Toaz.info method-statement-for-tie-ins-pr d35edff4590d2bfb72016845a98313fb (1)

PROJECT: West Qurna I Project
PLANT: Major Tie-ins DS6 Facilities
Company Job No. Company Doc. No.
061171 IQWQ-SA-KSMTH-D6-0031
Contractor Job No. Contractor Doc. No.
AWQ0301 - 1 & 2 061171-SRQ-301-PIP-MST-69700
Document Title:
METHOD STATEMENT FOR PIPING TIE-INS
TRAIN C - FIRST PRIORITY
Sh. 2 of 21 Rev 0
CONFIDENTIAL
This document is the property of ExxonMobil Iraq Ltd who will safeguard its rights according to the civil and penal provisions of the law.
Revision History:
Rev. Date SECTION /PAGES REVISED REASON FOR REVISION
A 23-Jan-2020 - Issue for Internal Review
B 10-Feb-2020 Page 1 and Sections 5,6 & 7 Doc. Numbers and comments incorporated
C 16-Mar-2020 Sections 5,6 & 7. Appendix 2 added Company comments incorporated
0 04-Apr-2020 Issued for Use

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TABLE OF CONTENTS
1. PURPOSE...................................................................................................................................4
2. SCOPE........................................................................................................................................4
3. TERMS, DEFINITIONS AND ABBREVIATIONS .......................................................................4
4. REFERENCES, STANDARDS AND CODES ............................................................................5
5. ROLES AND RESPONSIBILITIES.............................................................................................6
6. PROCEDURE .............................................................................................................................6
6.1. GENERAL REQUIREMENTS ................................................................................................... 6
6.2. RESOURCES AND SCHEDULE (MANPOWER, EQUIPMENT AND MATERIALS) ..............7
6.2.1. MANPOWER ............................................................................................................................. 7
6.2.2. EQUIPMENT AND FACILITIES................................................................................................ 8
6.3. PROCEDURE............................................................................................................................ 8
6.3.1. SURVEY .................................................................................................................................... 8
6.3.2. PREPARATION......................................................................................................................... 9
6.3.3. DEPRESSURIZATION AND ISOLATION ................................................................................ 9
6.3.4. TIE-IN WORKS........................................................................................................................10
6.3.5. TIE-IN COMPLETION .............................................................................................................12
7. HSE REQUIREMENTS.............................................................................................................12
8. QUALITY REQUIREMENT.......................................................................................................14
9. ATTACHMENTS .......................................................................................................................15
10. APPENDICES ...........................................................................................................................15

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1. PURPOSE
The purpose of this Method Statement is to describe the activities, identify resources, equipment, apply
quality control and HSE measures to ensure that all works related to the execution of the Train C Tie-
Ins are carried out safely and in accordance with project specifications.
2. SCOPE
This method statement encompasses the cut of the existing pipelines, removal of flanges, Bolt
Tightening, installation and testing of prefabricated spools into existing pipeline. Where specified,
Golden welds will be performed on the 2 flanges which has to be fitted as part of Tie-In.
This document will ensure that the work is carried out in accordance with the applicable codes,
standards and best practices specified in the CONTRACT DOCUMENTS within the Major Tie-Ins DS6
Facilities at WQI, Iraq.
3. TERMS, DEFINITIONS AND ABBREVIATIONS
PROJECT Major Tie-Ins DS6 Facilities WQI, Iraq
COMPANY ExxonMobil Iraq limited
CONTRACTOR Saipem S.P.A Iraq Branch
SUBCONTRACTOR Calethon Construction Group
NDE-SUBCONTRACTOR NDT International
CONTRACT DOCUMENTS Documents that form the CONTRACT issued by the COMPANY
WORK Means the temporal and permanent, new, revamped and
refurbished facilities constituting the PROJECT, including the
services of fabrication, construction and installation, supplying of
materials and equipment, to be provided by the SUBCONTRACTOR
to satisfy the obligations pursuant to the contract undertaken with
the COMPANY.
DS6 Degassing Station 6
HSE Health Safety and Environment
JSA Job Safety Analysis
PPE Personal Protective Equipment
AGT Authorized Gas Tester
PTW Permit to work
ITP Inspection and Test Plan
IN Inspection Notification

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QA Quality Assurance
QC Quality Control
NDT Non Destructive Testing
NDE Non Destructive Examination
4. REFERENCES, STANDARDS AND CODES
All works will be followed according to CONTRACT DOCUMENTS, specifications and drawings.
• IQWQ-FT-LTTDS-00-0004 - Pipe Welding Data Sheets.
• IQWQ-FT-RSPDS-00-290302 - Specification -Upstream Process Piping Welding And Inspection.
• IQWQ-FT-LSPDS-00-030604 - Vents, drains, flushing and cleaning.
• IQWQ-FT-LSPDS-00-031902 - Upstream piping fabrication, erection, inspection, & cleaning.
• IQWQ-FT-LSSTD-00-0007 - Pipe standard details.
• ASME B31.3 - Chemical & Process Piping.
• ASME B16.25 - Buttwelding Ends.
• AWS D 1.1 - Structural welding code.
• IQWQ-SA-KSMTH-D6-0002 - Method Statement for Piping Fabrication and Installation.
• IQWQ-SA-KSMTH-D6-0013 - Method Statement for Torquing of Bolts.
• IQWQ-EI-QSCAS-00-0001 - Project Quality Assurance General Requirements.
• IQWQ-SA-QPQAC-D6-0001 - Project Quality Plan.
• IQWQ-SA-QPQAC-D6-0003 - Quality Management Requirements for Construction
CONTRACTOR.
• IQWQ-SA-QPQAC-D6-0004 - Quality Control Requirements for Construction SUBCONTRACTOR.
• IQWQ-FT-SPSAF-00-0001 - Health, Safety & Environment Plan.
• IQWQ-SA-SPSAF-D6-0011 - HSE Manual for Construction.
• IQWQ-FT-SPSAF-00-0004 - Emergency Preparedness and Response Plan.
• IQWQ-SA-SPSAF-D6-0003 - Medical Emergency Response Plan.
• WQ1FOD - Safety Manual.
• IQWQ-EI-SSPDS-00-0002 - Project Safety Specification for Safety.
• IQWQ-EI-OSPDS-00-0003 - As-Built - Redline Procedure.
• IQWQ-SA-QPWLD-D6-0017 Golden Weld Procedure
All other specifications mentioned and incorporated within the above Reference Documents.

