CONTRACTOR LOGO

Project No. REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

METHOD STATEMENT

REPLACEMENT OF ORBIT VALVES WITH ACTUATOR FOR U-1300 DRIERS TRAIN 2

OMAN LNG

Project No. XXXXX

Sur-Oman

0 29 May 2017 Issued for Review SDL

Rev. Date Description of Revision Prepared Reviewed Approved

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CONTRACTOR LOGO

Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

TABLE OF CONTENTS

1 PROJECT DESCRIPTION ................................................................................. 4

1.1 Project Objective...................................................................................... 4
1.2 Scope ...................................................................................................... 4
1.3 Purpose ................................................................................................... 4

2 DEFINITIONS AND ABBREVIATIONS ............................................................. 4

2.1 Definitions ................................................................................................ 4
2.2 Abbreviations ........................................................................................... 4

3 CODE STANDARDS AND REFERENCE DOCUMENTS .................................. 5

3.1 International Codes.................................................................................. 5

4 SITE VISIT DETAILS ......................................................................................... 5

4.1 Purpose of the Site Visit .......................................................................... 5
4.2 Site Visit Findings .................................................................................... 5

5 DETAILED SCOPE OF WORK FOR CONTRACTOR ....................................... 6

6 EXECUTION METHODOLOGY FOR VALVES ................................................. 7

6.1 Shutdown, Degassing, Purging ............................................................... 7
6.2 Removal of Valves ................................................................................... 7
6.3 Installation of Valves ................................................................................ 7
6.4 Testing/Pre-commissioning ..................................................................... 8
6.5 Startup/Commissioning ............................................................................ 8
6.6 Risk Assessment ...................................... Error! Bookmark not defined.

7 QA/QC................................................................................................................ 8
7.1 Inspection and Test Plan (ITP) ................................................................ 8
CONTRACTOR to follow the following Inspection and Test Plan for the Orbit
valve. ....................................................................................................... 8
Inspection Code: ................................................................................................ 8
7.2 Lifting Plan ............................................................................................... 9
7.3 Flange Management ................................................................................ 9
7.4 Scaffolding ................................................ Error! Bookmark not defined.

8 MATERIAL REQUIREMENT ........................................................................... 10

9 SPARES AND GENERAL CONSUMABLES .................................................. 10

10 SPECIAL TOOLS ............................................................................................ 10

WALKIE-TALKIE .......................................................................................................... 11

11 SAFETY ........................................................................................................... 11

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CONTRACTOR LOGO

Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

12 CONSTRUCTIBILITY....................................................................................... 11

13 ATTACHMENTS .............................................................................................. 11

ATTACHMENT1 ......................................................................................................... 12

ANNEXURE -1 .............................................................................................................. 12

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CONTRACTOR LOGO

Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

1 PROJECT DESCRIPTION

1.1 Project Objective

The objective of this work pack is to replace the orbit valve with actuators for U-1300 driers in
Train-2.

1.2 Scope

Contractor shall replace the Orbit valves with actuator for U-1300 in train-2. The purpose of this
work pack is to compile the information/ work requirement, plan and execution work for the valves
pertaining to U1300 driers in Train-2.

This document is the detailed engineering Work Pack for the replacement of existing valves with
new orbit valve with actuators. It lists the applicable design document and engineering drawings/
deliverables that are required by the Construction Contractor to perform the required scope of
work.

1.3 Purpose

The purpose of this procedure is to provide a common structure to the method of passing
information to other groups for their use, Primarily the Projects and its Contractors.

This procedure describes the format, preparation and control of Construction Work Packs and
defines the objectives, contents, responsibilities and approvals required. Construction Work packs
for projects, which include construction activities. These are used to transmit the information,
including Job Cards and Inspection Test requirements to construction.

2 DEFINITIONS AND ABBREVIATIONS

2.1 Definitions

COMPANY OMAN LNG LLC

CONTRACTOR Construction CONTRACTOR

PROJECT Replacement of Orbit valve with actuator for U1300 driers Train-2.

SHALL The use of the word shall means mandatory requirement

SHOULD The use of the word should means strong recommendation

2.2 Abbreviations

FAT : Factory Acceptance Test

GA : General Arrangements

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CONTRACTOR LOGO

Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

HAC : Hazardous Area Classification

HSE : Health, Safety and Environment

LNG : Liquefied Natural Gas

P&ID : Piping and Instrumentation Diagram

PEFS : Process Engineering Flow Scheme

PTW : Permit to Work

QA/ QC : Quality Assurance/ Quality Control

3 CODE STANDARDS AND REFERENCE DOCUMENTS

3.1 International Codes

4 SITE VISIT DETAILS

4.1 Purpose of the Site Visit

To familiarize and identify the locations of existing valves proposed to replace with new
valves and actuator.

To identify the laydown area, constructability and material handling requirements for the
replacement of valves.

