ZULUF PROJECT (0-8887) : 10-08643-0005 Saudi Aramco 0-8887-2-P-3130-MC2-A GAS-JGC-MOS-MECH-006 FA NMR Ref NO

ZULUF PROJECT (0-8887)
SA JOB ORDER NO. 10-08643-0005 OWNER SAUDI ARAMCO
PO NO. 0-8887-2-P-3130-MC2-A PURCHACER JGC
ISSUE PURPOSE
VENDOR DOC NO. GAS-JGC-MOS-MECH-006 FA
(FA, FI, FC, AB, CAN)
NMR REF
JGC DOC NO. V-3130-MC2-A -
NO.
1006
- - 0055 - 000
SA DOC NO.
DUMMY PO NO. SERIAL SHEET REV.
VENDOR NAME GAS ARABIAN SERVICES COMPANY

EQUIPMENT/
—
MATERIAL NAME
ITEM/TAG NO. —
METHOD STATEMENT & JSA FOR ABOVE GROUND PIPING

DOC TITLE
FABRICATION AND INSTALLATION WORKS
Method Statement and JSA
Subcontractor Name GAS Arabian Services
Contractor Name JGC Corporation
Company Name Saudi Aramco
Contractor Doc. No. V-3130-MC2-A-1006
Subcontractor Doc. No. GAS-JGC-MOS-MECH-006
METHOD STATEMENT & JSA FOR ABOVE GROUND PIPING

FABRICATION AND INSTALLATION WORKS
GAS-JGC-MOS-MECH-006
FOR APPROVAL
Zuluf Onshore Oil Facilities Project
SUBCONTRACTOR CONTRACTOR
REV DATE PAGE DESCRIPTION
PREP'D CHK'D APP'D SEC. HSE QC MGR. SM/CM
MGR. MGR.
00 25-Nov-2023 All Issue for approval Riyaz Relish Munawar

METHOD STATEMENT & JSA FOR
ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
TABLE OF CONTENTS
Page
Issue / Revision Record
1.0 Scope 3
2.0 Purpose 3
3.0 References 3
4.0 Definitions 4
5.0 Responsibilities 5
6.0 Resources 7
7.0 Material Receiving, Handling and Storage 8
8.0 Erection and Installation 16
9.0 Inspection 28
10 Safety Plan 30
11 Attachments 31
ISSUE / REVISION RECORD

Document No Issue Revision Page No
GAS-JGC-MOS-MECH-006 1 0 Page 2 of 31
ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
Issue Revision Paragraph Description Date

2 0 All Issued for Approval 25-Nov-2023
NOTE: Where revisions affect the whole document, NO identification will be placed adjacent to the revised
paragraph.
1.0 SCOPE
This method statement is made to enumerate the procedure in the A/G Piping Fabrication and Installation Works and
inspection of pipe spools including welding of pipes & fittings for Zuluf Onshore Oil Facilities Project Safaniya, KSA
2.0 Purpose
The scope of this procedure will provide all details involved in the A/G Piping Fabrication and Installation Works and
inspection of pipe spools including welding of pipes & fittings for Zuluf Onshore Oil Facilities Project Safaniya, KSA
3.0 REFERENCES
The latest revision of the isometric’s drawings following shall be used as reference with this method statement for
Erection/Installation of Metallic AG/UG piping.
ANSI / ASME B31.3 - Process Piping

ASTM-B16.9 - Factory made wrought Butt Weld Fittings
ASTM-B16.5 - Pipe Flange and Flanged Fittings (NPS 1/2 through NPS 24 Metric/Inch
Standard)
ASTM-B16.47 - Large Diameter Steel Flanges (NPS 26 through NPS 60 Metric/Inch Standard) SAES-
L-100 - Applicable Codes & Standards for Pressure Piping Systems
SAES-L-105 - Piping Material Specification
SAES-H-200 - Storage, Handling & Installation of externally coated pipe
SAES-L-150 - Pressure testing of Plant Piping & Pipelines

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FABRICATION AND
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SAES-L-310 - Design of Plant Piping
SAES-L-350 - Construction of Plant Piping
SAES-W-012 - Welding Requirements for Pipelines
SAES-L-108 - Selection of valves
SAES-L-109 - Selection of Flanges, Stud bolts & Gaskets
SAES-A-004 - General Requirements for Pressure testing
SAES-L-125 – Safety Instruction Sheet for piping & pipelines
SAES-J-100 - Process Flow Metering
SAES-J-600 - Pressure Relief Devices
SAES-J-700 - Control Valves
SAEP-351 - Bolted Flange Joints Assembly
SAEP-35 - Valve Handling, Hauling, Receipt Tests and Storage.
SAEP-385 - Preservation of Project Materials and Equipment.
SAES-H-201 – General specifications for over-the-ditch external and internal FBE coating of field girth welds.
SAES-H-002 – Internal & external coatings for steel pipelines & piping
SAES-A-206 – Positive material identification
SAES-A-007 – Hydrostatic testing fluids and lay-up procedures
SAES-W-011 – Welding requirements for on-plot piping
SAES-W-016 – Welding of special corrosion resistant materials 02-
SMSS-005 – Butt welding pipe fittings
4.0 DEFINITIONS
3.1 SATIP - Saudi Aramco Typical Inspection Plan
3.2 SAIC - Saudi Aramco Inspection Checklist
3.3 SATR - Saudi Aramco Test Report SAES
3.4 SAEP - Saudi Aramco Engineering Procedure
3.5 G.I. - General Instruction
3.6 ITP - Inspection & Test Plan
3.7 RFI - Request for Inspection
3.8 COMPANY - Saudi Aramco
3.9 JGC - Japan Gas Company


ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
3.10 GAS - GAS Arabian Services

3.11 SAPMT - Saudi Aramco Project Management Team
3.12 SAPID - Saudi Aramco Project Inspection Dept
3.13 SAES - Saudi Aramco Engineering Standard
5.0 RESPONSIBILITY
A. The Project Manager is responsible for appointing site supervisory personnel to organize, coordinate, and
oversee the execution of the work detailed in this method statement. Ensure that this plan is implemented and followed
in a timely manner and according to the project schedule. Provide adequate resources and top management
support to implement this Plan. This includes proper staffing, financial support, and management support for
necessary actions taken.
B. SITE Manager is responsible for all overall site management to plan, organize, initiate according to the
requirement of the work detailed in the method statement and to manage the project progress and in compliance
with regulations and oversees the direction of an entire project or a specific stage within it to ensure it meets expectations
and deadlines. strategies to hasten work and simplify approaches or adjust deadlines without compromising on quality
or safety.
C. The Construction Manager shall be responsible for the overall direction, coordination, monitoring, and control of all
the activities detailed in this method statement. He shall be responsible for encouraging all workforce for safe and productive
working culture and deal with site supervisors for implementing work in proper procedure at site. Ensure that Contractor
Personnel, Drivers, Subcontractor, and supplier/s’ personnel subcontractor are trained and informedof this method of
statement document, JSA and other requirements. Verify and ensure that the work is proceeding in accordance with the
approved procedure, method of statement, JSA and other requirements.
D. QA/QC Manager- QA/QC Manager is the Management representative for the quality of this Project. He shall
ensure the Quality System is established, maintained and implemented and shall report to Top management
on specific intervals as per Project Quality Plan and make recommendations for Quality System improvements.
QA/QC Manager is responsible for the implementation of this procedure is being followed by the Execution
andshall verify all the required quality control activities such as tests and inspections for the Above Ground Piping Pre-
fabrication and erection activities. He shall assure the overall Project team is aware of Project Requirements for this
Project. He is also responsible for the overall distribution and implementation of this procedure.QA/QC Manager is
the prime responsible personnel for the overall activities of QA/QC Department. He is assisted by QA/QC Supervisors,
who reports all daily QC activities, deficiencies, drawbacks etc. at site.


ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
E. QA/QC SUPERVISOR- the QA/QC Supervisor will be responsible for the necessary inspections and tests to be carried out
for all the activities involved in the above ground piping fabrication and erection works as per the Saudi Aramco Test
Inspection Plan (SATIP) and Project Specification. QA/QC Supervisor reports to QA/QC Manager. All QC Engineers and
Inspectors are directly under him, who in turn divide works and oversee each person activities. He shall Supervises
and coordinates all activities related to Quality Control and Quality Assurance of inspection to be completed and to be
signed off by the client. Works with all supervisors engaged in construction, installation to ensure the Quality Control
System is executed and client quality requirements are achieved. Examines blueprints and inspection data shall ensure
uniformed Project compliance. Inspects work shall ensure conformance with specifications defined in the Project
Specifications. Witnessing test packages and coordinates with production for initial testing and 3rd party inspection (i.e. NDE)
of the completed work. The QA/QC supervisor shall acts as a liaison between field supervision, and client
representative(s) to ensure that quality issues are identified and corrected through the construction that repair process.
F. PIPING INSPECTOR- Piping QC Inspector is responsible for controlling and reporting of all the piping quality control
activities including receiving and handling of piping materials, pressure testing and fit-up inspection etc., reports directly to
QA/QC Supervisor or QA/QC Manager. Piping Inspector is responsible to inspect all the piping materials and dimension
check prior to fabrication. Piping QC Inspector inspects fit-up of joints to define the welding clearance. He is also
responsible of all Calibration Certificates that determine of instruments/machines using for piping works. Piping inspector will
ensure internal spool cleaning prior to installation / erection of piping spools and latest revision of drawings to be followed
at site.
G. WELDING INSPECTOR- Welding QC Inspector is responsible for controlling and reporting of all the welding
activities including receiving and handling of welding consumables as per respective QCP and SATIP. The Welding Inspector inspects the
joint before, during and after welding activity that gives clearance for NDT requirements. Once welding is completed, visual
inspection will be done and non-destructive inspection shall be carried out as required by the specification. The welding
report shall be prepared by QC Inspector and submitted to JGC / Client. Welding Inspector will verify the calibration of all
welding equipment, ensure calibration stickers pasted on, keep update the calibration record upon each calibration activity
and implementation of correct/compatible WPS for welding of different materials. Welding Inspector is also responsible
for conforming the weld repair location before excavation of weld.
H. NDE COORDINATOR- NDE Coordinator is responsible to co-ordinate, monitor and controlling of all NDT activities that
shall reports directly to QA/QC Supervisor as well as QA/QC Manager. NDE Coordinator is responsible for maintaining
and handling all NDE records. Evaluate the performance of third-party service provider in the event of increasing backlog,
increasing percentage of re-shoot or any other identified quality issues. NDT Coordinator is responsible to prepare and
distribute approved NDT request to NDT crew and to prepare tracer sheet.
I. Construction Foremen/Supervisors/Workers shall be responsible for monitoring the progress of construction projects
and ensuring compliance with construction safety regulations. They supervise Construction Workers and subcontractors,
educate Construction Workers on site safety practices, and evaluate employee’s performance. The site foreman shall be
responsible for the direct execution of works involved the pipe installation/welding/testing

ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
process according to the plan and shall directly control and give instruction to the working personal. Workers are responsible
for all the physical activities in site which He shall perform with proper tools/equipment. PPE and good housekeeping around
the working area.
J. The Site Engineer is responsible for the execution of the works detailed in this method statements. He will be
responsible for instructing the Foremen / Superintendent about the requirements of the contract, including all
restrictions, safety regulations, scope of work and time schedule. In addition, he will be responsible for related logistic matters
and all matters related to HSE and the quality of the work.
K. The Safety Supervisor shall be responsible for the implementation of the HSE Plan on site. He shall coordinate with the client
representatives and JGC HSE to ensure the effectiveness of HSE plan at site. He shall ensure that all project HSE requirements
are compiled at the site. Act as a member of emergency response team.
L. GAS Trained flagman shall be assigned with heavy equipment such as excavator, backhoe-loader to control traffic
management and vehicular passing safely. To prevent personnel injury and property damage during equipment
reversing on blind spot area.
M. The GAS Safety Officer shall ensure that all required permits are available prior to commencement of work and to make sure that
the permit is available in the specific workplace with proper permit box. He shall check the compliance of all personnel with
safety requirements such as wearing PPE as well as work areas for any unsafe conditions. He shall liaise with the site supervisors to
ensure that work is carried out in accordance with the project safety plan procedure.
N. GAS Work Permit Receiver shall be the authorized personnel for all concerned work permit related activities and shall be
the responsible channel to contractor.
6.0 RESOURCES
6.1 EQUIPMENT AND TOOLS:
CRANE
FORKLIFT
GENERATOR
WELDING MACHINE
DRILLING MACHINE


ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
PIPE PUNCHING MACHINE

PLASMA CUTTING MACHINE
AIR COMPRESSOR
ESSAB CUTTING MACHINE
PORTABLE GRINDING
MACHINE
CORE CUTTING DRILLING
MACHINE
CHAIN BLOCKS, HOIST,
PULLER
HYDRAULIC PALLET TRUCK
PIPE ROLLERS, CLAMPS,
SHACKLES
6.2 PERSONNEL / WORKFORCE
 Mechanical / Piping Engineer

 Piping Foreman / Supervisor
 Permit Receiver (including confined space)
 Fabricator/pipe fitter
 Land Surveyor (including survey assistant)
 Millwright technician/Mechanical technician
 Certified Welders
 HSE Officer
 Mech / Piping QC Inspector
 SA certified rigger
 Helpers (Certified Flag Men, Fire watch, confined space entry persons)
 Driver (Heavy & Light)
7.0 MATERIAL STORAGE AND HANDLING
Storage/Preservation of material received by SUBCONTRACTOR shall be carried out in accordance with the
requirements of the relevant technical specifications, project requirements and VENDOR recommendation right from the
commencement till the handover of FACILITIES to CONTRACTOR.
Additional measures required by the Manufacture VENDOR shall be implemented to protect equipment/material against
extreme heat or cold, humidity, water and windblown sand.


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FABRICATION AND
INSTALLATION WORKS
Weather sensitive materials and equipment (i.e., instruments, small tools, welding electrodes, delicate equipment and equipment for
special uses) shall be stored inside covered area or other weatherproof structures.
All materials stored outdoors will be positioned at least 100 mm off of the ground and above ground water pooling byuse of railroad
ties, timbers, wooden beams, pallets, concrete slabs or other appropriate means. Hole covers shall be fully intact and shall not have any
damage or cutting.
 Preservation of equipment shall be in accordance with relevant preservation procedures.

 Main recommendations about storage, protection and preservation are listed.
A.MATERIALS TO BE STORED INSIDE THE WAREHOUSE
The following materials (list is indicative and not complete) shall be arranged, differentiated, and kept separate in the shelving
inside the warehouse:
 Fittings, flanges and valves smaller than or equal to 2" bolts, tie rods and Gaskets
 Accessories and instrument assembly equipment particularly delicate materials for which storage in a closed
area or even in an air• conditioned environment is requested.
B.MATERIALS TO BE STORED UNDER SHED

Materials that can be exposed to the weather as long as they are protected by the original, undamaged wrapping can be stored in
the shed. These include but not limit to:
 Complete rotating machines
 Machinery, safety valves and control valves internals for columns and reactors catalysts.
 Refractory materials that do not need to be assembled immediately.
 The materials shall be stored off of the ground and protected with tarpaulin or polyethylene sheets. Safety and control
valves in particular must be stored in their own casing. These items are usually included in seaworthy packing with
silica gel bags to absorb humidity.
C.MATERIALS TO BE STORED IN UNCOVERED AREA
The following materials (list is indicative and not complete) can be stored in open fenced areas:


ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
Flanges, fittings, valves, filters over 2" shall be protected and covered with tarpaulin
Pipes below or equal than 2" stainless steel pipes should be separated from other different parent material to avoid any
contamination.
Machinery
Metal sheets and various steel sections.
Prefabricated supports, pressurised containers, heat exchangers, air coolers Pipes of
diameter greater than or equal to 2"
Structural steel works Grating
Prefabricated piping shall be done proper preservation to avoid any foreign materials to pass through.
D.TRACEABILITY AND IDENTIFICATION OF MATERIALS
The following rules help warehouse staff to locate the position of materials and to identify them without the risk of error:
 Materials shall be placed separately based on material type for easy identification.
 The location codes shall be highlighted in the areas by means of signs and also written on the shelves.
 All piping material shall be segregated by type of material grade, and arranged by size schedule and rating, in
ascending way from the biggest to the smallest. This will allow to easy track the items in the yard and in the shelf areas,
furthermore it will keep distance between similar material, same size schedule and rating but with different base material,
avoiding being confused one each other by mistake during marking and/or wrongly pick it up during issuance.
 All steel pipes shall be identified with bands of paint colored according to specifications issued by the Layout and Piping department
(TUB). It is advisable to extend this system to the fittings too.
 The location code must be accurately transferred to computer at the moment the materials are logged.
E.USE AND APPLICATION OF RUST PREVENTIVES
If required, all interior and exterior surfaces shall be clean and dry before any rust preventive materials are applied. Any standard
solvent shall be used for cleaning surfaces before the application of any rust preventive.
In special cases blasting, pickling or other chemicals shall be used for cleaning and inert gas used for rust prevention when specified
by Manufacturer / VENDOR.


ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
Kerosene or gasoline shall not be used as cleaning agents. CONTRACTOR/SUBCONTRACTOR shall specify the rust
preventive compounds to be used for each application.
F.PIPES/SPOOLS
1. In the loading, unloading and stacking operations, the pipes shall be handled at all times in a manner that prevents
damages (such as cuts, cracks, bends, buckles, etc.) to the pipe walls, beveled ends, and to the coating (including
internal coatings, if applied).
2. Pipe shall not be stored directly on the ground but at least 100 mm above, surfaces on which the pipe is laid or stacked
shall be flat and free of protrusions, assuring full uniform bearing for the pipe length or shall be provided with
suitable bearing strips equally spaced to avoid pipe bending/deformation.
3. Pipes shall not be drawn or rolled on the ground.
4. Separate stacks shall be prepared for the different pipe diameters, thickness and material grade of project, each stack shall not
be higher than 2 meters.
5. Threaded ends shall be protected with grease and fitted with metal, wood, or plastic caps.
6. All openings of austenitic stainless steel and internal lined spools shall also be sealed to prevent entry of
moisture.
All shop fabricated and field prefabricated piping spools requiring storage at the pipe spool storage area shall be
prepared as follows:
 If chemical cleaning is to be followed, flanges for shop fabricated piping shall be protected over the entire gasket
surface with metal hardboard or wood firmly fixed after applying and or renewing rust preventive agent on the
flange coupling surface.
 Rust preventive or grease must not be used on pre-cleaned pipe spools.

 All fabricated piping materials shall be stored so that shall not be in contact with the ground.
7. Requirements for coated pipes
a) Flanges shall be covered with a timber, metal or plastic cap fastened to the flange by bolting or wiring. The cap
dimensions shall ensure protection of the whole flange face and bevels shall be protected by means of covers fastened to
the pipe.

ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
b) Ends of threaded couplings shall be protected by means of caps.
c) Coated pipe shall not be rolled or dragged on the ground. The pipes are to be placed at least 150 mm elevated from the
ground on a wooden spacer plank, or sand bags wide enough to avoid damaging the coating.
d) Internally coated pipes shall be handled from the outside diameter only. Lined and coated pipes and fittings shall be handled
with wide fabric or rubber-covered slings and padding shall be used cloth or hemp belts, of a size appropriate for the weight to be
lifted, or with hooks at the ends.
e) FBE coated pipes shall not be stacked directly against each other at any time during storage. They shall be separated by
full encirclement non-compressible rubber padding or equivalent at least 10 mm thick. Two full encirclement separation
pads, two shall be located 1 to 3 m from each end of the pipe, others pads shall be placed to support the center section
of the pipe so that the distance from one pad to each other is approximately 5 meters. Additional separation pads
shall be used, if required, to keep the FBE coated pipes from touching each other. The separation pads shall be attached
by some mechanical means that ensures they will stay in place. Padding must be fastened fixed to the pipes to ensure
they remain in position.
f) Twenty-four meter (24m) double-jointed pipe lengths shall have at least 5 full encirclement separation pads placed so that
2 of them are 1 to 3 m from the outer ends of the pipe and 3 of them support the center section of the pipe. Placement of
the pads should be approximately equidistant from each other.
g) As required by the SAES-H-200, the FBE coated pipes shall be protected from direct sunlight in order to prevent
UV degradation. This shall be done by covering the stacked pipes with tarpaulins or similar protection. The tarpaulins
must be maintained in good condition for as long as the pipes are exposed, personnel involved shall wearing dust mask to
direct sunlight. In case FBE coated pipes are stored outdoors without appropriate cover for more than six months, FBE
coated film must be checked for premature deterioration.
h) Polyethylene coated pipes may be stacked directly against each other without the use of separation pads.
i) For flanged spools, if any, necessary precautions shall be taken to prevent flange interference between spools by using wooden
protection disks, rubber protections or sandbags.