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5. ROLES AND RESPONSIBILITIES
• CONTRACTOR’s Tie-In coordinator / Site Engineer shall be overall responsible for all activities
related to Tie-In works.
• CONTRACTOR shall be responsible for work permit requirements, risk assessment, tools and
tackles, crane and other handling equipment such as: torquing requirement, flange management,
hot work, PWHT, NDE, Hydro testing, etc.
• SUB-CONTRACTOR’S work site Supervisor shall be responsible for the preparation and execution
of Tie-In activities described in this method statement.
• SUB-CONTRACTOR’S QC Inspector & Engineering shall review the method statement to ensure
all the relevant material, reports of released spool of tie-in works have been accepted as per
applicable QCP by CONTRACTOR/COMPANY.
• SUB-CONTRACTOR’S HSE Manager/Supervisor/personnel shall be responsible for safe work
procedure during Tie-In.
• Authorized Gas Tester (AGT) shall make the necessary gas test in location in and around the Tie-
In from time to time to ensure a gas free environment.
• NDE-SUBCONTRACTOR shall perform all Non-Destructive Testing with adequate precaution and
safety, and to be safely executed by qualified equipment and professionals according to Project
Specifications.
6. PROCEDURE
6.1. General Requirements
• COMPANY will perform LOTO and shall be witnessed by CONTRACTOR. COMPANY Operations
Team shall isolate, depressurize and hand over to CONTRACTOR’s Tie‐In execution team.
• CONTRACTOR shall be responsible for submission of PTW and its signed approval from
authorized parties.
• Isolation shall be as per WQ1 PTW System, signed by relevant parties.
• Operations to issue an Isolation Certificate prior to commencing any work.
• CONTRACTOR shall only use the latest revision of the IFC Drawings. If upon approval by
COMPANY, any change made during the construction, the Tie-In Supervisor shall redline the
drawings and follow the specification IQWQ-EI-OSPDS-00-0003 AS-BUILT - REDLINE
PROCEDURE.

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• A calibrated Torque Wrench certified by a third party shall be used for checking the tightness of
the bolts according to the values specified by the vendor of the instruments, valves or any
equipment included in the scope of work. Follow the procedure and references included in IQWQ-
SA-KSMTH-D6-0013 Method Statement for torqueing of Bolts.
• All necessary inspections, including documentation and check sheets shall be as per ITPs
approved by CONTRACTOR/COMPANY.
6.2. Resources and Schedule (Manpower, Equipment and Materials)
6.2.1. Manpower
Following the Manpower required to execute each Tie-In:
Sr. No. Discipline No’s
1 Tie in Coordinator 1
2 Site Engineer 1
3 Supervisor (PH) 2
4 HSE Officer 1
5 Authorized Gas Tester 1
6 Foreman 1
7 Fitter 1
8 Welder 1
9 Helper 2
10 Storekeeper 1
11 Fire Watcher 1
12 Operator & Driver 1
13 Electrician 1
14 Rigger 1
15 Crane Operator 1
16 NDT Technician/Operator 1
17 Scaffolder (if required) 1
TOTAL 19

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6.2.2. Equipment and Facilities
Following the Equipment and Facilities required to execute each Tie-In:
Sr. No. Description Quantity
1 Cold cut & bevel machine 1
2 Reciprocating cold cut saw (for small pipes) 1
3 Multi Gas Monitor 1
4 Acetylene Cutting Set 1
5 Air Compressor 1
6 Hammer 1
7 Spanner 1
8 Welding Machine & Argon Torch 1
9 Grinding machine 2
10 Fire Extinguisher (DCP) 3
11 Fire Water Hoses fitted with water tanker 1
12 Pipe Fitter Toolbox 1
13 Boom Truck 1
14 Air Hoses 2
15 High Pressure Hoses with connector 40 M
16 Inflatable Plugs 2
17 Mechanical pipe plugs (where applicable) TBD
18 Hand Torqueing Wrench 1
19 Heavy Duty Flange Spreader 0
20 Diesel Generator 1
21 Welding habitat 1
22 Containment Drum (for residual liquid from cutting) 3
23
Hydrojet or equivalent cleaning equipment, and
Detergents/cleaning agent (to clean/remove residual
hydrocarbon at internal wall of cut pipping prior to
insertion of pipe plugs). Refer to Safety Guideline in
Appendix 2
1
6.3. Procedure
6.3.1. Survey
• Check for the feasibility of the Tie-In at the proposed location for clash, accessibility,
constructability, safety, live pipes and cables, wind direction, nearest muster point,
available F&G systems/alarms, etc.
• Identify the exact location and co-ordinates where the Tie-in is to be made.