4.2 Site Visit Findings

Site visit was conducted and existing valve no.113-KBS-301 and its accessories in the area U-
1300 Train-2 were inspected.

Following orbit valve accessories are mounted on the plate, and plate is directly
connected/mounted on the actuator with nut and bolt.

1. 4-way, 2-position, Pilot operated Valve (1 No.)

2. Adjustable Bleed Control (2 Nos.)

3. Filter Regulator with Pressure Gauge (1 No.)

4. 3-way Switching Valve (1 No.)

5. 3-way, Normally Closed Direct Acting Solenoid Valve (2 Nos.)

6. Exhaust Port Filter Silencer (2 Nos.)

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CONTRACTOR LOGO

Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

7. Check Valve (1 No.)

Refer Marked up copies provided in the attachment to understand more about scope of work.

5 DETAILED SCOPE OF WORK FOR CONTRACTOR

The CONTRACTOR shall responsible for planning, organizing and co-ordinating for replacement,
pre-fabrication, fabrication, installation, connection, cleaning, testing and pre-commissioning of the
valves.

CONTRACTOR shall perform replacement of existing valves and shall install new orbit valve
along with its actuators and accessories for the valves mentioned in Section 4 of this
document.

All new Valves, Actuators, cabling and wiring terminations shall be labelled/tagged/ferruled
as per standard installation practices of COMPANY.

Providing and fixing numbering and identification plates for valves and actuators as per
COMPANY approved policy.

Procured valve details/drawings shall be verified with site conditions.

Mobilize the construction team required for executing valve replacement and seek approval
from COMPANY HSE division and Site Operation for the proposed execution methodology.

Perform necessary construction safety sessions based on proposed method statement prior
to start of construction activities like risk assessment/job risk analysis for each individual
valve involving HSE team.

Prepare construction/installation, Pipe/valve support drawings if required to modify the

existing valve support or pipe supports based on new valve.

CONTRACTOR shall ensure preventive/corrective measures are in place to take care of

leakage or any other issues with new installed valves.

All installation activities shall be supervised by Competent Safety Officer/Fire Watchers.

Any dispensation w.r.t the safety will be duly approved by site HSE & HSE division

CONTRACTOR Scope includes identifying the existing facility structures, piping, equipment,
insulation, fire protection etc., that need to be dismantled and reinstated back as same before
dismantling.

CONTRACTOR and VENDOR Scope includes FAT/SAT, Third Party Inspection and testing
of new orbit valves as per COMPANY/ project documents and specification.

CONTRACTOR shall take prior approval from COMPANY before finalizing the tools to be
used as part of this project.

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Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

Specialized sub-CONTRACTOR and VENDOR required for testing and commissioning shall
be well organized/aligned and made available when required during execution.

Adhering to the COMPANYs HSE regulations and rules.

Submission of all test reports to COMPANY for approval, prior to installation.

6 EXECUTION METHODOLOGY FOR VALVES

Existing valves shall be removed and new valves to be installed as per the execution methodology
mentioned below.

The following proposed sequence shall be considered and planned to remove and installation of
valves as per project requirements.

Refer below Table-1 for list of valves in U-1300 Train-2 area.

Sr. Size& Attachment

Valve No. PEFS No. Line No.
No. Description No.

24 x 20,
1 113-KBS-301 T-2.912.114 24-P13002-61172Y
2433 H8L RF

Table - 1

6.1 Shutdown, Degassing, Purging

To perform replacement of valve 113-KBS-301 the shutdown of U-1300 Train-2 shall be planned.

Train-2 lines shall also be purged with N2 (3-5 times) to make line hydrocarbon free. The purging
nitrogen shall be vented. Line shall be handed over to the CONTRACTOR to initiate the valve
removal activities.

6.2 Removal of Valves

Refer Method Statement for Orbit valve : 213-KBS-301 provided in Attachment-1 for valve
removal procedure.

6.3 Installation of Valves

Refer Method Statement for Orbit valve : 213-KBS-301 provided in Attachment-1 for valve
installation procedure.

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CONTRACTOR LOGO

Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

6.4 Testing (In-House)

For In-house testing activity, follow the procedures/methods given in the Method Statement for
Orbit valve : 213-KBS-301(Attachment-1)

6.5 Pre-commissioning

For Pre-Commissioning activity, follow the procedures/methods given in the Method Statement for
Orbit valve : 213-KBS-301(Attachment-1)

6.6 Startup/Commissioning

For Start-up/Commissioning activity, follow the procedures/methods given in the Method

Statement for Orbit valve : 213-KBS-301(Attachment-1)

7 QA/QC

7.1 Inspection and Test Plan (ITP)

CONTRACTOR to follow the following Inspection and Test Plan for the Orbit valve.

