002-MS Nitrogen Filling , Cyrogenic Vaporizer.pdf

Pearl GTL Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT Contractor Project No : 5887 Project Document Number: T-4.305.139 Project Rev.: O Page 2

Purchase Order Number:

2MH127

Tag/Item Number(s):

0E-2091 A 0E-2091 B 0E-2091 C 0E-2091 D 0E-2091 E 0E-2091 F 0E-2091 G 0E-2091 H 0E-2091 J 0E-2091 K 0E-2091 L 0E-2091 M 0E-2091 N 0E-2091 P 0E-2091 R 0E-2091 T 0E-2091 U 0E-2091 V 0E-2091 W 0E-2091 X

0E-2092 A 0E-2092 B 0E-2092 C 0E-2092 D 0E-2092 E 0E-2092 F 0E-2094 A 0E-2094 B 0E-2094 C 0E-2094 D 0E-2094 E 0E-2094 F 0E-2094 G 0E-2094 H

Unit(s): ASU

PCWBS: Z

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

C O Issued for Company Comments OD MEY AG ICC

B Issued for Review OD MEY AG IFR

A Issued for Internal Review OD MEY AG IIR

GAMA Rev.

Project Rev

Date Description Prepared

By Checked

By

Approved By

Status

No. No. ORIGINATOR

LINDE ENGINEERING AG

Document Title:

METHOD STATEMENT NITROGEN FILLING, CRYOGENIC VAPORIZER

Contractor

Gama Qatar Co. W. L. L.

Document No. LOC470

GAM MTS PRE GTL 002 C Org.

Code

Doc.

Type

Disc. Code

Geogr. Area

Seq.

No

Rev. No

Vendor Code

Project Document Number: T-4.305.139 Rev No.: O

Doc. Title :

GAM-MTS-FSI-GTL-002 Rev. C Method Statement Nitrogen Filling, Cryogenic Vaporizer

Date/Rev. No :

GAM-MTS-PRE-GTL-002 Page 4 of 10

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TABLE OF CONTENTS

1 INTRODUCTION ____________________________________________________________________ 5

1.1 GENERAL ____________________________________________________________________ 5 1.2 SCOPE AND PRECAUTION _______________________________________________________ 5

2 HSSE ____________________________________________________________________________ 5

3 REFERENCES _____________________________________________________________________ 6

4 DEFINITIONS ______________________________________________________________________ 6

5 RESPONSIBILITIES _________________________________________________________________ 6

5.1 SITE MANAGER _______________________________________________________________ 6 5.2 FSI MANAGER ________________________________________________________________ 6 5.3 CLEANLINESS & PRESERVATION ENGINEER _________________________________________ 7 5.4 LIFT SPECIALIST ______________________________________________________________ 7

6 RESOURCES ______________________________________________________________________ 7

6.1 EQUIPMENT & MANPOWER _______________________________________________________ 7 6.1.1 EQUIPMENT ________________________________________________________________ 7 6.1.2 MANPOWER _______________________________________________________________ 8

7 METHOD OF EXECUTION _____________________________________________________________ 8

7.1 PRE-COMMENCEMENT WORKS ____________________________________________________ 8 7.1.1 WORK PERMIT _____________________________________________________________ 8 7.1.2 TRAFFIC MANAGEMENT PLAN ________________________________________________ 8 7.1.3 EQUIPMENT AND PERSONNEL ________________________________________________ 8

8 MEASURING AND FILLING PROCEDURE __________________________________________________ 8

8.1 GENERAL ____________________________________________________________________ 8 8.2 ASSEMBLY AND CHARGING ______________________________________________________ 9 8.3 DISASSEMBLY AND DELIVERY ____________________________________________________ 9

9 QUALITY ASSURANCE ______________________________________________________________ 10

10 ATTACHMENTS ___________________________________________________________________ 10

10.1 JOB SAFETY ANALYSIS ________________________________________________________ 10 10.2 TAGS AND SIGNS (SAMPLE) _____________________________________________________ 10

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1 INTRODUCTION 1.1 GENERAL

This document describes the methods proposed to be used for checking the pressure of and filling with nitrogen (as required) of Cryogenic Vaporizer as part of the preservation activities at ASU area that shall be carried out as part of ASU Construction works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City (RLIC) of Qatar including similar works up to the time of commissioning. The preservation shall be performed at ASU Area. The nitrogen filling and tagging activities shall be carried out by GAMA QATAR in coordination with the Contractor. All parties (LINDE Contractor, GAMA Logistics, Mechanical and FSI disciplines) involved in the preservation of the Cryogenic Vaporizer will conduct minuted coordination meetings as required.