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• Verify the specification of the material, including pipe size, material, flange rating, flange
facing, type of gasket, type of bolting, insulation requirement, existing coating requirement,
etc.
• Mark the Tie-In number on existing Line.
• Identify and check the associated facility availability for the completion of the Tie-In, like
steel structural supports, space for foundation supports, space for bolt tightening,
adequacy of existing supports, etc.
• Ensure all Tie-In spools have NDE clearance, hydrotested, painted, and have been
accepted by QA/QC.
• Ensure that only latest approved and issued documents are used prior to commencement
of shutdown and copy of the Hydro test results shall be attached to the work permit.
• Whenever hotwork (welding) of existing piping is planned, integrity of the existing pipe is
to be checked through visual inspection and UT method at the exact locations of the
existing piping to be cut, to ensure that there is adequate thickness, i.e. existing pipe is not
badly corroded, and there is not lamination issue at the cut/weld locations of the existing
pipe.
6.3.2. Preparation
• All shutdown material shall be inspected by CONTRACTOR/COMPANY. The Inspected
and certified materials shall be kept securely in the Tie-In Location.
• The material is to be shifted to the Tie-In location.
• Plant Operations and Tie-In Execution Team shall perform a joint survey to finalize the
location for spading, valve isolation (single or double), venting, draining, spool removal,
etc.
• Containment drums shall be provided to contain residue from drains, vents, splitting of
flanges, etc.
• Material arranged on site shall be bagged, tagged and deployed at the designated area.
• Scaffolding/work platform shall be erected and in place where required for the work.
• The Tie-In area to be sufficiently barricaded and enough warning signs posted prior to
commencing Tie-In activities.
6.3.3. Depressurization and Isolation
• Plant Operations will hand over to the Tie-Ins Execution Team a depressurized and
isolated system in order to commence the activities.

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• CONTRACTOR to perform a walkdown of the piping system to ensure that upstream and
downstream of the Tie-In location are adequately and safety LOTO and positively isolated,
prior to commencement of any Tie-In work activities.
6.3.4. Tie-In Works
• Refer to the Appendix 1. TIE-IN SEQUENCE LIST as a guidance for the activities before
and after the Shutdown.
• Coordinate the activities following the Interface Agreements (IA) IQWQ‐IA‐L‐FODO‐
MPMT‐2495, 2523, 2044 & 2062.
• All technical information such as: Connection sizes, ratings, schedules, Location/GA/3D
drawings and Isometrics refer to the attached Tie‐In documentation included in:
• IQWQ-KT-LDDET-6A-0084 Train C Coalescer Tie-In No. D6-624-052A&B.
• IQWQ‐KT‐LDDET‐6E‐0019 Purge Gas Tie-In No. D6-613-780A&B.
• IQWQ-KT-LDDET-D6-0003 OFR-004 Train C 1st Stage Separator Tie-In No. D6-623-
087A/B.
• IQWQ-KT-LDDET-D6-0021 OFR-005 Train C 2nd Stage Separator Tie-In No. D6-
623-459.
• IQWQ-PSN161-LDDET-6E-0022 Crude Oil From Train C Stage 1 to Stage 2
Separator Tie-In No. D6-623-788A/B.
• Survey exact coordinates of Tie-In points and get verified by CONTRACTOR and
COMPANY.
• After the system shutdown, wait for Plant Operations’ handover to start the activities.
• Perform all HSE requirements included in section 7 of this Method Statement.
• Ensure UT to check existing pipe wall thickness and no lamination issue prior to cut the
line.
• Place containment drums directly below the existing piping prior to cutting the line.
• Cut and Prepare existing pipe as per Project Requirements. Cold cutting method only shall
be performed on the existing pipe system.
• Means of a pipe dam or Inflatable Pipe Plugs/Balloon to be used in the lines to confirm a
tight seat prior to hot work. This will avoid any backflow of residue in the lines to be welded.
• Remove the section of the pipe indicated in the Destruct Scope and dispose it at the
designated area approved by COMPANY.

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• Prior to execution of any hotwork, follow the guidelines in the attached Appendix 2 -
Execution Sequence Safety Guidelines for Hydrocarbon Welded Tie-ins for the following
activities:
• Cleaning of internal of piping, to remove residual hydrocarbon at internal wall of the
piping, prior to insertion of inflatable balloons or mechanical pipe plugs as appropriate.
• Gas test of installed pipe plugs to ensure leak tight.
• Ensure venting points are available upstream and downstream of installed pipe plugs
to avoid / prevent build-up of back pressure.
• Continuous gas checks / monitoring during hotwork activity.
• Prepare the surface of the cut pipes, execute flange fit-up and proceed with the welding of
the flanges as per specifications. Reference: IQWQ-SA-KSMTH-D6-0002 - Method
Statement for Piping Fabrication and Installation, and “Golden Joint Procedure IQWQ-
SA-QPWLD-D6-0017”.
• Install the new spools as per attached isometric drawings.
• Install gaskets
• Bolt tightening activity shall follow IQWQ-SA-KSMTH-D6-0013 - Method Statement for
Torqueing of Bolts.
• Upon completion of the bolts tightening, the system will be prepared for LOTO de-
isolation activities.
• Conduct the inspections as per approved QCP, following the Section 8 of this Method
Statement.