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FABRICATION AND
INSTALLATION WORKS
8. Flanges
a) Flanges shall be stacked in pyramid shaped stacks, with a height of about 1 m. They shall be coupled in pairs, separated by discs
made out of soft material (cardboard, strips of soft wood, etc.) in order to protect the resting surfaces of the gaskets.
b) They shall be raised off the ground on wooden planks.
c) Flanges shall be protected with grease or other suitable preservative agent, over the entire gasket surface.
d) 0-Ring Type grooves shall be protected with lubricating grease.
e) Assembly of flange faces shall be done as per SAES-L-109.
f) The ends of thread and socket weld end valves and flanges shall be protected with tight fitting plastic caps.
9. Fittings
a) The fittings shall be properly arranged in stacks in order to prevent them from sliding down, the height of the stack shall
be proportionate to the diameter, and shall not exceed 1.5 m.
b) They shall be placed on a planked floor and in such a position that rainwater does not stagnate inside.
c) They shall be handled in the same way as the pipe.
d) Suitable measures shall be taken for material grades subject to corrosion in order to avoid it.
e) Welding ends shall have wood, plastic, or metal covers. Fittings shall be in steel-banded wooden crates or secured to
skids. Beveled weld ends shall have a securely fastened bevel protector
10. Valves
Indoor storage is required for all valves except the following:


ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
a) Manually operated valves size 2" NPS or larger may be stored outdoors on wooden strips, with the valve stem upright
and to be protected by tarpaulin.
b) Large automatic control valves 2" NPS or larger may be stored outdoors on dry paved area, or on pallets if a shed, roof or
tarpaulin siding (or equivalent) are provided.
c) Actuators on control valves and motor operated valves shall be protected against mechanical damage.
d) All exposed metal parts which may be affected by corrosion shall be protected with a suitable preventive lubricant like
molykote and grease.
e) Pressure relief and safety valves shall be stored in an up-right vertical position in weather protected areas. The flanged
ends shall be properly plugged, sealed and covered to prevent entrance of sand, dirt and rain.All valves stored outdoors
shall be entirely protected based on the requirement.
f) After being stored, all valves shall be in the closed position except plug and ball valves. All other manually
operated valves shall be provided with protective sheeting.
g) Critical points of the assembly such as the valve end ports, valve stem, actuator, gearbox, and auxiliary valves shall be
covered and preserved.
h) Valves shall be restrained from movements during transportation to avoid any damage to the main valve and its
accessories.
11. Gasket and Bolting
Gaskets, bolting, stud and nuts shall be stored under cover in dedicated areas according to various diameters.
12. Stainless steel (including austenitic)
a) The stainless-steel material, including the austenitic one, shall not be exposed to salt water or other products containing
salt and to the effects of the weather.
b) Stainless steel materials are well protected against exposure to rain, elements and seawater splash during shipment and
storage.

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FABRICATION AND
INSTALLATION WORKS
c) Storage and handling of SS and Ni Alloy fittings must ensure that there is no contamination from carbon steel (i.e.,
crane hook, steel sling).
d) Stainless steel equipment components and materials, including the austenitic ones, shall be protected as follows:
*Under cover (only for pipes fittings or other small items)
*Not in contact with carbon steel and alloy steel to prevent contamination
*Not in contact with the ground or with porous supports such as raw wood
13. Consumables
a) Where required SUBCONTRACTORs shall provide procedures for receiving, handling and storing the
consumables supplied by them.
b) The electrodes, especially the covered one and rods, shall be stored in a conditioned, dry and watertight area to avoid
moisture pick-up and contamination. VENDOR's recommendations shall be followed.
c) As per general indication here below data about the temperature and humidity level to be maintained:
d) If the electrodes are included in vacuum pack can stay at higher temperature that shall be verified inside vendor
datasheets.
e) Low hydrogen covered basic electrodes should be re-dried before use whenever there are application requirements
relating to weld metal hydrogen content and/or radiographic soundness (not needed for vacuum packing). max 60%
RH is allowed.
f) The electrodes that are seriously damaged by moisture cannot be restored to their original condition by baking and should
be scrapped.
g) The electrodes shall not be stacked more than four layers of electrodes in the redrying oven and it's
recommended not to redry covered electrodes more than three times.
h) The maximum storage time for all the electrodes is 3 years. After this time the product should be thoroughly checked
before use.

ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
i) SAES-W-011 Attachment I & II and consumable procedure's requirements for storage, baking and
reconditioning and SAIC-W-2010 attachment & manufacturer's recommendations shall be followed for controlled
environment and validity of consumables.
j) Uninterrupted power supply shall be available for Holding oven- welding consumable stores requirements.
14. Consumable Material Storage
The material shall be stored in well-ventilated areas/places, far away from ignition sources and with
fabrication/expiration date well indicated. Special precautions shall be adopted in accordance with VENDOR and safety
recommendations.
All consumables shall be stored and dried in accordance with the requirements of consumables enclosed in the SAES- W-011.
8.0 ERECTION AND INSTALLATION PROCEDURE

A. Preparatory Works:
a) Prior to start the activities, Supervisor competency to be verified the Prior to erection, the interior of all piping
components shall be thoroughly cleaned of loose scale, sand blasting grits or sand and all other foreign matter by air
blowing.
b) Cryogenic valves with seat vents and low temperature service valves will be marked and verified prior to
installation.
c) Injection points will be marked with flow direction and verified prior to installation.
d) If any internal parts of Check Valve removed for testing shall be replaced.
e) Rigging of pipe components shall be performed in accordance with approved rigging / safety plan and should not cause
any damage to the surface of the components.
f) Orifice plates, strainer, rupture discs, thermo wells, pressure gauges, in line instruments etc. shall not be installed
until the pressure test is completed.

ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
g) Piping shall be installed in such a manner that the resultant force on the equipment shall be kept to a minimum.
Proper care shall be taken at connection joints to pump, compressor and other mechanical equipment. Full Face
blind gaskets shall be provided between any equipment and piping connection flange joint. Flange alignment check
shall be performed and witnessed after reinstatement and initial opening of the flange shall be inspected to confirm with
the flange condition and free from damage or corrosion.
h) All piping openings shall be sealed before, during and after erection to prevent the ingress of moisture and foreign
materials. Flanged or threaded ends shall be sealed with tape, plastic cover or plywood.
i) Details of all modifications shall be reflected on line History sheets and as built drawings. All modificationsfor line
sizes above 2” shall be carried out only as per the revision isometrics from contractor. Piping with 2” and below shall
be routed as per site condition and properly supported as per the standard span with approved as built
drawing.
j) Modifications shall be reflected in isometric by JGC Procedure JCRF
k) All weld fit-ups shall be inspected by a piping inspector and give clearance for welding. All welded joints (field &
shop) shall be inspected by the welding QC Inspector. If the result of inspection is unacceptable, the joint shall be
repaired and re-inspected in accordance with B31.3 table 341.3.2 and welding procedure specification.
l) Special care shall be taken for flange face to enable proper alignment of connections.
m) Special care shall be taken while handling Safety relief valves, control valves, etc.
n) Piping connection to the compressors, turbines and specialty equipment shall be as per vendor’s
specification or instruction.
o) During inspection of orifice Flange Installation, inspector shall ensure correctness of instrument tapping holes
Isometric/ Engineering/ Instrument (Hook-up) drawings shall provide the necessary in-formation on how the instrument
tapping holes should be oriented. Visual inspection after welding shall be carried out to ensure visual acceptance of the
finished weld, root penetration shall be smoothly grinded off to the same level of the pipe inner wall, it should be properly
documented and witnessed /verified by the JGC /Aramco as per stipulated in the SAES- J-100.
B. INTERNAL CLEANING OF PIPE SPOOLS
a) The area piping supervisor shall identify the spools arrived from shop based on their material traceability.
b) Those individual spools, straight length pipe and doubled with two straight lengths shall be cleaned by blowing
air from compressor. It shall be visually inspected and accepted. This should be done safely by work force under
the supervision of piping supervisor.
ABOVE GROUND PIPING
FABRICATION AND
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c) The air compressor should be at a minimum pressure of 3.5 bar and maximum of 6 bar.
d) The piping inspector shall ensure that the inside of pipe is thoroughly cleaned and documented. He should also make
sure that such cleaned spool’s ends are covered.
e) During assembly and erection, the supervisor shall check and ensure that no foreign materials such as welding
consumables, lumber, gloves, etc. are left inside the piping system.
C. Modification/Fabrication of spool in job site:
1) Cutting:
Prior to cutting straight pipes, the following checks shall be carried out under supervision of Site Engineer/Supervisor/Foreman
with QC inspector:
 Material conformance with marked up IFC isometric.
 Color coding is in accordance with applicable project specification.
 Spool number and Isometric number is clearly marked on pipe to be cut.
 Traceability is transferred to piece of pipe to be cut, prior to cut off from main pipe.
 Straight pipes shall be cut, using flame cutting, plasma or mechanical cutting equipment, in
accordance with marked up ISO's.
 Pipe support material cutting, and fabrication activity will be done in a designated area within fab shop
area in and or outdoor.
 A quick check of actual installation location shall be done to avoid any clashes.
 Any grinding & cutting of pipe shall be performed using appropriate cutting tools.
 Grinding, cutting wheels shall store in separated place to avoid mixing for CS & SS etc.
2) WELDING
a) Any welding shall be done after fit-up inspection and acceptance of fit-up by Piping /Welding QC.
b) Welders shall have the qualifications stipulated in ASME SECTION IX to cover the kind of materials concerned in the
piping works. They also have to pass the Welder qualification test in accordance with Welding Procedure Specification.

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c) Welding shall follow the code requirements with various “P” class materials, and approved WPS / PQR’s
d) No welding shall be done if there is impingement of any rain, snow, sleet or high wind on the working area. However,
welding may be done provided that suitable protection is installed.
e) The pipe and bevel surface shall be cleaned and free from rust, oil, paint, sand, moisture and other material
that is detrimental to welding.
f) Welding consumables should be stored in mother oven to avoid any moisture content in the electrodes and portable
quivers shall be used in the welding areas to maintain the dryness of the electrodes to avoid any defects.
g) Weld bead shall be carefully laid to avoid undercut, pinhole, slag inclusion, crater, imperfect penetration, etc. Welding
rods always should be stored under dry condition.
h) Grounding wire shall be firmly fastened by screw or clamp to the material to be welded, at the position as near as
possible to the welded part.
i) Inside of circumferential weld bead shall not have any burr, arc strike or fragment of welding rod and all adhering
substances shall be removed as far as possible. No welding will be performed on piping while connected to rotating
equipment.
j) Welding circuit (to ground etc.) shall not be through any valves or instrument.
k) Welding circuits shall be as close as possible to the welds being performed and on the piping being welded. Spatter, arc
strike, slag, etc. of welded part shall be thoroughly removed down to the metal surface.
l) Provide Bridge tacks in minimum number necessary for fit-up.
m) Use jigs (bridges or clamps) made of material which quality is the same as or better than the base metal.
n) As per ASME B31.3/ ASME B16.25 in the case of butt welding of piping materials having different thickness, the welding of the
piping materials shall be worked so that thicker side thickness should be accordance with thinner one. In the case that the
difference of inside surface is more than 1.5mm, thicker surface shall be finished as 1:4 minimum sloped for taper
bored, minimum slope 22.50 for bored.
o) Before welding first layer, both ends of tack weld bead shall be sharpened with grinder in order to allow
complete fusion.
3) PIPING WORKS ON THE PIPE RACK
a) Straight run pipe shall not be pulled through the pipe racks unless a roller is used, or the steel/precast face is covered
with carpet to avoid paint damage.