1.2 SCOPE AND PRECAUTION N2 (Nitrogen) is hazardous, especially in confined spaces. All measures will be taken prior to start of operations. During the work on and in the vicinity of open flange connections, care will be taken so that dust and moisture can not get inside the equipment. Nitrogen filling will be performed by the GAMAs Cleanliness and Preservation Engineer. The methodology will be presented to the Contractor and will be approved prior to execution. Wind intensity and velocity is to be taken into consideration. It is important in order to be able to decide if certain works can be carried out safely. Area influenced by the operation of the man-basket will be taken into consideration. Competency of personnel to execute the works on the equipment will be assessed. Availability and safety of man-basket, operator, hand-tools, measuring equipment, connectors, hoses and the N2 Bottle will be ensured.

2 HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL and/or its PMC requirements and instructions.

In addition all employees and GAMA subcontractor employees on site will have gone through GAMA Qatar Site Safety Induction, LINDE ENGINEERING AG Site Safety Induction and QSGTL Safety induction for site safety, health, environmental and security prior to resuming work activities at site. Other training courses (i.e. Working in Confined Spaces, Working at Heights, etc.) will be attended as required by LINDE ENGINEERING AG or QSGTL and/or PMC.

Risk Assessment will have been prepared by the Risk Assessment Team (RAT) ranking the hazards associated with project works and control measures to be taken to mitigate the hazards to an acceptable level.

Each scope work or task will have a completed and approved Job Safety Analysis (JSA)

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identifying the potential hazards and control measures that will be implemented to protect people and environment.

The JSA (RA) will be used by Supervisor as the basis of conducting his daily TSTI meeting and his weekly Tool Box Talk.

For additional safety requirements for a particular or specific task please refer to the JSA prepared for that task.

All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves) at site at all times as required.

3 REFERENCES T-4.233.760 : Cryogenic Vaporizer Steam Heated-O2 Vaporizer and

Condensate Vessel T-4.233.891 : Cryogenic Vaporizer Air Heated N2 Vaporizer Preservation

Procedure T-13.376.921 : Preservation of New Equipment, Technical Specification T-13.377.539 : Flawless Start-up

4 DEFINITIONS

Company : QSGTL and/or its PMC

Contractor : Linde Engineering AG

Sub Contractor : GAMA QATAR Co. W.L.L.

Contract : QSGTL Pearl Project C2 ASU Construction Works

QCP : Quality Control Procedure

ITP : Inspection and Test Plan

QA/QC : Quality Assurance / Quality Control

HSSE : Health, Safety, Security and Environmental

JSA (RA) : Job Safety Analysis (Risk Assessment)

FSI : Flawless Start-up Initiative

CA : Construction Area

Package Unit : Major components assembled at the manufacturers plant e.g. Linde Engineering AG

CV : Cryogenic Vaporizer

ASU : Air Separation Unit

MSDS : Material Safety Data Sheet

5 RESPONSIBILITIES

5.1 SITE MANAGER The Site Manager will provide inputs to the project execution plan to ensure that strategies & philosophy of the project are properly addressed.

5.2 FSI MANAGER The FSI Manager is responsible for the overall management of the Preservation Team to ensure that safe and effective operations are conducted and properly documented.

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5.3 CLEANLINESS & PRESERVATION ENGINEER

He will be overall responsible for planning and safe execution of the whole job including:

Organizing of equipments, material and tools needed for the job.

Confirming the preservation location.

Assigning skilled personnel for the job.

Conducting TSTI with the concerned work force prior to start of work.

Ensuring that relevant work permits and Method Statement for the job are obtained prior to start of work and made available at site.

Conducting of activities to be carried out for the work in a safe manner as per this method of statement.

Tagging of the vessel(s) and keeping the records. Records are auditable by Company.

Conduct inspection and surveillance.

Notify to Contractor engineer for inspection as applicable.

Ensure that all Contractor and Company regulations are followed.

Ensure that all personnel involved are in safe working condition at all times.

