.

6.2 Installation
1) Installation shall be done on a clean, smooth and dry surface.
2) Check for the external sizes of the duct to be insulated and cut the insulation
accordingly on a cutting table with knifes.
3) Clean the duct surface to be insulated and brush approved adhesive CP-129 on the
duct surface in strips about 15cm wide, at a coverage rate of 200ft/gal. Adhesive
shall not completely cover the surface.
4) Apply the insulation, foil face up, to the duct surface while the adhesive is still wet.
Do not let it dry too much.
There are two different kinds of installation according to the duct size:
a. Duct width ＜300mm:
Wrap the insulation around the duct surface, making sure all edge joints are
closely butted. Apply uniform hand pressure to outside surface of insulation to
obtain good bond.
b. Duct width ≥ 300mm:
Fix self adhesive pins to each face of duct, at least 1 pin per 0.09 square meters.
Position the insulation, press firmly until the pins penetrate through the
insulation totally, fit the lock washer over pins.
Apply uniform hand pressure to the insulation, making sure good bond.
5) Tape all joints and openings with 75mm wide glass reinforced self adhesive
aluminium tape. Make sure the insulation is well sealed from vapour.
6) For duct with width larger than 600mm, add light gauge galvanized angle to the
edges of insulation to prevent them from being damaged by support angles.

External Duct surface (Item No. 7, 8, 9 are designed only for external ductwork)
7) Clean the surface of insulation KSF foil, apply 1 coat of CP-45 Vapour barrier &
Weather proofing coating (Gray) as a tack coat, at coverage rate of 2 gal/100 sq. ft.
8) While the tack coat is still wet, apply 1 layer of glass fibre reinforced mesh to the
duct surface with seams overlapped at least 5cm.
9) Apply the finish coat of CP-45 (White) at coverage rate of 4 gal/100 sq. ft.

10) Clean and clear the workplace immediately after insulation.

11) Ensure no damage of the insulation during and after the insulation procedure.

6.3 Inspection after Installation.

1) After duct insulation work is completed，the CSCEC site Engineer will inspect the
installation and make sure that the insulation is done as per approved material
submittal and the installation is done as per standard.
2) After inspection by CSCEC site Engineer, RFI can be submitted to the consultant.
This inspection may be done together with the inspection of duct installation.

7.0 Organizational Responsibilities

DOCUMENT TITLE : Method Statement for Installation of Duct
Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 6 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 1. The Project Manager will

1) Be responsible for all interfaces and other communications as required during the
execution of all activities.
2) Reviews the method statements prior to execution and explain the same to his
subordinates ahead of the job plan.
3) Manage and lead his workforce to ensure good workmanship and a quality result.
4) Must be aware of all test results, test frequencies and approved materials to be used.

2. The QA/QC Engineer

1) Shall conduct inspections as per the method statement.

2) Ensure that all the procedures in the method statement are implemented and
followed.
3) Ensure that all necessary records such as Request for Inspection(RFI), test
reports, material approval and others must be in-place prior to commence
with the work

3. The Site Engineer & Foreman

1) Shall execute the job as per the approved method statement, drawings and
specification.
2) Issue the correct and approved materials and explains the daily tasks to his
workforce.
3) Works hand in hand with the Project Team to deliver a quality output.

8.0 Manpower

1. Construction Manager
2. Site Engineer
3. Foreman
4. General Workers

9.0 Distributions

1. Project Manager
2. Construction Manager
3. Site Engineer
4. QA/QC Engineer
5. Foreman

10.0 SAFETY

1. All appropriate safety protective gear, i.e. helmet, safety shoes, gloves, goggles,
etc should be worn by workmen and approved by safety Engineers.
2. Wear the safety belt while working on a scaffold or step ladders at high levels.

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 7 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 APPENDIX A

Risk Assessment

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 8 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 Project: Abudhabi Crude Oil Pipeleine
Attachment A: RISK ASSESSMENT for Asphalt Road/Pavement Owner : IPIC
TITLE: Construction of roads DEVELOPED BY: Sign: Date:23 Feb 2011
PRELIMINARY IMPLEMENT REVISION APPROVED BY: Sign: Date:
1 BASIC PPE REQUIRED FOR THIS JOB

Long Shirt Sleeves Long Trousers Hard Hat Safety Footwear Overalls P2 Mask Ear Plugs Safety Glasses Goggles Gloves

2 EXTRA PPE REQUIRED FOR THIS JOB (AS IDENTIFIED IN THE RECOMMENDED PROCEDURES BELOW)
ADDITION REFERENCES Plant Hazard Assessments Construction Drawings HSE Procedures Other (Risk Assessment)