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FABRICATION AND
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b) Install, align and fix the roller assemblies at rack beams. Rollers will be employed primarily to move random lengths
along the racks.
c) Install required pulleys to complete with Chain block. The pulley and cable will be used to pull the pipes from loading
end, along the rollers and to its final position Cranes will pick-up the pipes either directly from trailers or from
temporary lay down nearby the pipe rack.
d) The position of lines shall be marked on the sleeper / pipe rack beams according to coordinates on Isometrics.
e) Once the pipe is initially positioned at rollers (on two spans), hook the pipe to a Chain block. Pipe should be tied in such a
way so as not to damage bevel at pipe end.
f) When the pipe is being pulled, a watcher will check the travel of pipe such that it will safely and correctly ride the
succeeding rollers. A signaling system for safe execution and control of pulling will be employed.
g) Once the length of pipes reaches its destination, it will be removed from rollers using chain blocks.
h) At interconnecting pipe racks the same roller system will be utilized where new steel works is installed and when there are no
obstructions.
i) Spool shall be lifted on the rack / sleepers on their designated position by using chain pulley block or crane.
j) After lifting it shall be inserted into the pipe rack & placed in a required location, where the welding is going to be
carried out.
k) Piping being welded shall be grounded on pipe and not to steel structure and shall not go through valves or bolted
flanges.
l) After placing the pipes, joint fit-up shall be made from scaffolding platform which is made below the joint
location between two grids.
m) If tie-in alignment with outside pipe rack piping is required, coordination of pipe installing between working teams shall
be done for ensuring proper alignment.
n) For installation of slop lines, check levels of tie-in points (both high and low) shall be checked. The line slope shall be
given between these two points. Slope is obtained by different shoe height and shim plates.
o) For installation of branch, header shall be installed and aligned before commencement of branch installation. During lifting
and fit-up by chain block, care shall be taken to avoid any damage on components of structure. By distributing load to
strong components of structure, bending or twist of structure shall be avoided. Structure shall be protected to avoid damage
to the galvanized surface

ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
4) PIPING AROUND ROTATING EQUIPMENT (PUMP & COMPRESSOR)
a) Pump and compressor piping shall be installed up to a break point between the nearest pipe support and the equipment.
b) No welding will be performed on piping while connected to rotating equipment. Temporary / Permanent support shall be given to
the piping all the time to avoid load on equipment nozzles.
c) All bolting will remain loose at rotating equipment until final pipe stress.
d) Final tie-in weld for alignment with equipment nozzle shall be done after initial alignment of equipment.
e) Align equipment nozzle flange and spool flange within acceptable tolerance by checking gap by dial gauge or filler gauge
in minimum 4 points in circle of raised faces. Tie-in weld shall be done when alignment is within acceptable range.
f) Flange gap shall be checked with filler gauge after welding.
g) Final bolt up to rotating equipment will be performed under the supervision of the millwright and documented on the
applicable alignment records (millwright document).
h) No piping supports or support structure shall be placed over upward facing compressor nozzles that would restrict access
for maintenance of the complete equipment skid.
i) Each compressor nozzle shall be provided with an individual, removable, final piping spool.
j) Bolts, nuts, and washers shall be visually checked for proper size, grade, and dimension and for any physical damage
such as corrosion, rust and burrs. Also, the suitability of the stud bolts and nuts material for the service temperature
and the compatibility with the flange material shall be checked.
k) The gaskets shall be marked to identify rating and size and other principal characteristics. Gaskets with no marking
shall not be installed.
l) Lubricant shall be applied to both the nut bearing surface and the male threads.
5) INSTALLATION OF FLANGE
Prior to flange connection, following points shall be verified to get the good condition of flange joint.
a) Flange faces shall be aligned horizontally and vertically.
b) Flange face shall be protected from damage like scratch, dent, rust etc.
m) All bolts, nuts and gaskets shall be checked and be free from damage, corrosion etc, and shall be of correct
ABOVE GROUND PIPING
FABRICATION AND
INSTALLATION WORKS
c) Flange faces shall be cleaned by using metal wire brush to ensure a good seal.
d) Flange to be checked upon opening and shall be inspected based on the flange face,serration,rust,corrosion and mechanical
damage.
6) BOLT INSTALLATION
The sequence of bolt tightening shall be as follows using the cross technique and as per SAEP-351.
a) Lubricate (Anti Seize) stud (or bolt) threads in area of nut engagement, and insert all bolts, nuts and washers. No
lubricants will be put on flange faces with gaskets.
b) Calibrated torque wrenches (hydraulic/manual) shall be used for bolt torquing.
c) Tighten all inserted bolts, nuts by finger tight.
d) The bolting sequence shall consist of a series of uniform loading starting with the flange bolt in the 12 o’ clock position,
then transferring successively to the 3 o’clock, 6 o’clock, 9 o’clock etc. Increasing the load uniformly each time, the
sequence is completed. Example given in fig:

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FABRICATION AND
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f) Tighten bolt in sequential order at each step until final torque is reached.
g) Bolt tightening and torqueing shall be followed as per SAEP-351
h) Repeat tightening sequence until all bolts are stable at final torque level.
i) Final bolts up must have bolt face flush with top of nut as a minimum (see ASME B31.3 for full
engagement).
j) Bolting material identification stamping shall all be placed on one side and shall be in such a manner that
ensures ease of identification of bolting material throughout construction phase.
k) Torque values shall be obtained based on SAEP-351 Table F1 &F2.
7) INSTALLATION OF VALVES
a) Valves shall be installed as shown on the isometric drawing. The valves shall be installed in accordance with valve
manual.
b) Prior to installation of valve, tag number and flow direction will be verified with isometric drawing / P&ID and installed
accordingly.
c) Valves will be correctly handled to prevent damage to the valve body, handle and flange surface.
d) Welding between pipe and valve will be performed with valve open as per manufacturer’s instructions.
e) All the internals of BW / SW valves will be checked before welding and removed if welding will damage
internals (Follow valve manufacturer’s recommendations for welding & PWHT).
f) Valves shall be checked for correct operation before installation and spindle threads will be preserved to assure
good valve operation. (No greasing of spindles used in oxygen service). Only use approved lubricants & manufacturer’s
recommendations for cryogenic valves.
g) Isolation valves will be verified for hydro testing prior to final installation.
h) Tags to be introduced during the receiving inspection and maintained by assigned inspectors until valve
installation.
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FABRICATION AND
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8) INSTALLATION OF PIPING SPECIALTIES AND INLINE INSTRUMENTS
a) Piping specialties and instruments shall be installed after checking the flow direction, orientation and tag number to ensure it is in
accordance with the drawing and manufacturer’s instruction.
b)Special care shall be taken in handling instruments to ensure it stays clean and avoid shock to maintain the accuracy.
c) Installation of expansion joints shall be as follows...
d) Prior to the installation of expansion joint, set length shall be measured and checked with the drawing. The direction of flow shall be
checked.
e) Set bolt of the expansion joint shall be removed after the completion of testing and inspection. If steam blow cleaning is used, the
set bolts shall be removed before blowing.
f) Temporary strainers shall be installed in the suction of all applicable pumps, safety showers, control valves, instruments
etc. as required by testing and flushing procedure.
g) Installation of glass level gauge and sight glass shall be done with proper care to avoid any damage.
h) Orifice plates shall be installed in accordance with the flow as indicated on the orifice handle.
9) INSTALLATION OF PIPE SUPPORTS
a) All supports, anchors, guides and other support attachments shall be installed in accordance with details indicated
in the pipe support drawings, isometric drawings.
b) Separate storage facility shall be made to store fabricated supports in area wise and material wise.
c) Fabricated CS, AS and SS supports shall be placed separately with proper identification like type of support, sequence
No etc. with legible marking.
d) Attachments, such as supports, bracing, lugs and T-bars shall be installed in the field.
e) Installation of supports shall be performed in accordance with construction specification for piping construction works.
10) HEAT TREATMENT

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FABRICATION AND
INSTALLATION WORKS
a) Materials and temperature for preheat treatment and stress relieving shall be in accordance with
ANSI/ASME B 31.3 Table 330.1.1 / Table 331.1.1 / SAES-W-011 and approved WPS / PQR.
b) Preheating shall be performed by propane flame or by other appropriate method prior to connecting the weld. But
preheating for low alloy steel shall be with electric heating coils.
c) Heating band width at preheating shall be more than 25mm to each from bevel end.
d) In case that heat treatment is performed at the field, this shall be done as follows.
e) Around the heating coil, insulation of standard shape without damage or other abnormality shall be
provided.
f) As a rule, temperature at one point at the centre of weld bead shall be measured. However, according to the thickness
and diameter of pipe, two-point measurement may be required. As far as Finger Element is used, the two-point
measurement shall be adopted when pipes are 14" nominal size or over (at top and bottom if horizontally placed.).
g) The chart of automatic temperature recorder shall be submitted as temperature record.
h) In the process of cooling down after the heat treatment air-cooling shall be done after the temperature of the pipe
becomes 300C or below.
i) The pipe shall not contact other kinds of metal during heating.
j) In case of small pipes of 2” or below, stress relieving may be performed by heating with burner under full supervision
of SUBCONTRACTOR / CONTRACTOR QC inspectors after getting approval from Owner. If setting of electric
heat coil is not practical, In this case, sufficient control of temperature shall be performed to avoid uneven heating.
When we use temperature-indicating crayons for temperature checking, the concerned QC inspector shall be well
educated in the temperature measuring.
k) Holding time in heat treatment when performed with burner shall follow the requirements of code and project
specifications after reaching the stipulated temperature.
l) The preheat temperature shall be established over a minimum distance of 75 mm on each side of the weld

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FABRICATION AND
INSTALLATION WORKS
9.0 INSPECTION
9.1 TEST AND INSPECTION TO BE DONE BEFORE WELDING WORKS
a) Prior to start construction work ensure that the Welding Procedure Specification (WPS) is approved by the JGC /
ARAMCO.
b) Welder Qualification certificate and welding process identification card is approved by Contractor and the
identification card issued to welder.
c) Ensure the welder is qualified for the welding process and welder has a welder qualification card (JCC) for the
particular WPS.
d) Certificate of materials shall be inspected. The quality of welding rod shall be equal to or better than the corresponding
one stipulated in related standard and code. Welding rod shall comply with the classification of usage stipulated by
AWS and ASME SECTION II PART C.
e) Groove angle, shape, root opening, thickness of land, etc. shall be measured by gauge to see whether these
dimensions are as per specification. No existence of uneven groove face, residual notch, residual slag due to cutting, etc.
shall be confirmed. No adhesion of oil, paint, sand, or other foreign materials, and no rusting are also to be
confirmed.
f) Tack weld shall be done as symmetrically. Tack Welding will be done using a qualified welder and preheat
requirements of the WPS shall apply to tack welding. Confirm that length of tack weld bead, number of tack welds, root
opening, condition of applying tack welding jig, condition of preheating and condition of arc strike are all appropriate
as per SAES-W-011.
g) Following are to be confirmed for preheating
1. Preheating shall be performed using electric coils or by flame

2. Preheating shall be maintained throughout the weld (360°) during welding
3. Preheating temperature is according to Table 330.1.1 of ASME B31.3
4. Width of preheating is more than 25mm, but need not exceed 100mm
5. Temperature shall be measured by surface temperature gauge or temperature stick. Measuring shall be performed at
the position apart from the shoulder of groove by the distance same as the thickness and not only at heated surface but also at
opposite surface, as much as possible.
6. Burner flame shall not be applied directly to the groove face
7. Welding rod shall be adequately heated and dried by drying furnace according to the brand of the welding rod.