5.4 LIFT SPECIALIST Shall be operating the man-basket (if and as required), to achieve a safe measuring and filling of N2 gas in the Cryogenic Vaporizers.

6 RESOURCES

6.1 EQUIPMENT & MANPOWER A list of equipment and manpower is given below.

6.1.1 EQUIPMENT

Manometer

T-piece

Hose

Gas Pressure Regulator

Atmospheric Monitoring Equipment

Nitrogen Bottle

Holding Clamps

Hand Tools

Full PPE and Safety Harness

Aerial Platform/ Manlift/ Man Basket

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6.1.2 MANPOWER

Site Manager

FSI Manager

Cleanliness & Preservation Engineer

Man-Basket Operator

HSSE Personnel

Helpers

7 METHOD OF EXECUTION

7.1 PRE-COMMENCEMENT WORKS

7.1.1 WORK PERMIT The measuring of internal pressure and filling with Nitrogen gas of the Cryogenic Vaporizer starts with the preparation of Method Statement and issuance of a Permit to Work.

7.1.2 TRAFFIC MANAGEMENT PLAN Area will be soft barricaded and secured. Access road to operation area and enough space for movement of man-basket during operation will be arranged and made available.

7.1.3 EQUIPMENT AND PERSONNEL All equipment shall be inspected, tested and approved by the CONTRACTOR. All equipment and tools shall be available at the site. All personnel shall be inducted and trained before they commence work on site and have sufficient knowledge. All personnel shall be competent to execute all the works pertaining measuring N2 pressure and filling as required of Cryogenic Vaporizer.

8 MEASURING AND FILLING PROCEDURE

8.1 GENERAL The Cryogenic Vaporizer is filled with N2 gas to avoid oxidation of internals and needs to be kept at this state during storage and after erection up to the time of commissioning. The N2 pressure will be checked at intervals of one month by the CONTRACTOR, and will be refilled as required to achieve 0.5 bar internal pressure. Observations will be properly recorded, and copies will be forwarded to COMPANY. The vessel(s) (Cryogenic Vaporizer) and or the container will be tagged appropriately after

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each inspection and/ or refilling to reflect the status of preservation. (See Attachment-2 for samples).

8.2 ASSEMBLY and CHARGING Read the dials supplied on Cryogenic Vaporizer and record the readings. If the readings are below 0.5 bar (50 kPa/ 7.25 psi/ 0.5 atm) fill as required.

Perform Gas Testing if the Cryogenic Vaporizer is in a confined space.

Adjust the filling nozzle to properly connect with filling equipment.

Position the N2 Bundle securely on ground.

Do not expose the N2 Bundle to direct sun-light for elongated durations.

Operate and position the man-lift so that the measuring and filling operation can be performed safely and effectively.

Remove the plug on the Ball Valve on a suitable charging nozzle. Attach the T-Piece on the Ball Valve.

Install the Manometer on one of the free ends of the T-Piece.

Connect the hose to the other end of the T-Piece.

Connect the other end of hose to the Isolation Valve. Ensure the Isolation Valve is at closed position.

Connect the Isolation Valve to the Gas Pressure Regulator. Check that Gas Pressure Regulator is at its lowest setting.

Connect the Gas Pressure Regulator to the N2 Cylinder .

Turn the Ball Valve (existing valve on the vessel) open.

Record the internal pressure displayed on the Manometer.

If it is less than 0.5 bar, open N2 Cylinder valve slowly to avoid pressure shock.

Increase output of the Gas Pressure Regulator to 0.5 bar. Turn the Isolation Valve slowly to open position.

Check the Manometer to read 0.5 bar.

Turn the Isolation Valve off, when 0.5 bar is reached.

Turn the Ball Valve on the vessel off.

8.3 DISASSEMBLY and DELIVERY Disconnect the T-Piece from the Ball Valve.

Plug the Ball Valve with the previously removed plug and use a gasket to ensure tightness.

Dismantle the arm of the Ball Valve and using a duct tape attach on or near to the Ball Valve to alleviate future operations.

Affix (if missing) an A4 size easily readable danger notice (supplied) on all sides of the vessel or on to the door of container, as required to ensure visibility at both sides of the vessel.

Affix (if missing) an A4 size easily readable warnings (supplied) on all sides of the vessel or on to the door of container, as required to ensure visibility at both sides of the vessel.