Inspection Code:

W Witness Verification of Compliance with the Procedure/Specification is required in

the form of document record

R Review Review of Documents to ensure Compliance with Project requirements

M Monitor Monitor the activity on a random basis to ensure acceptable procedure

are being followed

H Hold The verification of compliance with the specification is required prior to

further activities

P Process Specific Steps / Actions Performed in accordance with known standards /

Specified Requirements / Work Instructions resulting in successful
completion of the noted activity.

AP Approve Submit the document for approval

Operations Inspection / Control CONTR CLIENT CLIENT VENDOR Remarks

ACTOR OPR. INSP.
Acceptance Document
Criteria

Removal of As per
Existing Orbit Schedule P R W
Valve

Material As given in R M M H Material

Datasheet/G Identificat
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Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

Identification eneral ion

Arrangement
Drawing

Drawings Issue R R W & AP -

Examination As per
P R W
and certification Drawing

Dimensional As per
P M H
Inspection Schedule

Check of Name
Plate

Check of Final
Book

Marking

Hydrostatic test

Functional Test

Seat Leakage
Test

7.2 Lifting Plan

Lift Plan shall be in place, when there is need for any Lifting activity envisaged in the project.

Lift Plan shall be prepared for object which weighs more than 5 ton or if the lifting height is more
than 30 meters.

Lifting Weight is the sum of the weights of the load, spreader bars, chain blocks, slings, shackles
and any other attachment to the load.

Lifting plan procedure shall be followed as given in the COMPANY document attached in
Attachment-9, Heavy Lifting Procedure for Heavy Lifting.

7.3 Flange Management

The procedure defines the method/requirement for bolt tightening for piping system using
manual/hand torque wrench, hydraulic torque wrench and hydraulic stud bolt tensioner.

Bolt Diameter < 2 : General torque wrench (Manual/hand Torque Wrench or Hydraulic torque
wrench if applicable).

CONTRACTOR shall refer Flange Management procedure provided in the Attachment-8.

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CONTRACTOR LOGO

Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

8 MATERIAL REQUIREMENT

All material supplied by the VENDOR shall be in accordance with the COMPANY standards and
specifications. Where material in accordance with COMPANY Standards and specifications is not
available, the CONTRACTOR construction team shall propose equivalent alternatives for
COMPANY approval prior to commencement of work.

CONTRACTOR shall check the procured material from VENDOR available in Warehouse with the
drawings.

Refer to the following table, which identifies the brief scope of supply of materials.

BILL OF VENDOR WAREHOUSE CONTRACTOR P.O. No. REMARKS

QUANTITY

Orbit Valve X

4 Way, 2 X
Position, Pilot
Operated Valve
With Adjustable
Bleed Control

3-Way X
Switching Valve

Air Filter X
Regulator (0-
10 Bar
Adjustable)

Check Valve X

Solenoid Valve X Existing Solenoid

- 24vdc, 3 Way Valve shall be re-
Solenoid used.

Proximity Type X
- Valve Status
Existing Proximity
Indication With
Switches shall be
Required
re-used.
Installation
Accessories

9 SPARES AND GENERAL CONSUMABLES

10 SPECIAL TOOLS

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CONTRACTOR LOGO

Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

Walkie-Talkie

11 SAFETY

CONTRACTOR must provide a full-time trained and dedicated team for safety and
housekeeping.

Engineering should incorporate Safety-in-design requirements which support

construction, operations and maintenance operations.

Development and implementation of the CONTRACTORS safety program must take into
account a labour force consisting of different nationalities. Provisions must be made to
arrange for the necessary safety lessons and meetings to ensure that all workers fully
understand project safety requirements.

12 CONSTRUCTIBILITY

The CONTRACTOR shall ensure that space provided for lifting device/crane location and access
road is adequate and shall check the nature of the surface. CONTRACTOR shall ensure that the
surface condition is suitable for total lifting load. CONTRACTOR shall re-check if the crane
location and nearby area is free from excavations at the time of replacement. The load bearing
capacity of all the crane locations shall be assessed by a competent authority/CLIENT personal.

CONTRACTOR shall check if there is sufficient boom clearance during any lifting operation.

13 ATTACHMENTS

1. Method Statement

2. Marked up PEFS

3. Valve and Actuator Control System

4. Flange Management

5. Inspection and Test Plan

6. Lifting Plan

7. Flange Management

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CONTRACTOR LOGO

Project No. QEN-3-464 REPLACEMENT OF ORBIT VALVES WITH Doc. No.

ACTUATOR FOR U-1300 DRIERS TRAIN 2

ATTACHMENT1
A. System Schematic diagram

B. P&ID& Tie-in Philosophy

C. Demolition Piping Isometrics

D. Demolition Piping General Arrangement

E. Construction Piping Isometrics

F. Construction Piping General Arrangement

G. Material Handling Report (Relevant Pages)

H. Marked-up JB Interconnection/Loop Diagram

I. Tie-in Schedule

J. Cost Summary

ANNEXURE -1
Risk Assessment

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