PROJECT : RASGAS ONSHORE EXPANSION PROJECT, PHASE 2 (RGX2)

COMPANY : RASGAS COMPANY LIMITED

CONTRACTOR : CTJV (JV OF Chiyoda – Technip)

SUBCONTRACTOR : Dodsal Engineering and Construction Pte Ltd

JOB NUMBER : RG6-CS-004

METHOD STATEMENT
FOR
INSTALLATION OF IMPULSE LINE, AIR TUBING
AND PRESSURE TESTING

DOCUMENT NUMBER : DOD-MST-INS-004

REVISION NUMBER :0

Issue Reviewed Approved

Rev. No Reason for Issue Prepared Dodsal
Date Dodsal Dodsal
Contractor’s comments Avaneesh
Bikas
B 25.04.07 Incorporated and Issued Ravi Shivdasan Chaudhary
Sinha
for Approval.
Contractor’s comments Avaneesh
Antonio
C 19.07.07 Incorporated and Issued Nitin.N.Baviskar Chaudhary
Marchese
for Approval.
Company’s Comments
Pankaj Shukla Avaneesh Antonio
0 16.09.07 incorporated. Issued for
Chaudhary Marchese
Construction.

Document No. DOD-MST-INS-004, rev. 0

Installation of Impulse Line, Air Tubing and Pressure Testing. Page 1 of 11
 REVISION CONTROL SHEET

Sr. Rev. Issue Issue

Description
No. No. No. Date
Contractor’s comments Incorporated and Issued
1 B 0 25.04.2007 for Approval
Contractor’s comments Incorporated and Issued
2 C 0 19.07.2007 for Approval.
Company’s Comments incorporated and Issued
3 0 0 16.09.2007 for Construction.

Document No. DOD-MST-INS-004, rev. 0

Installation of Impulse Line, Air Tubing and Pressure Testing. Page 2 of 11
 INDEX

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 RESPONSIBILITIES

6.0 PROCCEDURE

7.0 DOCUMENTATION

Document No. DOD-MST-INS-004, rev. 0

Installation of Impulse Line, Air Tubing and Pressure Testing. Page 3 of 11
1.0 PURPOSE

The purpose of this Method Statement is to accomplish the Installation of Impulse line, Air
Tubing and pressure testing of Process and Field instrument in accordance with
Project Specifications, Codes and Standards

2.0 SCOPE

This scope covers Installation of Impulse line, Air Tubing and pressure testing of
Process and Field instruments, within subcontractor’s scope of work for RasGas
Onshore Expansion Project, Phase-2.

3.0 REFERENCES

3.1 Contractor’s Documents

RG6-S-00-1370-002 : General Requirements for Instrumentation

RG6-S-00-1370-029 : Site Calibration and Testing of

Instruments

RG6-S-00-1370-026 : Instrumentation – Installation of Field

Mounted Instruments.

RG6-S-00-1370-010 : Instrumentation - Instrument Piping and

Tubing

RG6-S-00-1378-001 : Instrument Installation Drawings Design

Procedure.

RG6-S-00-1370-005 : Instrument - Control Valves

RG6-D-00-1370-009 : Standard Drawings

RG6-S-00-1378-001-01 : General Notes / Symbols / Legend

for Instrumentation

3.2 Subcontractor’s Documents

DOD-QMS-M001 : Quality Assurance System Manual

DOD-QA/QC-PQP-M130 : Project Quality Plan
DOD-HSE-RG-HSEP-H001 : Health, Safety, Environment Plan
DOD-QCP-QC-001 : Material Control & Storage
DOD-QCP-QC-002 : Material Receiving Inspection
DOD-ITP-INS-004 : ITP for Installation of Impulse line, Air
Tubing and Pressure Testing
DOD-QCP-INS-004 : QCP for Installation of Impulse line, Air
Tubing and Pressure Testing

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4.0 DEFINITIONS

Company : RasGas Company Limited

Contractor : CTJV (Chiyoda – Technip Joint Venture)

Subcontractor : Dodsal Engg and Construction Pte Limited

Supplier : Sub-Contractor to Dodsal Engg and

Construction Pte Ltd.

5 RESPONSIBILITIES

5.1 CHIEF CONSTRUCTION MANAGER: shall be responsible for the implementation of

this Method Statement and shall pass on instructions down the line to maintain the required
HSE and Quality standards , practices and procedures at each stage of the work.

5.2 E&I MANAGER / DEPUTY E&I MANAGER: Shall be responsible for the
implementation of this Method Statement and ensure the required HSE and Quality
standard, practices and procedures are maintained at each stage of the instrumentation
works.

5.3 SENIOR INST ENGINEER: Shall be responsible for the implementation of this Method
Statement and correct working techniques and shall ensure that the instrumentation works
are carried out as per approved IFC drawings, Project Specifications & Standards. He shall
be responsible for overall site supervision and work execution with strict adherence to this
method statement and required HSE & Quality standards, practices and procedures at site.
He shall arrange for necessary inspection & documentation.