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FABRICATION AND
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8. Heating temperature and drying time (including re-drying) shall be in accordance with the manufacture's
instruction.
9.2 NDT (NON-DETECTIVE TEST)
a) Selection of joints to cover NDT requirement is performed by Contractor and COMPANY.
b) All welds shall be visually examined. Visual examination shall be performed prior to other NDT .
c) Where less than 100% radiographic coverage is required, random selection of welds shall be based on the weekly weld
production. I.e., progressive examination through Lot selection.
d) For progressive examination requirements, a lot shall be defined as all of the same kind of welds made in the same
production day on a specific line classification. The progressive examination of any lot is aimed to ensure the weld
quality of an entire project. However, the welder performance shall be evaluated separately in accordance with the
corresponding inspection procedures.
e) Any weld rejected for film quality shall add suffix “RS” along with the joint number in reshoot film.
f) NDT control procedure shall be followed for all applicable NDT processes.
9.5 POST WELD HEAT TREATMENT (PWHT)
a) Materials and temperature for preheat treatment and PWHT shall be in accordance with approved WPS/ SAES-
W-011
b) Post weld heat treatments (PWHT) shall be in accordance with ASME B31.3-2012. A written procedure
describing the general PWHT requirements shall be submitted for review and approval.
c) The PWHT procedure shall include descriptions of the equipment, method of heating, location and type of heating
elements, temperature measurement, and thermocouple locations. The review and approval process shall be the same
as described for welding procedures.
d) Around the heating coil, insulation of standard shape without damage or other abnormality shall be
provided.
e) The chart of automatic temperature recorder shall be submitted as temperature Record. All charts shall be marked
with the date and sufficient information to uniquely identify the joint/component being heat treated.

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FABRICATION AND
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f) The pipe shall not contact other kinds of metal during heating.
g) PWHT will be carried out using "Electrical resistance heaters" (As per the approved Procedure )
h) Flanges shall be protected from oxidation as recommended in SAES-W-011.
10. SAFETY PLANS
1) During execution of the job all measures shall be adopted to ensure safe working.
2) The work shall be executed in accordance with the approved Job Safety Analysis (JSA).
3) All precautions and signages shall be in place prior to commence work.
4) All employees must wear PPE according to the requirements specified in the JSA.
5) The workers will be made aware of safety requirements related to AG piping Installation activities through daily,
weekly, and monthly toolbox and safety talks.
6) Toolbox meetings shall be conducted by a qualified safety officer prior to starting the work.
7) Access and good housekeeping should be maintained in all areas.
8) Waste Management should be strictly followed to keep the work area neat and clean. Waste management plan shall be as JGC
waste management procedure “CE-566000-001.”
9) The works shall be carried out in compliance with the applicable HSE legal and contractual requirements as well as with the CE-
565997-001,” Contractor Site Safety Program” (HSE), CE-565998-001 “Environmental Management Plan (EMP) and CE-566017-
001 “Hazard Identification & Risk Management Plan”.
10) The significant HSE hazards and risks related to the works covered by this document have been identified, and
documented in “JSA” attached in Appendix A.
11) Prior to implementation of works at site, Job Safety Analysis will be conducted and reviewed with the participation of the
Contractor Engineer, Supervisor and HSE.
12) The identified hazards and associated risks and mitigation controls shall be communicated to the workforce through registered
briefings at the beginning of each shift.
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FABRICATION AND
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11. Attachments
 JSA for Above Ground Piping Fabrication and Installation Works.

JOB SAFETY ANALYSIS DOC. No. Rev
Project Zuluf Onshore Oil Facilities Project JGC DOC. No. V-3130-MC2-A-1006 0
Contractor JGC Arabia Ltd. PO No.

Sub-Contractor GAS Arabian Services Work location Safaniyah, Saudi Arabia
Description of Activity /JSA Title JSA FOR A/G PIPING FABRICATION AND INSTALLATION Area Classification GREEN FIELD  BROWNFIELD
S.No JSA Participants’ Name: Position Signature Contractor’s Review & Approval
Site Engineer Reviewed By
1 Riyaz Khan
2 Relish Babu Construction Manger
3 Anvar Ummer Safety Supervisor Name:
4 Approved By
5
Note: Contractor’s JSA participants team shall comprise of DISCIPLINE engineers, supervisors, and safety personnel
Hazards, Risks & Control Measures provided in this JSA shall be communicated to all personnel involved in this job execution and shall sign the communication sheet - (responsibility supervisor /foreman)
SAPMT Site Engineer SAPMT Site Superintendent SAPMT Field Compliance Team
Name: Name: Name:
Position: Position: Position:
Date: Date: Date:
GI 2.100, SP-0000-16540-0001, SP-0000-16540-0061,SP-0000-16540-0047, SP-0000-16540-0006 G.I. 7.025, GI 7.026,G.I. 7.028, G.I. 7.029,
References (GI; SAES; SMS ; others G.I. 7.030, G.I.02.102 and GI 8.001
CHECK ( ) REQUIRED PPE, SAFETY EQUIPMENT, AND CONTROLS REQUIRED

Hard Hats  Welding gauntlets  Rescue Equipment  Spill Control  Other PPE (Specify)  CSE 
Safety Glass /Goggles  Face Shield  Air Blower fan  Gas tester (3 in one)  Disposable cover all  Isolation / LOTO 
Safety Shoes/Boots  Respirator  Signs  Life Jacket/Work Vest  Full Body Harness  Excavation/Road Closure 
Safety gloves  Air Supplied Hood  Barricades  Life Rings  Suspension trauma 
Hearing Protection  SCBA  Fire Extinguishers  Permit to Work  Fall Arrestor 
Equipment Crane, trailer, pick up vehicles, low Bed Trailer, boom Truck, heating blankets, gen set, fuel tanker, measuring tools, power tools (portable grinder, portable buffing
machine, portable grinder, chain blocks, hoist, puller, welding machine, essab cutting machine, plasma cutting machine, air compressor, core cutting drilling machine, pipe
punching machine, hydraulic pallet truck, pipe roller, clamps, shackles
JOB INVENTORY LIST
No. Job Name/Description Hazards or Potential Losses Risk Level
1.1 Failing to comply with work permit and JSA requirements can result in the accidents
Preparation of works 1.2 Workers unaware of work-related hazard and emergency procedure M
1 PWHT, Pipe spool air cleaning, Plasma welding, Gas
welding, Compressed gas cylinder use, storage and 1.3 Unauthorized entry and works
handling. Welding machine usage
2.1 Unauthorized driver and equipment operator being involved in the job
2.2 Use of improper road access/ short cuts.
Delivery, Transportation and storage of materials,
2.3 Blocking of emergency vehicle routes
2 pre-fabricated structural steel members, bolts, M
2.4 Falling loads from transport vehicles.
support, and other materials into the work area
2.5 Unguided movement of equipment might lead to falling loads, collision with other
equipment or existing structures and hitting nearby workers.
Modification/Fabrication of spool in job site 3.1 Personnel injuries like hand, eye injuries
3.2 Potential burn injury/ produced spark /flames during hot works
Welding, cutting, grinding, and fit up associated with the 3.3 Unauthorized person being tasked for welding jobs
3 L
work) 3.4 Electrical hazard / Electrocution
3.5 Fire hazard
4.1 Falling Hazards
4.2 Lifting work to include lifting of pipes, pipe support and other work-related material
4.3 Crane tipping over
4.4 Crane hitting the existing facilities
4.5 Crane topple, suspended load and drop, hit on to personnel and structure
Installation of pipe spool, pipe support, fittings, flanges 4.6 Noise
4 4.7 Physical and health hazards from using different types of tools M
and valves
4.8 Electrocution
4.9 Fire
4.10 Heat Stress
4.11 Pinch points
4.12 Improper steel materials support
5.1 Falling Hazards
5.2 Falling of objects ( Materials and tools)
5 Stringing of pipe in the pipe rack using pipe roller 5.3 Pinch points M
5.4 Inadequate procedure or Unsafe work procedure
5.5 Defective lifting gears
6.1 Unstable ground condition
6.2 Run over / Struck by equipment
6.3 Collision
6.4 Poor Maintenance
6 Manlift Operation 6.5 Equipment failure M
6.6 Falls (man, materials and tools).
6.7 Caught in between /Pinch Point
6.8 Unqualified Person utilized
6.9 Tip-Over
7.1 People being exposed to radiation
NDT (Non-Destructive Test) 7.2 Unauthorized access
7. H
7.3 Incompetent personnel
7.1 Lack of housekeeping resources, Uncollected spoils, refuse, Obstructed access (ladders,
8. Housekeeping walkways, exits), Slip, trips, fall hazards, Fire hazards (combustible refuse uncollected),
L
Dropped, Improper materials stacking or segregation
RISK ASSESSMENT MATRIX
ACTION
SN JOB STEPS HAZARDS IDENTIFIED CONTROLS
BY
Performing personnel shall be made aware of the Emergency Reporting Procedure a GAS EMERGENCY CONTACT NUMBERS:
nd Contact Number
Munawar Hussain Project Manager 0595042707
A. EMERGENCY 911 REPORTING INSTRUCTIONS:
Relish Babu Construction Manager 0557149584
 Dial 911 from a Saudi Aramco telephone
Anvar Ummer Safety Supervisor 0501136997
REPORT AS FOLLOWS: JGC EMERGENCY CONTACT NUMBERS:
Say: This is an emergency!
JGC Main Emergency Main emergency contact 0537260400
I am calling from: Provide LOCATION (e.g., Plant, Building No., House No.)
Mr. Taira Fujii Construction Supt 0550506174
I see a: Provide NATURE OF EMERGENCY (e.g., fire, explosion, gas release, hostile
act, bomb threat*) Veallu Jaga Daseen SH&E Manager 0502632975
There are: Provide QUANTITY of people hurt and requiring medical assistance
The phone no. here is: Provide PHONE NUMBER
My name is: Provide YOUR NAME SAUDI ARAMCO AREA REGIONAL SECURITY CONTROL CENTER
My badge number is: Provide YOUR BADGE NO. (RSCC) From an outside phone or mobile phone, call:
* Note: In the event of a threat (e.g., bomb), relate the actual threat to Security if
possible. RSCC Seven Digit 911 Numbers
Eastern Area 013-872-0911
REPEAT THE ABOVE INFORMATION AND ANSWER QUESTIONS
Southern Area 013-572-0911
DO NOT END THE CALL UNTIL SECURITY CONTROL DISPATCHER TOLD TO DO Northern Area 013-673-0911
Central Region 013-285-0911
Western Region 013-427-0911
SAFANIYAH AREA: If the number is busy or unavailable, try the following:
Nearest Ambulance 997
ACTION
BY
1.1.1 Do not start any work preparation until signed permit is available at
the site.
1.1.2 Specific work permit system must be followed according to JGC PTW
1.1 Failing to comply with work requirements and in accordance with SA GI 2.100
permit and JSA 1.1.3 Make sure STARRT meeting is conducted to all workers prior starting
Site Engineer,
requirements can result in the works.
Foreman,
the accidents 1.1.4 Make sure applicable required checklists are performed and available
Supervisor,
at work site prior starting any activity.
HSE Officer,
1.1.5 Joint site inspection shall be performed by the permit issuer and WPR Permit Receiver
prior to start the work.
1.2.1 STARRT meeting shall be conducted prior to start the work and
explain about the hazards involved in the activities and its control
Preparation of measures.
1
works 1.2 Workers unaware of work-related 1.2.2 All project personnel shall have completed the emergency
hazard and emergency procedure response procedure training from JGC.
1.2.3 Emergency reporting procedures and emergency contact number
shall be posted at the prominent location and the HSE bulletin board.
1.2.4 Location of the assembly point shall be communicated to the
worker during TBT and STARRT meeting.
1.3.1 Only project personnel that have completed the JGC Orientation
and medical screening will be mobilized to project site.
1.3 Unauthorized entry and work
1.3.2 Each individual working in the project should have received specific
training based on the training needs analysis.
1.4.1.Topic to be discussed must be based on the activities and safety