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• Below is an example diagram for the activities of cutting, field welding and installation
of new spools:
6.3.5. Tie-In Completion
• After completion of Tie-In activities, painting shall be carried out as per painting
procedure in the welded area and where touch up is required.
7. HSE REQUIREMENTS
• SUBCONTRACTOR Safety Supervisor shall carry out the site inspections to ensure that safety
work plan is followed prior to start work.
• SUBCONTRACTOR Safety Supervisor shall review safety action plan and ensure the
implementation of JSA. Ensure that Critical Task Risk Assessment (CTRA) for the isolation,
Spading & Tie-In activities shall be approved prior to Tie-In activities.
• Work permits shall be obtained from the concerned authorities including revalidation at
predetermined intervals. The personnel shall also be in possession of oil field pass / security

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pass suitable to the work locations. All permits and passes shall be issued before start of any
related work.
• Ensure that Hot work permit is obtained by the site Supervisor responsible to execute the activity
prior to commencement of isolation, spading other Tie-In Activities.
• Ensure that all rigging accessories like belts, D-Shackle etc., that have been certified by third
party will be used.
• All testing equipment and tools shall be inspected and certified by a third party (when applicable)
and shall be Intrinsically safe if required by CONTRACTOR/COMPANY according to the Project
Specifications.
• All personnel shall have attended HSE induction / awareness training programs conducted in-
house.
• Daily Toolbox Talk shall be carried out as per execution plan. Personal involved in Tie-In
activities including equipment operator and driver shall be given a toolbox meeting on the
procedure to safety carry out the work and precaution to be followed during Tie-In execution.
• After toolbox talk each person should sign in the toolbox talk form which will be attached along
with work permit.
• Ensure that the work area has been properly barricaded and warning boards displayed prior to
start the Tie-in activity.
• Ensure all the residues are properly drained for the pipeline which needs to be disconnected.
• Work area shall be maintained neat and clean by performing good housekeeping before, during
and after finishing the activities.
• Ensure that the fire water hose connection that have been made available for the Tie-In activities
have been connected and the hoses run to the work location prior to start the Tie-In activities.
• Ensure that a sufficient number of approved fire extinguishers are available at the Tie-In location
prior to start of any hot work activities.
• All personal working shall wear personal protective equipment (PPE) as applicable such as
safety shoes, Helmets, Gloves, Goggles, Dust masks, H2S escape mask, H2S monitor as
specified in work permit requirements.
• Ensure that Multi gas monitor shall be properly calibrated and approved.
• Ensure the gas test to carried out and minimum two manpower shall be ready with SCBA before
opening any flange.
• For activities in confined spaces, workers shall have undergone the Confined Spaces Training
prior to being able to carry out such activities.

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• Ensure confined space procedure is followed including proper ventilation availability of rescue
equipment and standby man.
• Ensure availability of trained firewatcher round the clock during hot work activity.
• Ensure welding job shall not be done in wet condition or during rain.
• Gas test for Flammable atmosphere to be conducted up to 15 meters of Tie –In location and
confirm 0% LEL.
• Prior to and during hot work, continuous gas monitoring of the reading at the point of work shall
not exceed 1% of LEL, preferably 0%. For cold work without respiratory protection, breathing
area combustible / flammable gas / vapour concentration shall be less than 10% of LEL. and
continuously monitor the gas presence.
• Standby water tank shall be available at work site.
• Follow HSE MS procedure and ensure all the precaution stated in the work permit are taken and
communicated the CTRA requirements with all work forces through Toolbox talk and meetings.
• SUBCONTRACTOR Safety Manager shall keep the updated IQWQ-FT-SPSAF-00-0004
Emergency Preparedness and Response Plan and IQWQ-SA-SPSAF-D6-0003 Medical
Emergency Response Plan, and instruct to the HSE supervisors to ensure the availability of First
Aid kits, escape route signs, emergency call numbers, emergency assembly point, etc. as well
as preparing schedules of exercises and drills periodically.
8. QUALITY REQUIREMENT
• All necessary inspections shall be carried out as per ITP approved by
CONTRACTOR/COMPANY.
• Prior to start any inspection activity, the Quality Inspector shall raise the IN, sending a written
Inspection Notification to CONTRACTOR 24 Hrs. in advance. The IN must be approved by
CONTRACTOR/COMPANY in order to proceed for the inspection.
• Quality shall be maintained by ensuring the systematic implementation of this procedure and
ensure that necessary quality records are generated as appended formats.
• All material related to the activities shall be inspected and stored according to manufacturer
recommendations and Project Specifications.
• The test equipment shall be calibrated and certified by third party. The certificates and records
shall be kept available during the inspections.

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• The Tie-In Supervisor shall conduct all the tests witnessed by CONTRACTOR/COMPANY.
SUBCONTRACTOR Quality Inspector shall be present during the tests recording the values in
the Inspection Forms.
9. ATTACHMENTS
• Task Risk assessment CA-16-041-WQ0301-F-0219_1 Piping Fabrication and Installation
• Tie‐In information packages (Work Packs):
• IQWQ-KT-LDDET-6A-0084.
• IQWQ‐KT‐LDDET‐6E‐0019.
• IQWQ-KT-LDDET-D6-0003.
• IQWQ-KT-LDDET-D6-0021.
• IQWQ-PSN161-LDDET-6E-0022.
10. APPENDICES
• Appendix 1. Tie-In Sequence List.
• Appendix 2. Execution Sequence Safety Guidelines for Hydrocarbon Welded Tie-ins.