5.4 INST SITE- ENGINEER / SUPERINTENDENT: Shall be responsible for the execution of
instrumentation works as per approved IFC drawings, Project Specification & Standards. He
shall be responsible for supervision of execution works with strict adherence to this method
statement and required HSE & Quality practices and procedures at site. He shall be
responsible to raise RFI for the works to be inspected and attend punch- points as required.

5.5 INSTRUMENT FOREMAN: Shall be responsible for the execution of the instrumentation
work as per approved IFC drawings ,specifications & standards, method statement and
responsible for implementation of required HSE and Quality Standards at site.

5.6 QC INSPECTOR : The Instrument QC Engineer/Inspector shall be responsible to forward

the RFI (Request for Inspection) Form No: DOD-RGX-F056 to CTJV after carrying out
internal inspection of the work. He will perform daily pre-inspection for instrument installation
works and confirm readiness for the inspection of the instrumentation works, compilation
and retention of reports and records as per QCP’S and ITP’S requirements as well as the
loop release. He will also be responsible for issuing non -Conformance Reports (NCR) and
punch list for the discrepancies of the work. All Tubes, pipes, fittings etc. works will be
inspected upon receipt at site and checked for any damage during transit and shall be
verified against manufacturer’s relevant test certificates & inspection reports duly signed.
OSDR (Overage, Short, Damage Report) to be prepared as applicable, shall be duly signed
by concerned personnel/ Deptt. / Client representative and to be immediately submitted to
the client with all the documentation & procedural requirements.
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5.7 SAFETY OFFICER :Shall ensure that all the Equipment, Tools and Tackles are certified
in accordance with the site HSE Requirement. All manpower, directly or indirectly
involved in this activity shall be informed of the hazards and risk factor. All regular
Safety Equipments (PPE) shall be used like helmet, goggles, work gloves, safety
harness etc.

6 ERECTION PROCEDURE

6.1 Safety

6.1.1 All equipment and accessories shall be verified and of adequate capacity according
to HSE requirements. Refer JSA No.: DOD-MST-INS-004

6.1.2 All personnel involved in Installation of field Instruments shall be informed of hazards
and will adopt preventive measures while undertaking subject instrumentation works.

6.1.3 All personnel must use their Safety Equipments and Personnel Protective Equipments
(PPE).

6.1.4 Tool Box meeting shall be held daily, prior to start of the work
6.2 MATERIALS
All Materials shall be supplied by M/s CTJV based on the M/s RasGas Standard,
and Project purchase documents & approved manufacturer’s specification.
All materials purchased by Dodsal will be approved before usage by
CTJV vía “MAR” (Material Approval Request) form no: DOD-RGX-F037

6.3 Equipments & Tools / Tackles

 Hydraulic Tube Bender

 Flat and Round Files
 Pipe Cutter
 Ladder, Magnetic sprit level
 Spanner / Alan key set
 Hydraulic Pressure Tester / Pressure Gauges

6.4 INSTALLATION OF IMPULSE LINE AND AIR TUBING

6.4.1 Upon receipt at the storage and handling area, the impulse line and air tubing
accessories shall be inspected by material QC inspector and recorded in the
MIR (Material Receipt Inspection Report) Form No: DOD-RGX-F051. And if
there is any mechanical damage / missing accessories, they shall be recorded
on the OSDR (Overage /Shortage/Damage Report) form no: DOD-RGX-F049
respectively.

6.4.2 Prior to start of Impulse Line installation, it is a must to identify all necessary
tools needed. All lifting harness and safety harness shall be updated. Obtain
the required work permits and safety clearances.

6.4.3 Cordon-off the area covered by the scope of working. Safety sign stating
“Impulse line work in progress” and “Do not enter “.will be posted in all
corner and side visible to anyone.

6.4.4 Physical damage shall be checked and the material traceability shall be

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 identified as per specifications before Installation.

6.4.5 All impulse points for flow and pressure measurement shall be fitted with isolation
valves mounted on the fluid pipeline.

6.4.6 In order to prevent impulse tubing from being plugged at the drain or stagnated by
gas, the piping shall have gradient of 1/10 (minimum 1/25)

6.4.7 In liquid impulse pipe, air bleeder valves should be installed at the highest part and
drain valves should be installed at the lowest parts. In gas impulse pipe, drain valves
should be installed at the lowest part and also in the vicinity of the instruments.

6.4.8 Instrument impulse piping / tubing shall be installed as shown on the

detailed instrument hook-up drawings. The details shall be finalized at site
once the instrument and tapping points are located.