1.4 Lack of knowledge/
requirements on the approved work permit.
understanding
1.4.2 Pre-task briefing shall be conducted at the work location.so that
workers can understand better by observing the actual site condition.
ACTION
BY
1.4.3 Continues two way communication must be followed to prevent

misunderstanding and misinterpretation of the information shared.
1.4.4 Supervisor / Foreman shall ensure workers understand what have been
discussed during the STARRT by asking questions about the work-
related hazards and ensure they understand the precautions and
methods to be followed
2.1.1 Only SA certified/SA approved third party certified equipment

2.1 Unauthorized driver and operators with valid certificates are allowed to operate heavy
equipment operator equipment.
being involved in the job 2.1.2 Transport vehicle drivers shall have SAG license .
2.1.3 All operators shall have completed project mandatory HSE training
prior to start the work. Site Engineer,
Foreman,
Delivery, Supervisor,
Transportation 2.2 Use of improper road access/ HSE Officer
2.2.1 Use proper access road route for heavy equipment is provided and
and storage of short cuts.
ensure drivers are aware of the proper route.
materials, pre-
fabricated
2 structural steel 2.3.1 Emergency routes to be identified and cleared from any obstruction or
members, bolts, 2.3 Blocking of emergency vehicle blocking at all times/This matter shall be discussed and clearly
support, and routes understood by the workers specially the vehicle users/drivers
other materials 2.3.2 Heavy equipment parking area shall be provided.
into the work 2.3.3 Emergency access shall be barricaded and signage are posted.
area
2.4.1 Ensure that the load is secured and safe for travel before moving.
2.4 Falling loads from transport
2.4.2 Proper lashing shall be checked by the driver, rigger and HSE officer
vehicles
prior to every use.
2.4.3 Damaged /worn out lasing materials shall not be allowed to use.
2.5 Unguided movement of 2.5.1 One trained flagman to be assigned to assist the moving equipment
equipments might lead to falling 2.5.2 Provide PWAS and RVCCS to all heavy moving equipment
loads, collision with other before utilizing at Site.
ACTION
BY
equipment or existing structures 2.5.3 Install hard barricade to segregate pedestrians from mobile equipment
and hitting nearby workers. with appropriate signage to keep personnel away from the vehicle
movement.
2.6.1 Only trained and competent flagmen shall be assigned to direct traffic.
Pedestrian walkways shall be segregated from the equipment access
using hard barricade.
2.6.2 Install physical barriers to segregate pedestrians from mobile
equipment with appropriate signage to keep personnel away
2.6 Vehicles coming into contact from the vehicle movement.
with passengers or other 2.6.3 PWAS/RVCCCS shall be installed on the earth moving and
vehicles construction equipment in accordance with the project specification
and SA requirement. A trained flagman shall be assigned with each
equipment or vehicle.
2.6.4 All traffic rules and signs should be followed (on site approved speed
limit.
2.6.5 All employees shall be wearing full personal protective equipment.
(helmet, safety glass, high visibility vest, safety shoes)
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2024-01-03 11:33:05
Stacking of pipe 2.7 Poor Access/egress 2.7.1 Safe access shall be maintained at site for vehicles and equipment. --------------------------------------------
spools at site and 2.7.2 Categorize pipe spools to facilitate organized storage and retrieval. Insert Job step and control for Stacking of
structure elevation
2.7.3 Use appropriate support as pallets, wood for secure stacking. pipe spool at site and structure elevation.
2.7.4 Pedestrian walkway shall be provided for the safe access.
3.1.1 Ensure workers to wear their complete PPE’S like helmets, safety
shoes, safety glasses, hand gloves, face shields, welding hood / apron
Modification/ 3.1 Personnel injuries like hand, eye
for welders prior commencing hot works.
Fabrication of injuries
3.1.2 All personnel who operate power tools must have hand and power Site Engineer,
spool in job site tool training conducted by the competent person and shall be issued Foreman,
with hand and power tools authorization card. Supervisor,
3
HSE Officer,
Permit Receiver
3.2 Potential burn injury/ produced 3.2.1 Signed hot work permit in hand prior to start of the activity.
spark /flames during hot works 3.2.2 For welding works, ensure workers are wearing welding gloves,
apron, welding hood, fire retardant clothing as their protection from
burns / spark / flames during hot works.
ACTION
BY
3.3 Unauthorized person being tasked 3.3.1 Only certified and Saudi ARAMCO approved welders are allowed to
for welding jobs perform welding job
3.4.1 Welding machine’s power outlets must be GFCI/ELCB protected

3.4.2 GFCI/ELCB shall have a maximum rated tripping current oft 10 mA.
3.4.3 All arc welding machines to be adequately earthed ground.
3.4 Electrical hazard / Electrocution 3.4.4 Proper routing / arrangement of welding cables shall be done. Do not
use damaged cable
Welding, Brazing and 3.4.5 Refrain to do welding jobs on wet areas that might trigger to
Cutting electrocution.
Consumable 3.5.1 A trained fire watch shall be assigned and he must remains in the
electrode storage area until 30 minutes after work completion to detect smoldering fire
Storage and use of and ensure safe condition.
compressed
3.5.2 Housekeeping including material arrangement and segregation will
gas cylinders
Welding generator
be implemented.
Welding and cutting 3.5.3 Any hot work to be initiated such as torch cutting of tie rods, etc. will be
at elevation made only after implementing the following:
Plasma cutting 3.5.6 Only competent personnel are allowed to do the activity.
PWHT (Post weld 3.5 Fire hazard 3.5.7 Fire Extinguisher available in the hot work area, currently inspected
heat treatment) / color coded.
3.5.8 Work area shall be isolated and ensure only employees involved
are within the barricaded area.
3.5.9 Protect and cover all nearby existing facilities from falling hot splatters
(Cable wires, gauges, valves, etc.) with fire blankets.
3.5.10 Oxy-Acetylene cylinders to be kept away from welding, cutting
Operations, falling hot splatters.
3.5.7 Flashback arrestor to be installed after oxy-acetylene cylinders and before
cutting outfit. uddimx0b
2024-01-03 11:44:59
-----------------------------------------
---
Installation of pipe 4.1.1 Fall protection training shall be provided for personnel exposed to fall Insert of all break down job steps
spool, pipe hazards. of welding and cutting and then
4 capture their hazards & controls,
support, fittings, 4.1 Falling of material or object 4.1.2 Fall hazard recognition and mitigation measures.
Include Job steps-
flanges and valves 4.2 Falling of people 4.1.3 Use, operation and inspection of temporary guardrail systems (including Supervisor,
1.Consumable Electrode storage
perimeter safety cable systems), personal fall arrest systems, and fall
2. Gas cylinder Argon,acetylene
ACTION
BY
protection to be used and this needs to be engineered and signed by a permit receiver
structural engineer.
4.1.4 Secure the openings with the hard barricade to prevent falls through
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2024-01-03 12:25:54
holes and openings in walking/working surfaces and walls.
--------------------------------------------
4.1.5 Removal of planks adjustment or scaffold modification is only Add-
will be
requested by scaffold erector only and proper supervision andRemoval
control.of planks adjustment or any scaffold
4.1.6 Restricted to piping team for any scaffold modification and adjustment.
modification is only will be requested by
4.1.7 STARRT meeting to be conducted prior to start the work by jobscaffold
supervisor,
erector only and proper supervision and
all associated hazards to be communicated to the involved workers.
control. Restricted to piping team for any scaffold
4.1.8 Work platform should be provided in accordance with SA CSM II-2, GI and adjustment.
modification
8.001 standard procedures.
4.1.9 Full body harness must be inspected by its user on a daily basis prior to
start the work and periodic inspection is also done by a competent fall
protection equipment inspector.
4.1.10 Full body harness must be use to protect from falls at a height of 1.8m
and all full body harness needs to have a double lanyard and also
suspension trauma straps are attached to the safety harness.
4.1.11 Partially completed pipe assemblies shall be ensure the stability and
secured with proper support.
4.1.12 Pipe installation personnel performing activities on walking/working
surfaces with unprotected sides or edges more than 1.8 m (6 ft.) above
a lower level shall be protected by a guardrail system, and personal fall
arrest system, etc.
4.1.13 Competent workers for the working at height to execute the activity and
the involved workers must be physically, mentally and medically fit for
working at height. Any health issue to be reported immediately to HSE
department to take appropriate action on timely manners.
4.1.14 Mandatory PPEs i.e., hard hat, hand gloves, safety shoes, safety goggles,
reflective vest etc. must be worn at all the times at site. Additional PPEs
shall be provided according to the job requirement.
4.1.15 OSHA, BLS and First Aid certified supervisor to be assigned to be

assigned to monitor the ongoing construction activities.
4.1.16 Appropriate safety Signage to be installed around the working area and
bulletin board with emergency contacts list shall be posted on job
sites.
4.1.17 The work at height will be ceased in case the wind speed is 65km/h
or above, and during rains.
ACTION
BY
4.1.17 Personnel involve in working at height shall tie-up their hand tools
with rope to their waist to prevent tools from falling.
4.1.18 No excess material shall be left and/or installed on top of the
structure where the work is ongoing.
4.2.1 Cranes shall be inspected by the crane operator prior to each shift.
4.2.2 Lifting plan shall be prepared by the SA certified rigger prior to lifting .
4.2.3 Slings shall be in accordance with GI 7.029 and ASME B30.9 or
equivalent. Other rigging hardware shall be in accordance with GI
7.029 and ASME B30.20 and manufacturer certificate is available with
the information of proof load test of 200%.
4.2.4 The SA certified rigger shall visually inspect slings and other rigging
hardware prior to each use per GI 7.029 and each sling shall have its
own sling inspection log (SA 9657)
4.2.5 Before starting the activity, the perimeter of the area must be excluded
/barricaded and warning signage shall be posted including emergency
contact list.
4.2 Lifting work to include lifting of 4.2.6 Tag lines shall be used to control suspended loads, unless their use may
pipes, pipe support and other cause a greater hazard. Tag lines shall not be tied around the
work-related material hand/wrist. They shall be fully gripped by all fingers.
4.2.7 During the placement of pipe spools, loads shall not be released from
the hoisting line until the spools are properly secured.
4.2.8 All lifting work will be stopped immediately when the wind speed
exceeds the 32km/h; the boom will be brought down and secured.
The lifting work will be stopped as per the weather condition
depending on the visibility.
4.2.10 Clear communication and clear visibility to be always maintained
between the operator and the rigger concerning the lifting load.
4.2.11 ALL lifts are directed by certified rigger as per GI 7.028. Rigger III can
rig load up to 10 tons, Rigger II can rig load up to 40 tons and rigger
I can rig all loads and approve critical lift plan.
4.3 Crane tipping over 4.3.1 Check wind speed and do not lift when wind speed is or more than
32km/hour.
ACTION
BY
4.3.2 Always follow load chart for lifting any load.