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APPENDIX 1
TIE-IN SEQUENCE CHECK LIST

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TIE-IN SEQUENCE CHECK LIST
PRE-SHUTDOWN
SHUTDOWN
Item
No
Description Yes No
1 Spool fabrication?
2 Support fabrication
3 Foundation / Support installed?
4 Punch “A” Item Cleared?
5 Spools and valves Hydro tested?
6 Spool released for tie-in?
7 Loose materials stage to company (Bag & Tag)?
8 Tie-in Method Statement / Work Packs approved?
9 Tie-in points identified and tagged?
10 UT (wall thickness and lamination checks) of cut/welded
points on the existing piping have been completed?
11 Crane position identified and surveyed?
12 Scaffolding / work platforms (if required) have been
erected?
13 Equipment and Manpower mobilized to site?
Item
No
Description Yes No
1 Work Permit?
2 System Isolation - walkdown of existing piping system to
confirm that Tie-In location is adequately LOTO and
positively isolated for safe execution of tie-in work?
3 Internal wall of piping cleaned / removed of residual
hydrocarbon prior to insertion of pipe balloons /
mechanical pipe plugs and commencing hotwork?

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SUBCONTRACTOR CONTRACTOR COMPANY
NAME
DESIGNATION
SIGNATURE
DATE
4 Vent points available upstream and downstream of
installed pipe balloons / mechanical pipe plugs (to prevent
back pressure build-up)?
5 Gas Testing?
6 Spool Installation/Bolting (Tie-In)?
7 Plumpness and alignment?
8 Bolted connection tightened / torqued per procedure, and
bolt tightening / torquing inspection report signed by
COMPANY representative?
9 NDT completed per procedure and accepted by
COMPANY representative?
10 Re-Open Valve (by Operations)?
11 Service test?

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APPENDIX 2
EXECUTION SEQUENCE SAFETY GUIDELINES FOR
HYDROCARBON WELDED TIE-INS

STEP 1
Line depressurized, drained, isolated and handover by Operation to Projects for tie-in execution
STEP 2
Cold cut section of existing line for tie-in, and collect any remnant hydrocarbon liquid in the line for disposal
STEP 3
• Cleans internal of pipe wall to remove remnant / residual hydrocarbon prior to insertion of inflatable plugs eg. using high
pressure water jet, with hydrocarbon detergents / cleaning agents as required
• Provide venting points upstream and downstream of the inserted pipe plug locations to prevent build-up of back pressure
behind the installed pipe plugs ie. open vent or drain points in the piping, and if this is not available, install spacer plates /
teflon strips at the spading locations to provide gap at spades for pressure relief purpose
STEP 4
• Inserts inflatable plugs approx. 500 mm into both sides of the tie-in pipe section and inflate plugs to set in position
• Snoopy test the installed plugs to confirm that these are leak tight
• Gas test the open ends of the pipe section to ensure hydrocarbon free – 0% hydrocarbon by volume
• Commence beveling of the tie-in pipe ends, with continuous gas testing during the beveling activity
• CAUTION – never place yourself directly in the “line of fire” of the plugs in case plugs are dislodged from its set position
500 mm 500 mm
STEP 5
• Fit up tie-in spool piece and commence welding, with continuous gas testing during the welding activity
• Carry out NDT of the completed welds
STEP 6
• Upon acceptance of the NDT results and tie-in, remove the inflatable plugs from the tie-in pipe section
• Install the tie-in isolation valve or blind as specified in the drawings
• Lock out and tag isolation valve to prevent unauthorized operation
• Handover completed tie-in pipe section to Operations
Execution Sequence Safety Guidelines for Hydrocarbon Welded Tie-in (Tee Connection)

STEP 1
Line depressurized, drained, isolated and handover by Operation to Projects for tie-in execution
STEP 2
Cold cut section of existing line for tie-in, and collect any remnant hydrocarbon liquid in the line for disposal
STEP 3
• Cleans internal of pipe wall to remove remnant / residual hydrocarbon prior to insertion of inflatable or mechanical plugs eg.
using high pressure water jet, with hydrocarbon detergents as required
• Provide venting points upstream and downstream of the inserted pipe plug locations to prevent build-up of back pressure
behind the installed pipe plugs ie. open vent or drain points in the piping, and if this is not available, install spacer plates /
teflon strips at the spading locations to provide gap at spades for pressure relief purpose
STEP 4
• Inserts inflatable or mechanical plugs approx. 500 mm into both sides of the tie-in pipe section and inflate plugs to set in position
• Snoopy test the installed plugs to confirm that these are leak tight
• Gas test the open ends of the pipe section to ensure hydrocarbon free – 0% hydrocarbon by volume
• Commence beveling of the tie-in pipe ends, with continuous gas testing during the beveling activity
500 mm 500 mm
STEP 5
• Fit up tie-in spool piece and commence welding, with continuous gas testing during the welding activity
• Carry out NDT of the completed welds
STEP 6
• Upon acceptance of the NDT results and tie-in, remove the inflatable or mechanical plugs from the tie-in pipe section
• Install the inter-connecting tie-in spool piece as specified in the drawings
• Handover completed tie-in pipe section to Operations
Execution Sequence Safety Guidelines for Hydrocarbon Welded Tie-in (Open Pipe Connection)
500 mm 500 mm

