001-FSI-MS Nitrogen Filling , Molecular Sieve Adsorber.pdf

LIN-PMC-DOC 18153Senders Transmittal Ref

Michael PiwonkaTransmittal Originator

Transmittal Discipline

LIN - LINOriginator Organisation

ME - MechanicalTransmittal Comment

Issue Purpose ICC - Issued for CompanyComment

Transmittal Subtype P18 - ImplementationContractor Plans &Procedure (QMS)

Transmittal Created Date 4 Aug 2008Actual Completion Date 23 Aug 2008

Number of Documents 1Focal Point Wes Jordan

Transmittal Number PI-092-LIN-PMC-TX-16442Transmittal Status CLOSED

Transmittal Package

T-4.250.983

Comments Supporting DocsNo.No comments! No Supporting Documents1No comments. No Supporting Documents2Acceptable No Supporting Documents3

A ICCNo.Document Number Revision Title

1 ACCEPTEDMETHOD STATEMENTNITROGEN FILLING,MOLECULAR SIEVEADSORBER

Issue Purpose Review Rating Code

1 of 1 Printed On: 26 Aug 2008 08:34 Printed By: Michael Piwonka Page:

Pearl GTL Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT Contractor Project No : 5887 Project Document Number: T-4.250.983 Project Rev.: A Page 2 of 19

Purchase Order Number:

2MH127

Tag/Item Number(s):

1V-2131A 1V-2131B 1V-2231A 1V-2231B 1V-2331A 1V-2331B 1V-2431A 1V-2431B 2V-2131A 2V-2131B 2V-2231A 2V-2231B 2V-2331A 2V-2331B 2V-2431A 2V-2431B

Unit(s): ASU

PCWBS: Z

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

D A 27.07.08 Company Comments Incorporated OD MEY AG CCI

C O 23.06.08 Issued for Company Comments OD MEY AG ICC

B 19.06.08 Issued for Review OD MEY AG IFR

A 16.06.08 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, MOLECULAR SIEVE ADSORBER

Document No.

GAM MTS PRE GTL 001 D LOC470

Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T-4.250.983 Rev No.: A

adminText BoxReleased for Construction

adminText BoxRFC

Doc. Title : GAM-MTS-FSI-GTL-001 Rev. D Method Statement Nitrogen Filling, Molecular Sieve Adsorber

Date/Rev. No : 27.07.2008

T-4.250.983 Rev. A Page 4 of 19

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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 _________________________________________ 6

5.4 LIFT SPECIALIST ______________________________________________________________ 7

6 RESOURCES ______________________________________________________________________ 7

6.1 EQUIPMENT & MANPOWER_______________________________________________________ 7

6.1.1 EQUIPMENT _______________________________________________________________ 7

6.1.2 MANPOWER _______________________________________________________________ 7

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 ______________________________________________________ 8

8.3 DISASSEMBLY AND DELIVERY ____________________________________________________ 9

9 QUALITY ASSURANCE______________________________________________________________ 10

10 ATTACHMENTS ___________________________________________________________________ 11

10.1 JOB SAFETY ANALYSIS ________________________________________________________ 12

10.2 TAGS AND SIGNS (SAMPLE) _____________________________________________________ 18


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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 Molecular Sieve Adsorber (MSA) 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 Molecular Sieve Adsorber will conduct coordination meetings as required.

1.2 SCOPE AND PRECAUTION 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 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 will be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as required.

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) 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


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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-4.131.850 : Molecular Sieve Adsorber, Detail Drawing, Nozzles T-4.193.584 : Procedure for Nitrogen Filling, Air System Barlage T-13.376.921 : Preservation of New Equipment, Technical Specification

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 MSA : Molecular Sieve Adsorber fabricated by Linde Engineering AG 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.

5.3 CLEANLINESS & PRESERVATION ENGINEER

He will be overall responsible for safe execution of the whole job including: Organizing of equipments, material and tools needed for the job. Confirming the preservation location.


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QQQ AAA TTT AAA RRR Assigning skilled personnel for the job. Conducting TSTI with the concerned work force prior to start of work. Ensuring that relevant work permits for the job are obtained prior to start of work. 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. 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, to achieve a safe measuring and filling of N2 gas in the Molecular Sieve Adsorbers.