Affix (if missing) an 10cm X 10cm size easily visible safety signs (supplied) on all sides of the vessel or on to the door of container, as required.

Store the N2 Bundle as instructed on MSDS.

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9 QUALITY ASSURANCE

A Quality Assurance System shall be operated conforming to related standards.

10 ATTACHMENTS

10.1 JOB SAFETY ANALYSIS

10.2 TAGS and SIGNS (Sample)

JSA Number: T-4.305.139

Normal Approvals: Name Date

JSA by: Mr.Emre Yazc 23.09.2008

Job Supervisor: Mr. Osman Davaslgil 23.09.2008

Name Date

Discipline Superindent(LINDE)

SHES Representative(LINDE)

2. Permit To Work.

LINDE EMERGENCY TELEPHONE NO. HSSE MANAGER: 583 40 72RLIC HOT LINE : 474 88 88

JOB SAFETY ANALYSIS / RISK ASSESSMENT

Page No: 1 of 5

Job being analysed: NITROGEN FILLING, MOLECULAR SIEVE ADSORBER

Additional Approvals (Determined by Job Supervisor in correlation with LINDE HSSE Manager).

Department/Section doing JSA: HSSE & Mechanical Dept. JSA Members: Mr. Oguz Baskoylu, Mr. Emre YazcJob Performers: Mr. Osman Davaslgil, Mr. Seyfettin Bayrak

General job requirements / Common Personnal

Protective Equipment.

Signature

Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work.

2) Use additional sheets as necessary.

3) Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and shell Safety and Environment Procedures.

Approval required for hazardous work detailed in the LINDE work permit procedure.Changing conditions and emergency procedures: -Stop work. Switch of equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing

employees are reported to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning to work.

1. The following Personal Protective Equipment

shall be worn while installing manbasket: Approved

coveralls, safety glasses, safety helmet, safety steel

toe shoes and gloves. Signature

OTHERS (List Below):

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NEW REVISED

JSA Number: T- 4.xxx.yyy

RISKRANK

1 Using of Manlift 1,1 Mechanical Breakdown 1.1.1 Equipment shall be serviced maintained and inspected as per set

maintenance and inspection program.

1.1.1.1 Ensure equipment to be provided

with controls of the dead man type,

which only allow movement of the

machine to take place whilst they

are actually being operated.

1.1.2 Ensure E-Stop is in place through the

control system.

1.1.1.2 Dead man controls automatically

return to the neutral position.

1.1.3 Perform equipment daily check prior

to use.

1.1.1.3 Appropriate trained & certified

persons only to use equipment.

1.1.4 Supervisor shall ensure that work will

be properly supervised as per work

method statement.

1.1.5 Ensure an emergency stop should be

provided on the platform control

panel.1,2 Improper use of

equipment

1.2.1 Manlift shall not be used as cranes or

jacks unless they have specifically

been designed for this purpose by

their manufacturers.

1.2.1.1 Ensure equipment is inspected,

approved & colour coded as per

colour code chart.

1.2.2 Leaning out of the platform will not be

allowed.

1.2.1.2 Current inspection sticker must be

in place.

1.2.3 Colour code sticker to be available on

the equipment.

1.2.1.3

#####B 3 A 3 #####

RP CCURRENT

CONTROLSADDITIONAL

CONTROLS

JOB SAFETY ANALYSIS / RISK ASSESSMENTT-4.305.139

SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, CRYOGENIC VAPORIZER

Residual RiskInitial Risk

Job Performers: Mr. Osman Davaslgil, Mr. Seyfettin

Bayrak

CP

3##

ITEM ACTIVITY CONSEQUENCES

HAZARD / POTENTIAL

#####3A#####

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RISKRANK

RP CCURRENT

CONTROLSADDITIONAL

CONTROLS





Bayrak

CP

3##


HAZARD / POTENTIAL

#####3A#####

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1,3 Untrained personnel 1.3.1 Ensure platforms must only be used

by authorized personnel who have

been trained in the operation of the

type of platform in use.

1.3.1.1

1.3.2 Initial training should cover operating

principles, machine controls and

environmental conditions, which are

likely to be encountered.

1.3.3 Training and practice in this type of

work undertaken is essential.

1.3.4 Ensure that equipment operator is

certified by third party, valid

certificates.