6.4.9 Instrument Impulse line shall be kept as short as possible and the number of
joints shall be kept to a minimum. For impulse line, supports shall be
provided for every 1 meter Interval.

6.4.10 Prior to installation, the material shall be checked against the material
schedule to ensure it is to the correct specification and pressure rating.

6.4.11 Pipe bender’s shall be used for bending pipes which shall be free from kinks or
flats

6.4.12 The Impulse line / tubing shall be inspected and particular attention shall be
paid to the following:

 Section of pipes shall be cut square, have the ends reamed and be free from burr or
grease.

 Impulse lines shall slope towards or away from the tapping point as applicable. The
minimum slope shall be 1 in 12 or as specified in the installation drawing.

 Where threaded fittings are used thread forms are compatible and approved sealant
to be used.

 For longer lengths the tubing shall be supported approximately one-meter intervals.
Non-conductive space material shall be applied to isolate tubing from the support.
Impulse lines shall be grouped closely together.

 Where applicable vent and drain ports are installed as per the standard installation
drawings.

 Vent and drains are installed at the highest and lowest points of the piping
arrangement.

 Long piping/tubing runs which have intermediate union connections shall have tubing
off-sets to facilitate connection and disconnection.

 The piping /tubing shall not under go under stress or tension.

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  The piping / tubing arrangement is adequately supported throughout to minimize the
possibility of mechanical damage and vibration.

 The installation shall not obstruct access ways or passage to equipments.

 Sufficient access shall be maintained to minimize deleterious effects from hot or cold
surfaces, condensate and etc.

 All tubing fittings and components in any tubing assembly shall be Swagelok as per
Project Specification RG6-S-00-1370-010,

6.4.13 Differential pressure systems shall be checked to ensure connections are to

the correct high and low pressure instrument ports. The tubing shall be run
together as much as possible.

6.4.14 Impulse line shall be drained or vented to atmosphere to ensure no ingress of

moisture or foreign bodies.

6.5 Instrument Air Distribution System:

6.5.1 The Instrument headers and sub-headers shall be installed as per the approved
instrument hook-up and air supply layout.

6.5.2 Prior to installation, the material shall be checked against the material schedule to
ensure it is correct specification and pressure testing.

6.5.3 Short lengths of flexible armored tubing may be used on places, where sufficient movement
is not available in standard tube. Air flow shall not be restricted through fittings.

6.5.4 Tubing which run together, shall be installed vertically one above the other. More than three
runs shall be installed on tray. Any joints if necessary , shall be staggered.

6.5.5 The tubing runs should not exceed 100 m (300 ft.). Volume boosters may be used to give the
required response provided other control characteristics are not down graded.

6.5.6 The pipe line shall be thoroughly cleared before installation of equipment. When the pipe line
is flushed, the equipment shall be replaced by a dummy pipe.

6.5.7 Where a plastic sheath is used, the sheath shall continuously cover the tube to the seal
within a fitting.

6.5.8 Teflon tape shall not be used downstream of the filter regulator.

6.5.9 Air supply tubing shall be 6mm O.D for transmitter and receiver applications and 10 mm O.D
for controller and control valve installations as per standard drawings and specifications.

6.5.10 Piping downstream of instrument isolating valves shall be installed direct or with a “Swan
Neck “down to the filter regulator.

6.5.11 Pneumatic tubing should be run away from hot environments and potential fire risk areas
and should be located away from places where it may be subjected to mechanical damage ,
split liquids or corrosive gases. Tubing should be run so that it does not interfere with access
to or removal of other equipments.

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6.5.12 Pneumatic instrument multi-tube bundles may be laid in sand filled trenches if deemed
necessary. In case the trenches contain electrical cables, multi-tubes shall be appropriately
segregated, grouped together and identified separately.

6.5.13 The piping and tubing shall be inspected and particular attention paid to the
following:
 All main and sub-headers shall be sloped (minimum 1:12 or as specified in the installation
drawings) and provided with low point drains.

 All header and supply take-offs shall be connected to the top of mains or sub-header

 Instrument air piping shall not be pocketed (i.e. shall not contain U-sections)

 Instrument air piping shall not be installed underground (Without Ras Gas permission)

 From main instrument air header to the instrument air manifold NPS 1” or ¾” pipe shall be
installed.

 One NPS ½” spare valve shall be provided on each instrument air manifold.

 Single core tubes shall be supported and protected by tube tray. The instrument air
manifold shall be provided 6 or 12 points valve with drain valve.

 TAG plate showing instrument TAG No. to be installed at instrument air manifold.

 Instrument Air manifold may be preferably installed near instrument junction box. Air
tubing way to be commonly used with cable way.1” valve shall be installed by piping
at every 6 meters on main instrument air header.

 Air supply and signal transmission lines shall be routed to minimize exposure to
accidental
impact damage.