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 Nitrogen Bottle Holding Clamps Hand Tools Full PPE and Safety Harness Aerial Platform/ Manlift/ Man Basket

6.1.2 MANPOWER

Site Manager FSI Manager Cleanliness & Preservation Engineer Man-Basket Operator HSSE Personnel Helpers


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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 Molecular Sieve Adsorber starts with a request for 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 Molecular Sieve Adsorber.

8 MEASURING AND FILLING PROCEDURE

8.1 GENERAL The Molecular Sieve Adsorber is filled with N2 gas at 0.5 bar pressure 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) (Molecular Sieve Adsorber) will be tagged appropriately after each inspection and/ or refilling to reflect the status of preservation. (See Attachment-2 for samples).

8.2 ASSEMBLY and CHARGING Position the N2 Bottle on to the Man-Lift and secure using clamps. Do not expose the N2 Bottle 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.


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QQQ AAA TTT AAA RRRAttach the T-Piece on the Ball Valve. Install the Manometer on one of the free ends of the T-Piece (refer to the figure, below).

Connect the hose to the other end of the T-Piece. Secure the N2 Bottle properly on ground. 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.


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QQQ AAA TTT AAA RRR Affix (if missing) an A4 size easily readable danger notice (supplied) on all sides of the vessel. Affix (if missing) an A4 size easily readable warnings (supplied) on all sides of the vessel. Affix (if missing) an 10cm X 10cm size easily visible safety signs (supplied) on all sides of the vessel. Remove the N2 Bottle from the man-lift and store as instructed on MSDS.

9 QUALITY ASSURANCE

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


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10 ATTACHMENTS


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10.1 JOB SAFETY ANALYSIS

JSA Number: T- 4.250.983

Normal Approvals: Name Date

JSA by: Mr.Emre Yazc 27.04.08

Job Supervisor: Mr. Osman Davaslgil 27.04.08

Name DateDiscipline Superindent(LINDE)SHES Representative(LINDE)

2. Permit To Work.

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

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):

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. Adnan Sava

General job requirements / Common Personnal Protective Equipment.

Signature

JOB SAFETY ANALYSIS / RISK ASSESSMENT

Page No: 1 of 5

Job being analysed: NITROGEN FILLING, MOLECULAR SIEVE ADSORBER NEW REVISED

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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

LOWB 3 A 3 LOW

RP CCURRENT

CONTROLSADDITIONAL

CONTROLS

JOB SAFETY ANALYSIS / RISK ASSESSMENTT- 4.250.983

SCOPE : METHOD STATEMENT FOR NITROGEN FILLING, MOLECULAR SIEVE ADSORBER

Residual RiskInitial Risk

CP

3B

ITEM ACTIVITY CONSEQUENCESHAZARD / POTENTIAL

LOW3ALOW

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CPITEM ACTIVITY CONSEQUENCESHAZARD / POTENTIAL

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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.

LOW

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 3LOW3 A

B 5 MED A LOW4

RISKRANK

RP CCURRENT

CONTROLSADDITIONAL

CONTROLS





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1,5 Overturning of Machine 1.5.1 Ensure no excessive force by the operator on the platform by introducingan 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 4 LOWMED

3

B 4

B 3 LOWLOW A

RISKRANK

RP CCURRENT

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CONTROLS





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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 areawith sign boards to prevent unauthorized entry.

Nitrogen filling 4,1 Dropped tools

A 4 LOW

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 Inhaling nitrogenB 5 MED

4.2.1 Ensure that the operation is carried out in a well ventilated area or out doors.

4.2.1.1 Install "INERT GAS WARNING" signs, as necessary.

4,3 Handling pressurized equipment

Ensure that valve protection cap is in place.

4.3.1.1 Remove protection cap only to connect the bottle to the filling point.

Ensure the regulator is connected to the bottle and operational.

4.3.1.2 Use a check-valve.

Ensure that the bottle is kept under 50 degrees Celcius and not in elongated direct contact with sunlight.

4.3.1.3 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 LOW A 4 LOW

LOWC 5 HIGH

4

3

A 4

Moving of the nitrogen bottle to the "filling position" via man-lift

Dropped bottle3,1

A 3 LOW

B 2 LOW

4.3.1


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10.2 TAGS and SIGNS (Sample)


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