2.1.1 HEALTH & SAFETY: Assessment of Risks and Hazards

STEP 3: A B C D E
STEP 1: Likelihood of Occurrence STEP 2: Severity of Result STEP 4: Hazard Risk Assessment
1 H H H M M
H = High Risk (INTOLERABLE, significant and urgent
1. Expected To Occur (once per week) A Fatality 2 H H M M L
actions required- ImmediateAction).
2. Common (once per month) B Permanent Disability 3 H M M L L M = Medium Risk (ALARP, reduce risk to As Low As
3. Sometimes (once per year) C Lost Time Injury (LTI) Reasonably Practicable).
4 M M L L L
4. Rarely (once in < 20 years) D Medical Treatment
5 M L L L L L = Low Risk (TOLERABLE, monitor and manage risk).
5. Highly Unlikely (once in > 20 years) E First Aid Injury

RISK CATEGORY (RESIDUAL)

POTENTIAL ACCIDENT
BASIC JOB STEP RISK CONTROL MEASURES Risk
OR HAZARD LIKELIHOOD SEVERITY
Rating

HEALTH CONDITIONS
AFFECTED BY
1.Highly Unlikely 1.Medical Treatment 1.Low
A Insulation EXPOSURE TO 1. Keep good ventilation in working areas.
2. Sometimes 2. First Aid Injury 2.Medium
ADERHISIVES 2. Wear gloves to avoid body contact.

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 9 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
ADDITIONAL SAFETY COMMENTS:

• 　 All personnel working within upon foundation operations must be made of the hazards related to trench collapse
• 　 All persons in the crew to be instructed that they are not required to work in any situation or with any equipment that they do not believe is safe (If personnel feel at risk they are to stop work, inform their
supervisor of their concerns).
• 　 Ensure adequate communications are available to ensure the safety of all personnel involved in the above operation.
• 　 No unauthorised personnel will be allowed in to the works area.
• 　 Supervisors to ensure all requirements of this document are complied with.
• 　 Crew to be inducted prior to commencing work on the project.
Prior to the commencement of the work shift;
• 　 Plant pre-start checks to be completed. Report any safety related faults to supervision.
• 　 Permits to be arranged as required.

Reporting of incidents/accidents: Report to CPECC Project Management (HSE Manager or Project Manager) immediately. CPECC to report to ILF/IPIC within 60minutes of serious incidents/accidents
including significant near miss events. Pre-investigation report required within twenty four hours. Final investigation report required within seventy two hours. Refer to Incident Management and Reporting
Procedure and the Emergency Response Plan for further details.

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 10 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 APPENDIX B

Inspection & Test Plan

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 11 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 ABU DHABI CRUDE OIL PIPELINE PROJECT
QUALITY EXAMINATION PLAN
DEFINITION OF INSPECTION AND TEST PLAN SYMBOLS

“H” - HOLD: A point beyond which work shall not proceed without formal approval by appropriate inspectorate. Achievement of “H” points shall be notified
to Owner.

“W” - WITNESS: A point beyond which work may proceed without formal documented approval by any of the inspectorate. Achievement of “W” points
shall be notified to Owner.

“S” - SURVEILLANCE: A point where CONSORTIUM and others may carry out surveillance of work in progress and documentation associated on an
unscheduled basis, with no notification required by any party and without amendment to the scheduled production programme.

“R” - REVIEW: The documents are to be submitted to the appropriate inspectorate for review by Owner. Note that where a document is subject to Owner
approval, work shall not proceed until the Owner’s approval is given.

“C” - CERTIFICATION: Specific and appropriate certification documentation is to be included in the document package.

“A1” - 100% ACTUAL

“A2” - RANDOM ACTUAL

REMARKS:

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 12 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 ABU DHABI CRUDE OIL PIPELINE PROJECT Habshan - Fujairah(ADCOP)
INSPECTION AND TEST PLAN OF DUCT INSULATION
Date:23-Feb-11 DOCUMENT NO.: C024-25-50-90-3938
Sub-
Item Inspection Activity & Specific Acceptance Criteria, Verifying Contract
Contr TPI Owner
No. Check Point Area Code & Standard Record or
actor
Specifications , technical Submittals &
1 Material and test report submittal R R H H/R
Data sheet Acceptance Letter
Submittals &
2 Method Statement Submittal Specifications R R H R
Acceptance Letter
Specification & Material
3 Set out survey for Materials RFI W W/S H R
Submittal Approval
Specifications, Method
4 Set out survey for Procedure & Finished Product Statement & approved Checklist & RFI W W/S H R
Drawings

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 13 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011
 ABU DHABI CRUDE OIL PIPELINE PROJECT
Habshan – Fujairah (ADCOP)

Form No: 3938-01 CHECK LIST OF DUCT INSULATION

Project Description Area

Construction Drawing RFI No

Inspection Content Yes No

1 Materials are approved and undamaged.

2 Insulated ductworks were approved by TPI.

3 Insulation thickness is according to specification.

4 Installation followed the approved method statement and shop drawing.

5 Finished products are protected well.

Acceptance result

APPROVALS SUB
CONTRACT TPI OWNER
CONTRACTOR

Signature

Name

Date

DOCUMENT TITLE : Method Statement for Installation of Duct

Project No: E30153
Insulation
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT
Page 14 of 14
Habshan - Fujairah
DOCUMENT No.: C024-25-50-90-3938 Rev. A DATE 23/02/2011