Severity
Likelihood
Risk
Action Responsible Comment
Severity
Likelihood
Risk
1
1.1 Preparation and
compliance to work
permit requirements
Tool box talk safety
meeting
Untrained
people
Lack of
experience
Missed
information
Personal injuries
Property Loss
Workers involved in
Activity
Assign people who have attended safety orientation and training.
Involved employees shall be trained for specific activity.
Safety work permit and other pertinent
documents from SAIPEM should be secured before works commence
Sequence of work shall be discussed during tool box meeting
JSA to be discussed daily with the workers at the start of work
Supervisor / Foreman has to make sure all crew members have
required PPEs. (Helmet, FR Coverall, Glasses, Gloves, Shoes, Full Body
Harness "if working at height").
3 3 M Continuous supervision
Foreman/
Supervisor
Permit receiver
All concern
persons
3 2 L
1.2 Preparation of required
tools and equipment
Manual Handling
of inappropriate
Tools and
Equipments
Hand/limbs injury by
handling
inappropriate tools
& equipment
Workers involved in
Activity
Ensure tools and equipment are inspected.
Only recommended tools to be used for specific job.
Wear leather gloves
All hand tools should have inspection colour code.
To check proper colour coding and bears.
Aware in all sharp edges.
Power tools should have inspected sticker.
Foreman/
Supervisor
Permit receiver
All concern
persons
3 2 L
1.3 Preparation of work area Equipments
Gravity
Tripping hazards
(slip, trip, fall)
Employees
involved in activity
Identify the working area by barricading and placing signages
Keep material in order
Keep access clear of unwanted material
Good housekeeping must be done before and after the job.
Combustible material shall be covered/removed form working area.
Use Sign boards for showing way
Foreman/
Supervisor
Permit receiver
All concern
persons
3 2 L
1.4 Mobilization of
equipment and personnel,
Piping Material
Heavy
equipment
Vehicle/personnel
interface
Serious crushing
injury, death
Trained personnel, certified operator / Driver
Flagman available;
Flagman with reflective vest;
Segregation of working area;
Daily inspection of Equipments;
Works conducted during day time with good visibility
4 3 M Continuous supervision Lifting foreman 4 2 M
1.5 Mobilization of
Structural Material
Heavy loads Failure of load
lashing gear
Serious injury,
death, asset
damage and 3rd
party consequences
(if happen on the
road)
Load to be corresponding trailer bed;
Proper lashing gear and technique;
Indicate road conditions - frequent stop and recontrol of lashing gear
and load;
Speed limit obedience;
DDT training for the driver
5 3 H Continuous supervision
Lifting
foreman, driver
4 2 M
1.6 Mobilization of
Structural Material
Oversized loads Collision with
overhead structures
Asset damage (3rd
party)
Road survey for obstacles and overhead structures;
Known load height;
Escort vehicle
3 3 M
Lifting
foreman, driver
3 2 L
Last updated: 09 March 2020
Risk Assessment title: Piping Fabrication & Installation
Project: CA-16-041-WQ0301 & 2
Preparation, Mobilization to site (Personnel and Material)
Risk Level
Potential
Additional control
Risk Level
After
mitigation
Standard Control Measure
Activity
ID
Activity Description Hazards Hazard Release Consequence

Severity
Likelihood
Risk
Severity
Likelihood
Risk
Project: CA-16-041-WQ0301 & 2
Risk Level
Potential
Additional control
Risk Level
After
mitigation
Activity
ID
1.7 Mobilization of
Structural Material
Road traffic Road traffic incidents Serious injury,
death, asset
damage and 3rd
party consequences
(if happen on the
road)
DDT training for the driver;
Obey speed limits according to load and road conditions;
Seatbelt compliance;
Daily vehicle inspections by driver 5 3 H Continuous supervision
Respective
discipline
supervisor,
driver
4 2 M
2
2.1 Manual handling of
material
Manual Handling
Material
Sharp Edges
Physical body injury
Pinch point
Falling of material
Workers involved in
Activity
Conduct tool box talk and discuss all possible hazard and control
measures
Do not put fingers/body parts in the line of fire.
Aware of all sharp edges.
Don’t keep any loose objects on the lifting material
Make sure that maintain good communication between involved
people.
Use manual lift techniques.
Job Foreman/
Job Supervisor
3 2 L
3
3.1 Shifting material to work
Place by forklift / Boom
truck
Machinery
Movement
(Forklift, Boom
Truck)
Load
Uncertified people
Mechanical failure
Tilting hazard
Crushing with other
objects
Crushing people
Unsecured load
Blind spots
Company Asset /
Workers Involved in
Activity
3rd Party certified operator shall be operate the forklift / Boom Truck.
To Drive the Boom Truck operator must have Iraqi License along with
3rd party certification.
Before mobilizing equipment, follow SAIPEM equipment inspection
program.
Daily check list shall be prepared by operator.
Do not drive the forklift on uneven ground.
Do not carry/lift more than capacity.
Load to be secured while transporting.
Vehicle shall be with reverse alarm.
Certified flagman shall be assign for signaling.
Flagman visible to operator/ Driver.
Do not allow any others to sit/stand on the forklift.
Remove people from vehicle movement area
Lifting
foreman/
Operator /
Job supervisor
4 2 M
4
Mannual Handling Activities
Loading unloading of material/ pipe spools by mobile crane
Using of Forklift / Boom Truck

