PROJECT TITLE : REFURBISHMENT & UPGRADING WORKS FOR

VARIOUS PUMPING STATIONS (PHASE – 8)

PROJECT NUMBER : CP 729/2

CLIENT : ASHGHAL

CONSULTANT : PARSONS INTERNATIONAL LIMITED

DOCUMENT NO. : 729/2-GEN-DOC-0113

PETOSERV DOC’ NO : PT/CED-5058/MS/ M /025

REVISION : 01

METHOD STATEMENT FOR

INSTALLATION OF GATE VALVES &
CHECK VALVES (PS-17,PS40 &PSW1)

PETROSERV LTD

P.O.BOX: 7098

DOHA-QATAR
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1 10-10-2012 For Approval MOHAMMAD REHAN SUNEED SUBAIRKUTTY AMR GAMAL

0 13-08-2012 For Approval MOHAMMAD REHAN SUNEED SUBAIRKUTTY AMR GAMAL
Reviewed By Project Approved By Construction
REV DATE DESCRIPTION Prepared By (PETROSERV)
Engineer(PETROSERV) Manager (PETROSERV)
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INDEX

CONTENT TITLES PAGE NO.

1.0 Purpose 4
2.0 Scope of Work 4
3.0 Reference & Attachments 4
4.0 Equipment 4
5.0 Responsibility 5-7
6.0 Safety precautions. 7-8
7.0 Preparations 9
8.0 Sequence of activity for installation. 9
09. Pre requirement and handling and storage 10-11
10. Installation of valves 11-15
11. Final Check 15
12 (A) Weight of valves. 15-16
(B) Lists of items to be installed 17
13. HSE plan 17
14. Attachments: 17-18

a) Risk Assessments (Page No.19 to 22)

c) Contract Drawings no. (17-W356, 40-W357, W1-W358) (Page No.23 to 25)
d) Installation inspection checklist valves (Page No.26)
e) Approved ITP for valves (Page No.27 to 28)
f) RFI form (Page No.29)
g) Valves schedule (Page No.30 to 38)
h) Approved shop drawings.
i) Approved P &ID.
j) Approved valve foundation (concrete base) drawings.
k) Valid calibration test certificate for the devices.
l) Operation and maintenance Manual.
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1. PURPOSE:
The Purpose of this Method Statement is to installation of valves in pumping
stations PS-17, PS40 & PSW1 and describes the sequence of activities
involved in.

2. SCOPE OF WORK

This document applies to manage efficiently and control the supply and install
of valves and accessories s in the pumping station on going to attain the zero
tolerance accident.

3. REFERENCE & ATTACHMENTS

3.1.1 Project Specification (volume 2 of 4) –Section C Part 1, Clause 3.2.2 (d
&e), Clause 3.3.2 (e &f), Clause 3.4.2 (e &f).
3.1.2 QCS 2007 Specification , Section 8 –Part 5
3.1.3 Relevant Construction Drawings (17-W356, 40-W357,W1-W358)
3.1.4 Approved Material Submittal
3.1.5 Hazard Risk assessment
3.1.6 Checklist for installation of valves
3.1.7 Approved ITP for valves
4. EQUIPMENTS:

1. Jack hammer
2. Hand tools (sprit level, torque wrench, spanner and screw driver sets).
3. Crane capacity 20-50 ton.
4. Chain Block (2 ton)
5. Grinding and drilling machine.
6. Wire rope /nylon slings.
7. Ladders.
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8. Fork lift.
5. RESPONSIBILITY

5.1 PROJECT MANAGER:

Project Manager shall be responsible for the overall project. The Project
Manager will be based on site and will be responsible for the
management of the project, both on and off site, through delegation
of duties in accordance with the organization chart and for the
effective implementation of the project management system. He shall
ensure that the proper tools and tackles are available for the timely
completion of this job in a quality manner.

5.2 CONSTRUCTION MANAGER:

Construction Manager shall be responsible for overall project .the
construction manager shall be planned as well as handle any issues
which arise during the site work.
The construction manager shall be obtained all necessary permits and
licences and ensure that proper work procedures are being carried out
at site.