4.3.3 ASLI (automatic Safe Load Indicator) must be operative and
crane operator must not lift any load out of the load chart limit.
4.3.4 Check wind speed and do not lift when wind speed is or more than
32km/hour.
4.3.5 Use wooden mats under the crane outriggers to distribute the load.
4.3.6 Do not position the crane outriggers near any drain line otherwise
there is a chance of sinking of these outriggers resulting in crane
tipping over.
4.4.1 Trained banks men must guide the crane when moving inside the plant.
4.4.2 Crane positioning must be checked via site visit and marked on plot plan
4.4 Crane hitting the existing facilities of the plant to ensure that ground is stable for bearing crane weight.
4.4.3 Crane Operator and banks man shall ensure the safe distance from plant
facilities.
4.5.1 Check the maximum load of the crane to avoid overload
4.5.2 Check the ground where the crane is installed to avoid rollover
4.5 Crane topple, suspended load and 4.5.3 Be sure that a banks man is in the area to avoid any incidents damages
drop, hit on to personnel and 4.5.4 Lifting plan, permit to work, equipment maintenance and checklist,
structure competent crane operator, cordon off the lifting zone and correct rigging
method, competent rigger and signal man, tag line to control the load.
4.6.1 Use ear plugs if the noise exceeds 85db.

4.6.2 Adequate maintenance of the equipment must be performed to
4.6 Noise avoid unnecessary sound.
4.6.3 Safe distance to the equipment must be maintained by the crew for
low decibel levels.
4.7.1 All hand tools must be inspected by the person who’ll be using them
4.7 Physical and health hazards from
prior to be used.
using different types of tools
4.7.2 All damaged tools will be removed from site and replaced by new one. No
one is allowed to use an improper hand tool.
ACTION
BY
4.7.3 Mandatory PPE (hard hat, safety glass, safety shoes, and hand gloves)
to be worn at all times while working.
4.7.4 Worker who will use any type of power tool must be competent.
4.7.5 The machine being used must be inspected on a daily basis prior to
be used.
4.7.6 The machine being used must have a good condition emergency stop
switch (dead man switch), with good condition working start and
stop switch. All switches must be color coded and labeled.
4.7.7 All power tools must be inspected on a daily basis prior to be used.
4.7.8 Job-made extension cords shall be fabricated by an authorized/certified
electrician and IEC IP55 or higher rated receptacle and plugs shall be
used as per CSM I-11.
4.7.9 To make sure that suitable tool will be used for the job.
4.7.10 All personnel using the hand and power tools shall have hand and
power tools training received from the competent person and issued
with hand and power tools authorization card.
4.8.1 Damaged power tools will not be allowed to use at site. The damages
will be reported to the assigned safety officer and the power tool will
be removed from site. (The damages will include, but not limited to,
broken switch, substandard wiring, etc.).
4.8.2 All cable extensions will be arranged and extended by electricians only.
The electrician will make sure that the cable extension is in good
4.8 Electrocution condition free from any defects or substandard connections.
4.8.3 No cables will be exposed at site unless it’s mandatory upon the site
condition, if so, the cables will be elevated by non- conductors’ poles to
allow the people to pass below them without obstructions and without
being affected by them.
4.8.4 No cables will be fixed conductor material or structure, such as: scaffold,
fence, etc. if so than the cable must be protected by non-conductor
material such as PVC pipe.
ACTION
BY
4.8.5 Cable arrangements will be implemented at site. All cables will be buried
under ground where possible, after being isolated by non-conductor
material such as flexible or non-flexible PVC pipes.
4.8.6 Signage will be installed showing the location of the buried cable, with
emergency contact list.
4.98.7 All generators will be guarded (barricaded), and will be installed under a
shade, inside the spill tray or bund area. No one is allowed to switch on
the generator, switch it off, maintain it, connect wires, etc. other than the
electrician.
4.8.8 Daily inspection to be made for the generator. The generator will be
serviced and maintained periodically.
4.8.9 No worker will be allowed to use the control panel whether by connecting
cables, replacing a breaker, etc. only electricians are allowed to do this
task.
4.8.10 Electrical panel or DB will be barricaded and inspected on a daily basis.
4.8.11 One line diagram shall be posted on the electrical panel.
4.8.12 Signage and emergency contact list will be installed.
4.8.13 GFCI will be installed at the panel board with sensitivity of 10mA.
4.8.14 All panel boards will be locked and the keys will be kept only with the
designated electrician.
4.9.1 No smoking policy shall be enforced at all site unless

indesignated smoking areas.
4.9.2 Housekeeping including material arrangement and segregation will
be implemented.
4.9.3 Any hot work to be initiated such as torch cutting of tie rods, etc. will be
made only after implementing the following: HSE officers, supervisor
4.9 Fire 4.9.4 Hot work permit shall be in place to perform the spark
producing activities.
4.9.5 Combustible material around the work area shall be removed and/or
protected against sparks, slag or heat using fireproof material or by
wetting if appropriate. This includes combustible material below an
elevated welding or cutting work area.
4.9.6 Only competent personnel are allowed to do theactivity.
4.9.7 Appropriate mandatory PPEs shall be worn to include wind shield, goggles,
ACTION
BY
helmet, welding gloves, & welding aprons.

4.9.8 Fire extinguisher to be available always at the working areas and near
machinery. Training will be given to all involved personnel regarding the
proper usage of the fire extinguisher.
4.9.9 A qualified fire watch shall be assigned to any cutting, welding or burning
operation. The fire watch shall remain in the work area during these
activities and for no less than 30 minutes after the hot work has
finished.
4.9.10 The location of the fire extinguisher will be of 2m minimum and
5m maximum away from the source of ignition.
4.9.11 The fire points will be free from obstacles at all times.
4.9.12 Fire extinguisher will be inspected on a monthly basis(or
otherwise needed), tagged and registered.
4.9.13 Daily housekeeping will be conducted at site. All excess material will
be removed immediately and shall not be stored.
4.9.14 All packaging shall be removed immediately from site and stored in
a well-ventilated area, and protected from the direct sunlight.
4.10.1 Adequate drinking water will be provided and available.

4.10.2 Work breaks in the shelter will be made at regular intervals as
required by weather conditions.
4.10.3 Survey activities will be suspended in the event of adverse
weather conditions.
4.10.4 Workers must stop the tasks and report immediately to supervisor
in case of any heat stress symptoms(headache, nausea, dizziness
4.10 Heat Stress and weakness.)
4.10.5 Provide emergency contact number in case of emergency.
4.10.6 All personnel shall completed heat stress awareness training prior
to performing work during hot weather.
4.10.7 Do not work alone and buddy system shall be implemented.
4.10.8 Acclimatization process shall be implemented to expose new workers
to work in a hot environment for progressively long period.
4.10.9 Forced water parade shall be performed to encourage workers to drink
plenty of water to avoid dehydration.
ACTION
BY
4.11 Pinch points 4.11.1 Cut-resistant gloves shall be worn.

4.11.2 Place and maintain warning sign adjacent to pinch point hazards.
4.12 Improper steel materials support 4.12.1 Metal adjustable jacks shall be used with SWL indication on the support.
4.12.2 All supports shall be inspected and approved by the third party and
SWL is clearly marked.
Rigging foreman,
5.1.1 Fall protection training shall be provided for personnel exposed to Site Engineer,
fall hazards. HSE Officer
5.1.2 STARRT meeting to be conducted prior to start the work by job Work permit receiver
supervisor, all associated hazards to be communicated to the
involved workers.
5.1.4 Work platform should be provided in accordance with SA CSM II-2, GI
8.001 standard procedures.
5.1.5 Full body harness must be inspected by its user on a daily basis prior
to start the work and periodic inspection is also done by a competent
fall protection equipment inspector.
Stringing of pipe 5.1.6 Full body harness must be use to protect from falls at a height of 1.8m
5.1 Falling Hazards
5 and all full body harness needs to have a double lanyard and also
in the pipe rack
suspension trauma straps are attached to the safety harness and
using chain block
should meet ANSI Z359.1 standard.
and pipe roller 5.1.7 Pipe installation personnel performing activities on walking/working
surfaces with unprotected sides or edges more than 1.8 m (6 ft.)
above a lower level shall be protected by a guardrail system, and
personal fall arrest system, etc.
5.1.8 Competent workers for the working at height to execute the activity
and the involved workers must be physically, mentally and medically fit
for working at height. Any health issue to be reported immediately to
HSE department to take appropriate action on timely manners.
5.1.9 The work at height will be ceased in case the wind speed is 65km/h
or above, and during rains.
ACTION
BY
5.2.1 Barricading the area below where objects can fall and not permitting
personnel to enter the hazard area. Unauthorized entry or tress
passing the working area shall be strictly prohibited and controlled.
5.2.2 Secure the openings with the hard barricade to prevent falls
through holes and openings in walking/working surfaces and walls.
5.2 Falling of objects ( Materials 5.2.3 Personnel involve in working at height shall tie-up their hand tools
and tools) with rope to their waist to prevent tools from falling.
5.2.4 No excess material shall be left and/or installed on top of the structure
where the work is ongoing.
5.2.5 Appropriate safety Signage to be installed around the working area and
bulletin board with emergency contacts list shall be posted on job
sites.
5.2.6 Material shall not be stored in the working platform.
5.3.1 Cut-resistant gloves shall be worn while handling the pipe.
5.3.2 Personnel must avoid placing themselves within potential pinch area
while controlling the pipe.
5.3 Pinch points 5.3.3 Work areas shall be maintained so that all persons involved in stringing of
pipes shall be able to see and be seen by all other persons engaged in the
same activities.
5.4.1 Approved safe work procedure (MS) shall be followed.