6.5.14 Prior to testing, the instrument air tubing connected to instrument shall be
disconnected and the air supply sub-header must be blown-down to ensure no
debris or water is present as per MST: DOD-MST-INS-004

6.5.15 Pressurize the sub-header using dried filtered Air or Nitrogen with test gauge at the
end and isolate, held for 3 minutes. The pressure shall not fall.

6.5.16 The checking must be recorded on Form No: DOD-RGX-F421

6.5.17 Testing of Pneumatic piping / tubing with liquid is not permitted.

6.6 PRESSURE TESTING

6.6.1 Prior to start of leak testing job, it is a must to identify all necessary tools
needed. All calibration stickers and certificate for shackle, lifting harness and
safety harness shall be updated

6.6.2 Secure the required work permits and safety clearances

6.6.3 Redundant evaluation and verification made for the PID and datasheet of the
instrument. Ensure that all the impulse line / tubing is completed as per hook-up.

6.6.4 Cordoned the area covered by the scope of testing. Safety sign stating “Pressure Testing is
On Going “, and “Do not Enter“ will be posted in all corner and side visible to anyone

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6.6.5 Impulse line pressure test procedure will be pneumatic and not hydraulic across all sections
of plant to avoid the risk of water being left in cryogenic lines .

6.6.6 All instruments impulse line shall be pressure tested using Nitrogen.

6.6.7 Prior to testing, the instrument shall be disconnected and the impulse piping blown through
using compressed air to ensure no debris is present.

6.6.8 The Nitrogen Cylinder, complete with regulator and test gauge, shall be connected to a
drain or vent port and the impulse loop evacuated of air.The pressure gauge should be
ranged such that the test pressure indicates within 40 to 80% of the calibrated range.
The calibrated test pressure gauge shall be used.

6.6.9 The impulse line/ tubing shall be pressurized to a range of 110% of the maximum design
pressure. All the equalizing manifold valves shall be kept in open position at the time of
testing.

 The applied pressure should not exceed the allowable maximum pressure range of
instrument and to specified pressure range at instrument data sheet.

 Pressurize the Impulse line/ tubing to a low pressure of between 2 to 3 bar.

 Apply soap solution or other leak determining solution through unions, Tees, valves or
nipples to identify whether the system has leak or not. Preparation of tapping point list.

 The Instrument Impulse line / tubing shall be isolated from the pressure source and held for
3 minutes. The pressure in the system shall not fall.

 Perform a soap test at the compression fittings and, if no leakage is found continue
increasing to full test pressure.

 In the presence of leak slowly close the valve and drain the air inside the
line before proceeding to tightening loose bolts or part of the fittings.

 If leakage is found, the leakage point shall be identified using the soap water solution
snooping at the joints and the joints shall be repaired and tested again till the joints are
away from leak.

 Check for any leakage again, if leak is observed, that joint shall be isolated
and right marking has to be given. For the rest of testing, if found leaks, this
has to be sealed and testing has to continue until the desired result is obtained.

 After completion of the test, the impulse line / tubing shall be blown through and dried using
compressed air. Pressure testing records shall be recorded on the form no: DOD-RGX-
F421

6.7 Certification:

6.7.1 After successful completion of each test, the instrument shall be marked with a
colored label bearing the date of the test and the initials of the witnessing party.

The coding shall be as follows:

White - Defective Instrument

Blue - Pre- Calibration Tested
Yellow - Pressure Tested

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 Green - Cables and / or Air Tubing Tested.
Red - Instrument Loop Tested / Pre Commissioning.

This indication shall be shown on all components of the loop

6.8 FINAL INSPECTION

6.8.1 Visual inspection shall be conducted.

6.8.2 Proper fittings and accessories installation shall be checked

6.8.3 Pipe and Pipe fittings like, Ferrules and accessories shall be checked.

6.8.4 Proper clamping shall be inspected as per standard drawings.

6.8.5 Installation of tubing slopes shall be inspected as per standard drawings.

6.8.6 Fixing bolts shall be tightened properly with suitable washers.

6.8.7 Instrument Tags shall be reviewed as per Drawing.

6.8.8 Impulse Line flow direction shall be checked as per Drawing.

6.8.9 Instrument Manifolds shall be isolated during pressure testing.

6.8.10 Yellow color Sticker shall be fixed after Acceptance of Pressure Testing.

6.9 JOB SAFETY ANALYSIS (JSA)

6.9.1 Job Safety Analysis as per attachment JSA No: DOD-MST-INS-004

7 DOCUMENTATION

7.1 Application for New Work Start : DOD-RGX-F350

7.2 Material Receipt Inspection Report : DOD-RGX-F051

7.3 Over - Short - Damage Report : DOD-RGX-F049

7.4 Material Approval Request : DOD-RGX-F037

7.5 Impulse line /Air tubing Installation

and Pressure testing Report : DOD-RGX-F421

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