5.3 PROJECT ENGINEER:

Project Engineer is responsible for the overall site operation and works.
He shall ensure that the appropriate procedure is followed by all the
involved personnel taking into consideration all relevant shop drawings,
Reference drawings, statutory bench marks and reference points and
methodologies are correctly utilized. Responsible for the overall
fabrication installation, testing and commissioning activities. Responsible
for planning of site organization, resource mobilization, subcontracting,
site operation, construction methods and scheduling etc. ensure that
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proper approved documents are in place prior to start of production

activities.
5.4 SITE ENGINEER:-

5.4.1 Co-ordination with all site personnel & control of Labour.

5.4.2 Direct monitoring and supervision of work.

5.4.3 Tool Box talk to Labour.

5.4.4 Confirming Health Safety Environment.

5.5 SAFETY OFFICER: -(these responsibilities are included but not limited
to):

5.5.1 Assists the Project Manager for implementation and monitoring of

the HSE system.

5.5.2 Carries out Hazard Risk Assessment for the site.

5.5.3 Ensures work site is in safe conditions.

5.5.4 Ensures calibration & approval of all lifting equipments and

machineries.

5.5.5 Ensures first aid and emergency procedures for the site are
established and maintained.

5.5.6 Coordinates with the client for any safety related requirements at site.

5.5.7 Arranges safety induction program for the site personnel as required.
He ensures that daily toolbox meetings are conducted by Site
foremen/Supervisor.

(Refer H.S.E plan clause 8.6 Page no. 12 & 13 of 43)

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5.6 QUALITY CONTROL:

Quality is a throughout process of installation, testing & commissioning

of the system. However following steps shall be followed.

1. QA/QC Engineer along with project engineer will monitor that all
components are installed as per contract specifications and
approved submittals.

2. Works inspection shall be submitted to Main contractor/consultant

for the following stages of work as per ITP: a) material
receiving/inspection. b) Installation of valves. C) Testing and
commissioning of valves.

6.0 SAFETY PRECAUTIONS:

All work shall be carried out in accordance with approved PETROSERV’s

project safety plan. All personnel shall be provided with necessary
personnel protection equipment (PPE) and given required training to
ensure that all personnel involved in the work are aware of importance
of safety precautions, equipments and consequences of abusing them.
Excavation permits will be prepared to ensure that all necessary
precautionary measures have been taken and other requirements are
fulfilled.

a) In deciding manning levels account must be taken of the

location of manholes and sewerage facilities in relation to
availability of means of summoning assistance in emergencies.
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b) Unattended open manholes must be safely protected by suitable

barriers. Remember that some people are visually handicapped.

c) Whenever possible covers shall be lifted using lifting keys and

proper lifting and handling techniques or by the use of hydraulic
or other approved manhole lifting device.

d) Before entering the manhole ensure that the cover has been
removed to give natural ventilation for minimum of 5 minutes.

e) Before enter the drywell and wet well proper ventilation will be
used.

f) Test for toxic and flammable gases, and oxygen deficiency, using
approved detector. If toxic and flammable gases or oxygen
deficiency is detected do not enter the manhole.

g) Before the any lifting activity the area is cordon off with safety
ribbons/tape.

h) All machine, vehicles & equipments operator shall have valid

licences or certificate or approval.

i) Proper and safe support temporary supports, scaffolding,

platform and access ladders will be provided. Erect and inspect
the temporary works by authorized specialist.

j) The approved electrical lockout/tag out safety procedure (doc

no. 729/2-gen-doc-0055) will be fallowed strictly followed & also
approved HSE PLAN.

k) Refer H.S.E plan clause and there sub classes 16, 17, 18, 19, 20, 21,
22, 23, 25, 26, 27, 33, 34, 36, 39, 40. Document No.729/2- GEN-
DOC-0019)
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7. PREPARATIONS:

A. DOCUMENTS
a. Entry permits from Ashghal to enter pumping station.
B. Confined space permit.
C. Lock out/tag out (LOTO).
D. Permit of work.

8. SEQUENCE OF ACTIVITY FOR INSTALLATION:

1. Mechanical Screen.
2. Penstock.
3. EOT Cranes.
4. Ductile Iron Pipes & Fitting.
5. Valves and actuators
6. Dry Submersible Main Pumps.
7. Sump and Transfer Pump
8. Odour Control Unit.
9. High Pressure and Potable Pump
10. Air conditioning & Ventilation.
11. Instrumentation & control system.
12. Electrical items.
13. Civil work.

NOTE: 1) item no.1 to 10 will be covered under mechanical installation

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9. (A) PRE-REQUIRMENTS:

1. Ensure that approved materials are available to carry out the work.
2. Valves are transported from stores according to good engineering
practice and physical verification.
3. Prior to commencement of work, areas and access will be inspected to
Confirm that safety precautions ensured.
4. All relative documents (approved shop drawing and approved method
statement) will be checked by site engineer prior to commencement of
work.
5. Arrangements of suitable access / scaffolding for erection.
6. Tool box talk will be conducted with all the people involved in the
operation and discuss about the past lifts observations, assign individual
responsibilities before starting the job.