Severity
Likelihood
Risk
Severity
Likelihood
Risk
Project: CA-16-041-WQ0301 & 2
Risk Level
Potential
Additional control
Risk Level
After
mitigation
Activity
ID
4.1 Loading unloading of
material/ pipe spools by
mobile crane
Lifting Crane collapse
Mechanical failure
Tilting hazard
Uncertified people
Uncertified rigging
gears
Falling of material
Personnel injury
Serious injury,
death, asset
damage
Place the crane on compacted and levelled area.
Use proper out rigger pads.
Assign third party certified operator and riggers.
Crane shall be third party certified.
Daily check list shall be prepared by operator.
Do not lift more than capacity of SWL.
Do not drive the crane on uneven ground.
Use third party certified rigging gears.
Do not use damaged slings.
Don’t keep any loose material on the shifting material.
Crane lifts shall not be performed in wind speed exceeds 32 km/ h
(20mph) unless
otherwise specified by the crane manufacturer.
Use proper barricades and warning sign boards.
Don’t allow unauthorized people in the barricaded area.
Lifting
foreman/
Rigger
/supervisor
4 2 M
4.2 Loading / unloading &
Installation of Piping
Material
Lifting Rigging connections /
Points on Height
Access
Fall from height,
serious injury,
death
Avoid going to the under the load, rigging from sides as much as
possible;
Use retractable fall arrest system if wants to access on height rigging
points.
Ladder inspection program;
Maximize use of man lifts for access at height rigging points
Lifting
foreman/
rigger /
operator
4 2 M
5
5.1 Pipe Marking and Fitup Sharp Edges
Flying objects
Slip, trip and fall
Cut and pinch point
Eye injury
Workers involves in
Activity
Maintain enough distance while manual rolling the pipe.
Use leather hand gloves and beware of sharp edges.
Do not put any body parts in the line of fire.
Use proper hand tools (homemade tools are not allowed.
Use safety glass and do not see welding lights
Supervisor /
Foreman
4 2 M
5.2 Hot work
Cutting,Grinding,
welding
Electric
Welding
Machine
Fumes
Hot Surface
Eye injury
Dust allergy
Fire hazards due to
sparks
Electrical shock
Fire
Company Asset /
Workers Involved in
Activity
Trained fire watch deputed on the activity area fire,
RPM of wheel should be checked before going to use.
All electrical cable must be pulling on overhead, power tools shall be
provided by GFCI,
Use nose mask (NIOSH N95).Every day shall be change with new.
Asbestos cloth covering to be provided around the cutting and
grinding area to prevent
spreading of sparks.
Use leather hand glove "Pig Sking for Welding", safety glass and face
shield.
Welder to use all recommended PPE (Apron, leg guard. Hand sleeve)
Proper rated grinding wheel with guard shall be used, use proper plug
spanner to fixed wheel and proper PPE,
Flammable material to be removed before start work.
All electrical equipment to be inspected by competent persons and
put color code of month.
Supervisor /
Foreman
4 2 M
Marking of pipe and Fit-up & Welding

Severity
Likelihood
Risk
Severity
Likelihood
Risk
Project: CA-16-041-WQ0301 & 2
Risk Level
Potential
Additional control
Risk Level
After
mitigation
Activity
ID
5.3 Hot works in Brown Field
Hotwork Tie-ins
Hydrocarbons Producing sparks in
area present of
hydrocarbons
Fire, explosion,
multiple fatalities,
serious asset
damage
Strict adherence to PTW requirements;
Clear indication of areas forbidden for positive and potential ignition
sources;
Continuous gas monitoring;
Approved welding location;
Welding containment (welding habitat or welding tent, according to
distance from potential hydrocarbon sources);
Watchman, fire extinguisher, post welding fire watch (30min)
All of the above control measures and the following:
- Ensure existing piping system upstream and downstream of the tie-in
location is positively isolated and LOTO
- Install inflatable pipe balloons or mechanical pipe plugs to isolate tie-
in hotwork from the existing piping
- Internal pipe wall at tie-in cleaned and removed of residual
hydrocarbon prior to commencing any hotwork
- Vent points are avaialble / implemented upstream and downstream
of install pipe balloons / pipe plugs to prevent build-up pf back
pressure
- Implement the Welded Tie-in Execution Sequence Safety Guidelines
in Appendix 2 of the Method Statement for Piping Tie-ins Train C - First
Priority (Doc . # IQWQ-SA-KSMTH-D6-0031)
Mechanical
works
supervisor
4 2 M
5.4 Grinding, cutting Rotating
equipment
Grinding works,
rotating
grinding/cutting
discs, shattered disks
with high velocity
and energy
Serious injury,
death
Tools to be inspected daily by user and quarterly by competent
person;
Experienced worker;
Check maximum RPM of discs and grinding machine;
Cutting and grinding discus to be used strictly by purpose;
Never remove safety guard and side handle from grinder machine;
Grinding machine to be equipped with dead man handle;
Proper PPE to be used - safety goggles+face shield, hearing protection;
Warning signs placed
Mechanical
works foreman
4 2 M
5.5 Grinding, cutting Fire Spark generation Fire, asset damage,
burns
Fire watchman available;
Fire extinguisher available;
Use of fire blankets to prevent spark flying outside working area;
Use welding tents or habitats (as per plant requirement)
Good housekeeping to avoid accumulation of combustible waste;
Mechanical
works foreman
4 2 M
6 Work at height on Scaffolding Platform / by using Manlift
1