1,4 Fall of personnel 1.4.1 Safety harness shall be provided for

the use of all personnel working from

mobile work platforms so that in the

event of any advertent movement of

the platform they are working from,

they will not be thrown from it.

1.4.1.1 Discuss working at height hazards

in TSTI.

1.4.2 Boxes, hop-ups or ladders will not be

used to gain additional height or reach

from the platform of manlift machine

work platform.

1.4.1.2 Supervisor shall ensure that work

will be properly supervised at all

times as per work method

statement.

#####

Ensure supervisor/foreman who

will be using the manlift should be

particularly aware of the hazards

which may be encountered whilst

using these machines and of the

precautions which may be taken to

eliminate or minimize the hazards.B 3#####3 A

B 5 ##### A #####4

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RISKRANK

RP CCURRENT

CONTROLSADDITIONAL

CONTROLS





Bayrak

CP

3##


HAZARD / POTENTIAL

#####3A#####

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1,5 Overturning of Machine 1.5.1 Ensure no excessive force by the

operator on the platform by

introducing an element of side load.

1.5.1.1 When a manlift needs work in a

congested area, an approval for

the operation shall be obtained

from HSSE dept of Gama/Linde

authorized personnel's.

1.5.2 The outriggers or stabilizers, when

fitted, shall be fully extended and in

position, before the platform or boom

is raised.

1.5.1.2 Considering the effects of the

acceleration and deceleration of

the manlift.

1.5.3 The platform shall not be overloaded

exceeding the regulated safe working

load.

1.5.1.3 Discuss in TSTI.

1.5.4 Ensure the machine will be located to

the most suitable position for the job

to be carried out before any slewing

takes place.

1.5.5 Slewing of the boom to the extent that

causes the machine to overturn shall

be avoided.

1,6 Vehicle Movement 1.6.1 Ensure all vehicle movement to be

guided by competent banks men with

high visibility vests.

1.6.2 Ensure that each piece of equipment

is fitted with an automatic reverse

alarm and beacon or strobe light.

##### A

A 4 ##########

3

B 4

B 3 #####

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RISKRANK

RP CCURRENT

CONTROLSADDITIONAL

CONTROLS





Bayrak

CP

3##


HAZARD / POTENTIAL

#####3A#####

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2 Transportation of nitrogen bottle

2,1 Damaging of cylinder 2.1.1 Ensure the bottle is securly tied to the

vehicle.

2.1.1.1 Ensure the driver is warned to

avoid abrubt manouvers.

2.1.1.2 Ensure that the people are

instructed to avoid to drop the

bottle while carrying.

3.1.1 Ensure that the nitrogen bottle is tied

to the basket rails of the man-lift using

metal or plastic clamps.

3.1.1.1 Discuss in TSTI.

3.1.2 Barricade and secure the working

area with sign boards to prevent

unauthorized entry.

Nitrogen filling 4,1 Dropped tools

A 4 #####

4.1.1 Ensure that all hand tools are carried

in a tool box or attached to the

personnel.

4.1.1.1 Install barricades "exclusion zone"

with sign boards indicating

nitrogen filling works in progress to

prevent unauthorized entry.

4,2 Gas LeakageA 4 #####

4,2,1 Perform Gas Testing prior to start of

operation.

4,3 Inhaling nitrogen

B 5 #####

4,3,1 Ensure that the operation is carried

out in a well ventilated area or out

doors.

4.3.1.1 Install "INERT GAS WARNING"

signs, as necessary.

4,3 Handling pressurized

equipment

Ensure that valve protection cap is in

place.

4.4.1.1 Remove protection cap only to

connect the bottle to the filling

point.

Ensure the regulator is connected to

the bottle and operational.

4.4.1.2 Use a check-valve.

Ensure that the bottle is kept under 50

degrees Celcius and not in elongated

direct contact with sunlight.

4.4.1.3 Isolate cylider (bottle) at cylinder

valve when not in use.

Ensure that the bottle valve is opened

slowly to avoid pressure shock.

Ensure backfeed is not allowed into

the bottle.

##### A 4 #####

#####C 5 #####

A 4

3

A 4

Moving of the

nitrogen bottle to the

"filling position" via

man-lift

Dropped bottle3,1

#####

B 2 #####

4,4,1

4

A 3

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Documents

002-MS Nitrogen Filling , Cyrogenic Vaporizer.pdf