(B) HANDLING AND STORAGE:

1. Manufacturer storage instructions will be strictly followed as applicable.

2. Valves to be transported/unload as per manufacturer recommendation

and by the recommended equipment.

3. Storage area for valves has to be arranged with leveled wooden

platform, the area should be barricaded with tape.

4. Valves are to be unloaded from the vehicle by crane only.

Ensure that the vehicle parked in a safe area and parking brake is

applied.

5. The valves should be kept on the wooden platform only.

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6. The valves should not come into contact with any contaminative

substances prior to installation.

7. Always use fork lift to transport the valves.

8. The valves should be protected from direct sun light or moisture.

9. Hand wheels, actuators and gearboxes should not be used as lifting or

rigging points for valves.

10. ITP will be checked for storage and handling, refer the attached ITP

10 INSTALLATIONS OF VALVES:
We have different models of gate valves and non return valves (check
valves).
1. Series 54 Gate Valves (size 700 mm to 450 mm)
2. Series 37 Gate Valves (Size 300 mm to 100 mm)
3. Check valves 41/36 (Size 600 mm to 500 mm)
4. Check valves V2-08 (size less than 300 mm)

1) INSTALLATION DESCRIPTION OF SERIES 54 GATE VALVES:

A) BEFORE INSTALLATION OF THE GATE VALVES:

1. Take the picture to the area of valves erections.

2. Area of installation will be in the clean condition.
3. Installation will be carried according to manufacturer installation.
4. Check the weight of the valves to be handled safely.
5. All special packing material will be removed.
6. Ensure that the pipeline is completely free of debris or foreign matter.
7. Check the direction of operation/orientation of gearbox spindle.
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8. Check the valve, by operating it two or three times to ensure

freedom of spindle rotation and movement of wedge (gate).
9. Check the EPDM gasket (4mm thick).
10. Check the gasket for freedom from injurious defects or damage.
11. Check the flow direction arrows particular on parallel faced valves
or valves having bearing plates on the wedge.

B) INSTALLATION OF THE GATE VALVES (ACTUATED & NON ACTUATED):

1. Use the correct bolts (diameter, length and material).

2. Prepare the concrete base for valve support

3. Ensure that the seats and flange faces are clean.

4. The valves inside the chamber a crane is used for lowering the valve to

position.

4.1 Inside the pump station fork lift will be used for transportation and

chain block will be used for positioning.

5. Place the valve between pipe flanges, and insert the bolts.

6. Wooden blocks will be used as temporary supports below the flanges.

7. Gasket will be inserted between the flanges and hold in position.

8. Bolts and nuts will be inserted on all holes of the flanges.

9. Tighten the bolts in a diagonal sequence to ensure flanges are pulled

parallel.

10. Adjust the jack screw if required.

11. Finally tighten bolts to correct torque levels.

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12. Remove the temporary supports.

13. Once the valves will be installed, check that the valve still functions

correctly by operating it for a minimum of five turns.

14. Inside the chamber extension spindle and stem cap will be installed

as per approved drawing.

15. Extension spindle support will be provided.

16. Proper Hand wheel will be installed for hand wheel operated gate

valves.

17. For actuators valves connection will be provided as per electrical

method statement.

18. All the external debris will be cleaned off from the external surfaces of

the valve.

Same procedure will be followed in the installation of series 37 gate valves.

2. INSTALLATION DESCRIPTION OF SERIES 41/36 CHECK VALVES:

A) BEFORE INSTALLATION OF SWING CHECK VALVES:

1. All the packing will be removed.

2. Valve direction will be corresponded with the direction of the flow.

3. Ensure that the pipeline is completely free of debris or foreign matter.

4. Check the foundation of the valve.

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5. Check the EPDM gasket (4mm thick).

B) INSTALLATION OF SWING CHECK VALVES:

1) Prepare the concrete base for valve supports.

2) Use the correct bolts (diameter, length and material).

3. Ensure the valve interior through the end ports to determine whether it is

reasonably clean and free from debris.

4. Ensure the mating flanges facings for correct gasket contact face, surface

finish and condition.

5. For external chamber the crane is used for lowering the valves to position.

5.1 For inside the pump station use fork lift to transport the valve and chain block

to position the valve.

6. Wooden block will be provided below the flanges for temporary support.

7. Care will be taken that the lever and weight will be free of obstruction in its

path of movement.

8. The weight will be installed at the end of lever and the bolts of weight will be

tightened.

9. Place the valve between pipe flanges.

10. Insert the gasket between flanges and insert the bolts in the all holes of

flange.

11. Bolts will be tightened in a systematic manner to avoid undue stress in the

body valve.

Same procedure will be followed in the installation of check valve V2-08.

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12. Valve manufacturer representative will supervise the installation.

11. FINAL CHECK:

After completing all trims and accessories, a final inspection to be done:
1. Check that the valves still functions correctly by operating it for a
minimum of five turns.
2. Ensure that the gasket or washers are correctly seated.
3. All bolts in place and high strength bolts tightened to correct tension.
4. All the external debris and foreign matter should be cleaned off from the
external surfaces of the valves.
5. Touch up any damaged point.
6. Clean up the site.
Once the installation is completed the entire assembly is to be tested with trail runs.
Testing and commissioning will be done by in co-ordination with consultant & client.
During the installation of valves the safety procedure will be involved to do works in
safe manner like safety barricades confined space entry procedure, identifying and
controlling the safety hazards and monitoring the works.

This time our well trained working team will be involved with the proper safety
equipments (PPE).

12(A). WEIGHT OF THE VALVES:

S.NO LOCATION DESCRIPTION DIA (mm) Weight (kg)
1 Gate valve Rising stem, with 700 1700
Gearbox/Actuators
2 Gate valves non rising stem with 700 1650
PS-17 ,PS-40 spur gear box
3 and PS-W1 Gate valve Rising stem, with 600 850
Actuators
4 Gate valve Rising stem, with Spur 500 640
gear box
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S.NO DESCRIPTION DIA (mm) Weight (kg)

5 Gate valve Rising stem, with 500 670
Actuators
6 Gate Valves Rising stem, with Spur 450 520
gear box
7 Gate valves Rising stem, with 450 540
Actuators
8 Gate Valves Rising stem, Hand wheel 300 270
9 Gate Valves Rising stem ,with Spur 200 150
gearbox
10 Gate valves Rising stem ,Hand wheel 150 80
11 Gate valves Rising stem ,with spur 150 100
gear box
12 Gate valves Rising stem ,with Bevel 150 100
gear box
13 Gate valves Rising stem ,with 150 100
PS-17 ,PS-40 Actuators
14 and PS-W1 Gate valves Rising stem ,Hand wheel 100 60
15 Swing Check valve with lever, 600 1070
weight, guard and proximity switch
16 Swing Check valve with lever, 500 880
weight, guard and proximity switch
17 Swing Check valve with lever, 300 260
weight, guard and proximity switch
18 Swing Check valve with lever, 100 70
weight, guard and proximity switch
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12 (B) LISTS OF VALVES TO BE INSTALLAED:

Detail of valve for each pumping station please refers the Page No.30 to

38.

13. HSE PLAN:

Emergency plan (Section 40) covers all the potential emergencies as per Do.
No. : 729/2- GEN-DOC-0019

(1) .Emergency Evacuation Procedure:

Emergency evacuation procedure will be followed.
1) In case of any human injury.
2) In case of fire.
3) Project emergency contact telephone numbers and Petroserv personnel
telephone numbers will be displayed at all project location.

(2).EMERGENCY TELEPHONE NUMBER:

Police Civil Defense and Emergency -999
Water and Electricity Emergency - 991
Accident and Emergency – Hamad Hospital - 44392111
Telephone Directory - 180
Construction manager: Mr. Amr Gamal - 66237128
Project Engineer- Mr.Suneed SubairKutty - 66834721
Safety Officer – Mr. Jithin S. - 55363249

14. ATTACHMENTS:

a) Risk Assessments (Page No.19 to 22)

c) Contract Drawings no. (17-W356, 40-W357, W1-W358) (Page No.23 to 25)

d) Installation inspection checklist valves (Page No.26)

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e) Approved ITP for valves (Page No.27 to 28)

f) RFI Form (Page No.29)

g) Valves schedule ((Page No.30 to 38)

h) Approved shop drawings (to be attached once getting approved).
i) Approved P &ID (to be attached once getting approved).
j) Approved valve foundation (concrete base) drawings (to be attached once
getting approved)
k) Valid calibration test certificate for the devices (to be provided prior the start
of installation)
l) Operation and maintenance Manual.