5.4.2 Shifting of pipe spools on pipe rack should be done using roller or chain
blocks with SWL indication on the them.
5.4.3 Pipe roller shall be secured and bolted to structural beam and
5.4 Inadequate procedure or Unsafe inspected by the competent person prior to start the pipe shifting work.
work procedure 5.4.4 Pipes shall not be dragged, dropped, rolled or pulled while string along
the pipe rack.
5.4.5 Pipe shall not be loaded or stored on the scaffold working platform.
5.4.6 During erection of pipework, suitable additional temporary support shall
be provided to ensure that no extra stresses are imposed on the pipe or
connected equipment.
ACTION
BY
5.4.7 Scaffolding shall not be used as lifting point of attachment for lifting device
unless specially designed for that purpose.
5.5.1 All lifting slings and shackles shall have their manufacturer's certificate
indicating 200% load test and complies with B30.9 or B30.2.
5.5.2 All lifting slings and shackles shall be inspected before use and also
periodically by the SA certified rigger and records of inspection entered
5.5 Defective lifting gears
into the sling log.
5.5.3 Chain block shall meet the requirement of ASME B30.16.
5.5.4 Defective lifting gears shall be immediately discarded from service.
6.1.1 Make sure before establishing the manlift ground condition shall be
6.1 Unstable ground condition
suitable and compacted.
6.2.1 Ensure all moving heavy equipment’s shall be assisted by flagman. Rigging foreman,
6.2.2 Flagman shall keep the safe distance to run over on him while supervisor, certified
equipment operation. rigger, crane operator
6.2 Run over / Struck by equipment piping supervisor,
.2.3 Ensure area shall be barricaded and signage's shall be in place.
safety officer,
6.2.4 Make sure unauthorized entry shall be stopped during the manlift permit receiver
operation.
6.3.1 Always observe the area free from men, machinery interference.
6.3 Collision 6.3.2 Equipment shall be operated with flagman and warning alarm shall
6 Manlift Operation
be fitted on man lift to caution people working around.
6.4.1 All fall protection equipment shall be inspected monthly by the
competent fall protection equipment inspector and before use by
6.4 Poor Maintenance the user.
6.4.2 Makes sure the hydraulic lines are connected properly.
6.4.3 Visual checking shall be done on daily basis for any leaking part.
6.5.1 Manlift must have third party inspection and shall be inspected prior
to use. It shall be inspected and sticker issued by JGC.
6.5 Equipment failure
6.5.2 Work shall be stopped when wind speed reaches 32 kph or more.
6.5.3 Manufacturer’s operation manual shall be present and followed.
ACTION
BY
6.5.4 Conduct a daily documented pre-use inspection/function test of manlift.

6.5.5 Inspection shall be done on daily basis as per check list.
6.6.1 Workers inside man basket shall wear the inspected safety belt and
apply the 100 % Tie-off policy.
6.6.2 Ensure all working crew shall be trained on work at height training.
6.6.3 Materials and tools shall be secured properly and no simultaneous
work activity below, barricade and post signage below.
6.6 Falls (man, materials and tools). 6.6.4 Fully close and secure shut all entrance gates or chains before moving
or raising the manlift.
6.6.5 Loss Prevention's best practice for fall protection shall be filled up
and implemented on site.
6.6.6 Workers using the manlift shall have attended the Work at height training.
6.7.1 Sufficient gap shall be maintained from nearby structures/materials.

6.7.2 Ensure standby man shall be assign near manlift for emergency switch off.
6.7.3 Personnel awareness of objects that could strike the body or result in
a whole body pinch point type of injury (such as exposure to low
6.7 Caught in between /Pinch Point head space clearance issues, or head/body/extremities caught
between stationary object and manlift equipment components)
when working from manlift where a whole body pinch point injury
could occur.
6.7.4 Ensure adequate PPE shall be worn.
6.7.5 Ensure the anti-entrapment device is installed and operational.
6.8.1 Personnel shall be trained, qualified and certified for the specific manlifts
6.8 Unqualified Person utilized they will be utilizing.
6.8.2 Two operators will be required for each man lift operation. One on the
operator controls and another on the ground console.
6.9.1 Make sure carried weight is not larger than the capacity of
manlift platform and Only personnel shall use the manlift and
6.9 Tip-Over not tools, equipment or loads.
6.9.2 Ensure horizontal and vertical reach limit shall not be exceeded and
never override the safety device.
6.9.3 Make sure manlift shall not be operated if wind speed exceeded 32kph.
ACTION
BY
6.9.4 Ensure platform shall not be pushing or pulling while it is in air.

6.9.5 If restricted range of motion is selected so do not move machine into
unrestricted range of motion area.
6.9.6 Ensure surface shall be level and solid.
6.9.7 Make sure do not raise the boom unless the machine is on firm level
surface.
7.1 People being exposed to radiation 7.1.1 Access to controlled areas (high radiation areas) shall be restricted to Radiation Safety Officer
authorized personnel only. NDT Coordinator, NDT
technician
7.1.2 Radio graphic work shall immediately stop if unauthorized personnel enter
a controlled area.
7.1.3 Only authorized and certified personnel shall perform the radio
graphic test.
7.1.4 NDT technicians shall have the following radiation dosimeters and
monitoring devices, as a minimum:
 Calibrated radiation survey meter
 Thermoluminescent dosimeter (TLD) or film badge

NDT (Non-
7
Destructive Test)  Pocket or electronic dosimeter
 Personal radiation alarm (combined with a electronic dosimeter)
uddimx0b
2024-01-03 11:26:10
7.2 Unauthorized access 7.2.1 Ensure and verify the control measures by radiation safety officer.
--------------------------------------------
7.2.2 Plan the activities at silent hours lunch break or at night. Ensure and verify the control measure by
Radiation safetyRadiation
officer- Safety Officer
7.2.3 Area shall be shielded or barricaded with proper signage and standby
-Incorporate the control NDTasCoordinator,
follow,
man.
-Plan the activities for NDT at silent hours lunch
NDT technician
7.2.4 All NDT personnel comply the PPE including radiation suit. break or at night.
7.2.5 Controlled areas (where high levels of radiation may exist during-Area
radioshould be shielded or barricaded with
graphic operations) shall be barricaded and radiation warning sign shall
be posted.
7.2.6 24 hours of prior notification shall be disseminated to all the
affected contractor with safe distance calculation.
ACTION
BY
7.2.3 implement clear access control and establishing restricted zone.

Watchman shall be assigned.
7.3 Incompetent personnel 7.3.1 Contractor and subcontractor personnel performing radiography
NDT activities shall be certified per SAEP-1142.
Radiation Safety Officer
7.3.2 Ensure to follow the guidelines from Saudi Aramco GI 150.007. NDT Coordinator,
NDT technician
7.3.3 All personnel performing radiographic film interpretation (RTFI) shall be
certified to Level II and have met the requirements of SAEP-1140 or
SAEP- 1142, as applicable. Personnel performing RTFI shall have passed
the SA RTFI examination and be in possession of a valid RTFI certification
card.
7.3.4 Ensure that personnel operating the radioactive equipment are

adequately trained and certified in radiation safety procedures
8.1 Lack of housekeeping resources, 8.1.1 Proper planning and look ahead by Discipline Supervisor. Prior
Uncollected spoils, refuse, to commencing work, as part daily progress, he shall plan for:
Obstructed access (ladders, - Housekeeping resources - hauling equipment (loader, dump
walkways, exits), Slip, trips, fall trucks, forklift) and dedicated crew.
hazards, Fire hazards (combustible - Regular collection of rubbish, every end of shift at minimum Rigging foreman,
refuse uncollected), Dropped, - Waste skips / covered metal trash bins / disposable trash bags, etc. certified rigger, crane
Improper materials stacking or - Temporary staging area of scrap materials operator, supervisor,
- Pre-arranged staging area for construction materials, tools safety officer, permit
segregation
receiver
8 Housekeeping and equipment
- Access for personnel and equipment
- Barricades / signs required
8.1.2 Each working crew, upon work completion or end of shift, shall:
- Inspect and tidy up work area, make overall condition safe
- Collect hand tools, roll temporary cables up and safely organize
- Switch machines off, move to assigned staging area.
- collect / dispose of rubbish in waste skips.
8.1.3 Adequate supplies of housekeeping consumables to be maintained e.g.,
push brooms, disposable trash bags, etc.-
ACTION
BY
8.1.4 Use wooden pallets for proper stacking or handling of light materials
8.1.5 Permanent materials to be isolated and identified from construction
materials
8.1.6 Excavation debris shall be collected without delay and at minimum
disposed of daily at approved dump site pre-assigned by JGC or SAPMT
and/or local municipality.
8.1.7 Craft Supervisors shall always pay due regard to acceptable housekeeping.
8.1.8 Good housekeeping compliance to be enforced through daily work
permits
8.1.9 Task-specific JSA to be developed by Craft Supervisor shall include proper
housekeeping & requirements followed.

ZULUF PROJECT (0-8887) : 10-08643-0005 Saudi Aramco 0-8887-2-P-3130-MC2-A GAS-JGC-MOS-MECH-006 FA NMR Ref NO

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ZULUF PROJECT (0-8887)

SA JOB ORDER NO. 10-08643-0005 OWNER SAUDI ARAMCO

PO NO. 0-8887-2-P-3130-MC2-A PURCHACER JGC

VENDOR NAME GAS ARABIAN SERVICES COMPANY

METHOD STATEMENT & JSA FOR ABOVE GROUND PIPING

Subcontractor Name GAS Arabian Services

Contractor Name JGC Corporation

Company Name Saudi Aramco

Contractor Doc. No. V-3130-MC2-A-1006

Subcontractor Doc. No. GAS-JGC-MOS-MECH-006

METHOD STATEMENT & JSA FOR ABOVE GROUND PIPING

Zuluf Onshore Oil Facilities Project

00 25-Nov-2023 All Issue for approval Riyaz Relish Munawar

Issue / Revision Record

7.0 Material Receiving, Handling and Storage 8

8.0 Erection and Installation 16

ISSUE / REVISION RECORD

Issue Revision Paragraph Description Date

ANSI / ASME B31.3 - Process Piping

METHOD STATEMENT & JSA FOR

Document No Issue Revision Page No

METHOD STATEMENT & JSA FOR

3.10 GAS - GAS Arabian Services

Document No Issue Revision Page No

METHOD STATEMENT & JSA FOR

METHOD STATEMENT & JSA FOR

Document No Issue Revision Page No

METHOD STATEMENT & JSA FOR

PIPE PUNCHING MACHINE

6.2 PERSONNEL / WORKFORCE

 Mechanical / Piping Engineer

7.0 MATERIAL STORAGE AND HANDLING

Document No Issue Revision Page No

METHOD STATEMENT & JSA FOR

 Preservation of equipment shall be in accordance with relevant preservation procedures.

A.MATERIALS TO BE STORED INSIDE THE WAREHOUSE

B.MATERIALS TO BE STORED UNDER SHED

 Complete rotating machines

 Refractory materials that do not need to be assembled immediately.

C.MATERIALS TO BE STORED IN UNCOVERED AREA

Document No Issue Revision Page No

METHOD STATEMENT & JSA FOR

D.TRACEABILITY AND IDENTIFICATION OF MATERIALS

E.USE AND APPLICATION OF RUST PREVENTIVES

Document No Issue Revision Page No

METHOD STATEMENT & JSA FOR

3. Pipes shall not be drawn or rolled on the ground.

 Rust preventive or grease must not be used on pre-cleaned pipe spools.

7. Requirements for coated pipes

METHOD STATEMENT & JSA FOR

b) Ends of threaded couplings shall be protected by means of caps.

Document No Issue Revision Page No

METHOD STATEMENT & JSA FOR

b) They shall be raised off the ground on wooden planks.

d) 0-Ring Type grooves shall be protected with lubricating grease.

e) Assembly of flange faces shall be done as per SAES-L-109.

c) They shall be handled in the same way as the pipe.

Indoor storage is required for all valves except the following: