PEARL QATAR

Sea Water Reverse Osmosis Plant

GP - 047

Method Statements for

INTALLATION OF RO SKIDS, PRESSUE VESSELS AND

CONNECTING PIPES

Method Statement No: 517008-500-104, Rev. 1

Issued by: Metito

Rev. No. Date DescriptionPrepared Checked Approved

28-April-09 Issued for Information

M.W. Y.K. M.H.
011 Mar-09 Issued for Information
M.W. M.W. M.H.

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 TABLE OF CONTENTS

1. TITLE.

2. SCOPE OF WORK

2.1. General description

2.2. Plant and equipment
2.3. Material Handling & Storage
2.4. Site planning & preparation
2.4.1. Site management plan & Access route
2.4.2. Coordination with other contractor
2.4.3. Communication

2.5. Work methodology

2.5.1. Installation of skids
2.5.2. Installation of duplex & 316 L Stainless Steel lines

2.6. Organisation, Responsibilities & Supervision

2.7. Work Force

3. HEALTH & SAFETY

3.1. General
3.2. Protective & Safety Equipment
3.3. Information to personnel
3.4. Emergency Procedures
3.5. Permit Requirements

4. ENVIRONMENTAL ISSUES

4.1. Environmental Impact assessment.

5. QUALITY ASSURANCE

5.1. Contractual Requirements

5.2. Follow up & Evaluation

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1. TITLE
Installation of RO skids, pressure vessels and connecting pipes

2. SCOPE OF WORK

2.1 General Description

This Method Statement details the procedure to be carried out during the installation
of RO Skids and the pressure vessels along with the connecting pipes (Duplex
Stainless Steel, 316 L Stainless Steel and uPVC spools) for both the first and second
pass.

Note:
Hydro testing is not applicable after completing the RO skids & pressure
vessels pipes installations as there will be no way to separate the low
pressure pipes side from the high pressure one.

2.2 Plant and Equipment

S. No. Item Description Quantity Purpose

Allocation of Materials
(Spools, Skids &
1 Mobile Crane AS Required
pressure vessels)
inside the building
Moving Materials
2 Hand Pallet Trucks As Required
inside the building
For fixing /
Hand tools, drill machine, Spirit
3 AS Required measurement and
level, measuring tape, etc.
installation purpose

2.3. Material Handling and Storage

 Skids - 5 Skids each pass

 Duplex Stainless Steel Spools - 5 Lots
 316 L Stainless Steel Spools - 5 Lots
 uPVC product line Spools - 5 Lots

All Materials shall be transported by suitable vehicles and secured properly during
transportation. Loading and unloading shall be done carefully to prevent damage
due to impact, abrasion or lack of support.

All Spools should not be dropped onto hard surfaces and should not be dragged
along the ground. Loading and unloading of Spools should be carried out by crane &
nylon slings rather than fork lift, only hand pallet trucks shall be used for moving the
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 spools inside the building. No metallic slings, hooks or chains should be used in
direct contact with the spools. Special care shall be taken for the Stainless Steel
Spools.

Spools should be stored on a flat surface free from sharp projections, stones or other
objects likely to cause damage to the spools.

Always Refer to manufacturer’s recommendations & instruction manual.

2.4. Site Planning & Preparation

2.4.1 Site Management Plan and Access route

1. The Site Engineer shall be responsible for the installation as well as for the
co-ordination and interfacing with other trade activities during the installation
works.
2. The equipment tools and consumable required shall be planned and
arranged at the Site before commencing the Erection.
3. Site Safety and personal safety equipment shall be planned and arranged in
advance.
5. Toolbox talks shall be conducted at every morning before start of any job.
6. The Site Engineer and the Supervisor shall supervise and control all the work
at the Site.

2.4.2 Co-ordination with other Contractors

The Site Engineer shall be responsible for the co-ordination and interfacing
with other contractors during the installation works. If there is any interface
with civil contractor, they shall be informed well in advance and necessary
precautions shall be taken care of.

2.4.3 Communication

1. Toolbox Talks
2. Staff Meetings
3. Supervisor Instructions
4. Communication at Site shall be by cellular phones. Supervisory personnel
shall be issued with a cellular phone.

2.5 Work Methodology

2.5.1 Installation of the Skids

1. Check & verify that the civil work is completed in compliance with all
requirements for installation as per approved drawings and handed over for
mechanical works.
2. Before starting the installation drawing shall be studied carefully to check the
requirements.
3. Skids delivered to site are prefabricated members that are dismantled only to
facilitate the shipping.
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 4. Layout the skid and mark on the concrete foundation to make sure the
erection will be adjusted in the correct location.
5. Erection starts with the base panel that shall be placed as per the
markings on foundation.
6. Vertical members and panels are then attached and the bracing
members are installed in place.
7. For point 4 & 5 a chain block hanged from the concrete beam is used to
move and lift the skid steel members.
8. Anchoring the skid to foundation using the bolts supplied with the skid.
9. Pressure vessels are then allocated in place as per the approved
drawing and design.
10. The clamps supplied with the pressure vessels are used to fix each
pressure vessel to the skid frame as shown in the approved skid
drawings.
11. Final adjustments for the clamps is done after assembling the feed
header (Duplex or SS 316)

2.5.2 Installation Duplex & 316 L Stainless Steel Piping

1. All spools shall be visually inspected for any possible damage prior to
installation.
2. Spools must be adequately supported, pipe supporting shall be as referred to
manufacturer’s recommendations & instruction should be followed.
3. Layout the locations of the pipe supports and drill the holes of the required size
of anchor bolts for fixing the pipe supports on the floor as per the requirements.
4. Install the pipe supports on the floor as & where required.
5. Start installation with the spools that is connected to the pressure vessels.
6. Continue installations succeeding spools and make any required adjustments
for the support and go on with the line.
7. Final adjustment for the HPP location and turbo charger location should be
done to match with the installed spools.
8. Fix the clamps to attach the spools to the pipe supports and secure it with
correct bolts.
9. All gasket and flange surfaces should be cleaned from any dust or dirt. Gaskets
should be placed properly in the centre to achieve a reliable joint.
10. Align the flanges. Spools not yet connected should be aligned within the
alignment tolerances with the flanges already connected before the bolts are
installed. Bringing the flanges into alignment should not leave any residual
stresses in the piping system
11. Use a cross pattern bolt-tightening sequence. This pattern helps to achieve a
uniform bolt load around the flange. Use at least three rounds of tightening
around the flange, increasing the applied load in each round. This approach
helps achieve uniform bolt load around the flange circumference.
12. All work procedure in handling, storage and installation of stainless steel spools
shall follow the manufacturer’s installation instruction.
13. The sequence shall be assembling the feed line, then the reject line then the
product line (uPVC pre-fabricated spools – please refer to uPVC method of
statement)

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 2.6 Organization, Responsibility & Supervision:

S. No. Designation Responsibility

Manage the installation works for the

Sr. Site Engineer
fabrication of Skids
Health, Safety and Environmental
HSE Engineer
issues.
QC Engineer To control the quality as required
Supervise the installation as per
Supervisor/ Foreman approved procedure and HES
requirements
Technicians, Pipe Fitters &
Conduct the installation on site.
helpers

2.7 Work Force

S. No. Description No.

Plumbers / Pipe Fitters

Mechanical Technicians
Helper / Labour

3. HEALTH & SAFETY

3.1. General

3.1.1 Barriers and warning tape will be provided as appropriate. Tape will be used
as a warning of danger.

3.1.2 Prior to commencement of work a toolbox talk will be conducted by the

Supervisor.

3.1.3 All personnel shall be equipped with PPE

3.2. Protective & Safety Equipment

All work force shall be issued with the following personal protective equipment
(PPE):

• Working Gloves
• Safety Goggles
• Safety Shoes
• High visibility vests
• Safety Harness when required

Additional protective equipment will be issued when and as required.

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 3.3. Information to Personnel
Communication to personnel shall be made through:
• Safety Induction
• Toolbox Talk Programme
• Supervisors

Daily safety toolbox meeting will be conducted by the assigned supervisors and/or
HSE Engineer prior to daily work activities. In addition to the basic HSE instructions,
the following will be discussed:
All pertinent requirements of this Method Statement will be discussed with the
concerned personnel.

3.4. Emergency Procedures

METITO shall provide first aid kits on site for light injuries. In the event of an
emergency, all workers will be asked to evacuate and assemble at the designated
assembly area and wait for further instruction from supervisors.

3.5. Permit Requirements

Gate passes for the personnel and vehicle will be issued to enter the UDC pearl
Island. Prior to commencement of the works, METITO will secure site identification
badges for the personnel.

4.0 ENVIRONMENTAL ISSUES

4.1. Environmental Impact Assessment

No environmental impact is expected from the installation of RO Skids, pressure

vessels and the connecting pipes. However, complete environmental impact
assessment shall be submitted to UDC and ministry of Environment for approval for
the whole plant along with the intake and outfall piping.

5.0 QUALITY ASSURANCE

5.1 Contractual Requirements

RO Skids and piping Spools shall be installed as per the approved design in
accordance with the relevant specification standards and approved Fabrication and
GA drawings & manufacturer’s recommendations.

5.2 Follow-up & Evaluation

Daily Reports and bi-weekly Reports as well as Monthly reports will be issued to
follow up on the progress of the work.

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