Severity
Likelihood
Risk
Severity
Likelihood
Risk
Project: CA-16-041-WQ0301 & 2
Risk Level
Potential
Additional control
Risk Level
After
mitigation
Activity
ID
6.1 Working at height on
Scaffolding platform
Dropped object Falling tools and
construction
materials
Workers involves in
Activity
Good housekeeping;
Use of tool lanyards;
Barricading of area below
Respective
discipline
foreman
4 2 M
6.2 Working at height on
Scaffolding platform
Work at height Scaffolds, mobile
platforms, falling
from scaffold,
Workers involves in
Activity
All personnel for work at height must be trained for W@H;
Only certified scaffolders can assemble scaffolds or mobile platforms,
unless it is factory made mobile platform;
Weekly inspection of scaffolds or mobile platforms;
Green tag available;
No works can be done on scaffold or mobile platform if it is not
inspected;
Relocation of mobile platform can be done only when there are no
workers on them;
No modification of scaffold or mobile platform by unauthorized
personnel;
Safety harness must be worn all times. Safety harness must be
connected to anchor point once in working position;
never overreach from scaffold or mobile platform
Respective
discipline
foreman
4 2 M
7
7.1 Operation of man lift Unstable Surface
Other Objects
Nearby
Crushing
Unstable Load
Weather
Malfunction.
Uncertified operator
Man lift collapse
Personnel falling
Over loading.
Poor ground
condition.
Hit with objects.
Bad weather.
Working under
suspended load.
Company Asset /
Workers Involved in
Activity
Daily check list shall be filled by operator while inspection before
starting the activities
Certified operator only operate the man lift.
Flag man shall give proper signals to man lift operator.
Do not allow more than 225 Kgs/ 2 (two) persons and hand tools in
the man basket. (follow the machine manual)
Do not allow people to come out from the man basket.
Ensure the surrounding area is free of materials.
Ground must have proper level and compaction.
Identify the working area by barricading and placing warning signages.
Manift
Operator
Job Foreman/
Job Supervisor
3 2 L
8
8.1 General hazards Heat stress Works during hot
season
Heat stroke, death Regular TBT on heat stress management;
Provision of shaded ventilated area;
Provision of cool drinking water;
Work/rest cycles;
No lone working system;
Respective
discipline
foreman
3 2 L
8.2 General hazards Adverse weather
conditions
Rain, cold weather,
mud
Acute health
problems, slip and
fall injury
Work - rest cycle, according to weather conditions;
Provision of resting shelter, hot drinks available;
Provision of proper PPE for cold season
Respective
discipline
foreman
3 2 L
8.3 General hazards Wild animals Presence of wild
dogs and venomous
snakes, scorpions
Bites, injuries,
death Personnel trained in first aid;
First aid kit available;
Emergency numbers for DS6 clinic is available;
Inspect personal cloths and PPE before use for presence of scorpions;
Inspect working area for presence of venomous animals and insects
Respective
discipline
foreman
3 2 L
Using Manlift
General hazards

Severity
Likelihood
Risk
Severity
Likelihood
Risk
Project: CA-16-041-WQ0301 & 2
Risk Level
Potential
Additional control
Risk Level
After
mitigation
Activity
ID
8.4 General hazards Domestic and
construction
waste
Production of waste Environmental
damage, attraction
of wild animals
Waste containers with proper lids;
Timely evacuation of waste;
Hazardous waste segregation
2 3 L Continuous supervision
Construction
manager
2 2 L
8.5 General hazards Noise Equipment, power
tools
Acute and chronic
health effects
Working area mainly is noisy by the nature of works -
Depend on particular assessment hearing protection shall be used;
Hearing protection is mandatory for grinding, cutting works and
nearby, compressor and compressed air operations;
Mandatory warning signs around noise producing works
Respective
discipline
foreman
3 2 L
8.6 General hazards Toxic and
flammable gases
Release from plant
or field near by
Fire, intoxication,
death
Gas detector available;
Monitoring of wind direction;
Communication with COMPANY ER department;
Evacuation plan, availability of transport means for evacuation
Respective
discipline
foreman,
3 3 M
9
9.1 QC and dimensional
checks
Gravity Dimensional checks
at ground level,
falling overhead
objects
Hit by falling
objects, serious
injury
Control of working area, do not allow simultaneous works at same
area but different height;
Proper PPE, enforce use of helmets;
Control of previously installed structures for unstable structural
members
3 3 M QC supervisor 3 2 L
9.2 QC and dimensional
checks
Work at height Dimensional checks
at height, dropped
object, falling from
man lift, scaffolds,
mobile platform
Hit by falling
objects, serious
injury
Control of working area, do not allow simultaneous works at same
area but different height;
Proper PPE, enforce use of helmets;
Barricade area below;
Equipment lanyards to prevent dropping object;
Personnel trained for W@H;
Certified manlift operator
3 3 M QC supervisor 3 2 L
QC and dimensional control

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