Valves Installation Method Statements

PROJECT TITLE : REFURBISHMENT & UPGRADING WORKS FOR
VARIOUS PUMPING STATIONS (PHASE – 8)
PROJECT NUMBER : CP 729/2
CLIENT : ASHGHAL
CONSULTANT : PARSONS INTERNATIONAL LIMITED
DOCUMENT NO. : 729/2-GEN-DOC-0113
PETOSERV DOC’ NO : PT/CED-5058/MS/ M /025
REVISION : 01

METHOD STATEMENT FOR

INSTALLATION OF GATE VALVES &
CHECK VALVES (PS-17,PS40 &PSW1)
PETROSERV LTD
P.O.BOX: 7098
DOHA-QATAR
METHOD STATEMENT FOR 729/2-GEN-DOC-0113
PETROSERV LTD INSTALLATION OF GATE Revision 0
DOHA - QATAR VALVES AND CHECK VALVES Date 10.10.2012
(PS-17,PS40 & PSW1) Page 2 of 38
1 10-10-2012 For Approval MOHAMMAD REHAN SUNEED SUBAIRKUTTY AMR GAMAL

0 13-08-2012 For Approval MOHAMMAD REHAN SUNEED SUBAIRKUTTY AMR GAMAL
Approved By
DESCRIPTION Reviewed By Project
RE
DATE Prepared By (PETROSERV) Construction Manager
V Engineer(PETROSERV)
(PETROSERV)
INDEX
CONTENT TITLES PAGE NO.

1.0 Purpose 4
2.0 Scope of Work 4

3.0 Reference & Attachments 4
4.0 Equipment 4
5.0 Responsibility 5-7
6.0 Safety precautions. 7-8
7.0 Preparations 9
8.0 Sequence of activity for installation. 9
09. Pre requirement and handling and storage 10-11
10. Installation of valves 11-15
11. Final Check 15
12 (A) Weight of valves. 15-16
(B) Lists of items to be installed 17
13. HSE plan 17
14. Attachments: 17-18
a) Risk Assessments (Page No.19 to 22)
c) Contract Drawings no. (17-W356, 40-W357, W1-W358) (Page No.23 to 25)
d) Installation inspection checklist valves (Page No.26)
e) Approved ITP for valves (Page No.27 to 28)
f) RFI form (Page No.29)
g) Valves schedule (Page No.30 to 38)
h) Approved shop drawings.
i) Approved P &ID.
j) Approved valve foundation (concrete base) drawings.
k) Valid calibration test certificate for the devices.
l) Operation and maintenance Manual.
1. PURPOSE:
The Purpose of this Method Statement is to installation of valves in pumping stations PS-
17, PS40 & PSW1 and describes the sequence of activities involved in.
2. SCOPE OF WORK
This document applies to manage efficiently and control the supply and install of valves and
accessories s in the pumping station on going to attain the zero tolerance accident.
3. REFERENCE & ATTACHMENTS

3.1.1 Project Specification (volume 2 of 4) –Section C Part 1, Clause 3.2.2 (d &e), Clause
3.3.2 (e &f), Clause 3.4.2 (e &f).
3.1.2 QCS 2007 Specification , Section 8 –Part 5
3.1.3 Relevant Construction Drawings (17-W356, 40-W357,W1-W358)
3.1.4 Approved Material Submittal
3.1.5 Hazard Risk assessment
3.1.6 Checklist for installation of valves
3.1.7 Approved ITP for valves
4. EQUIPMENTS:
1. Jack hammer
2. Hand tools (sprit level, torque wrench, spanner and screw driver sets).
3. Crane capacity 20-50 ton.
4. Chain Block (2 ton)
5. Grinding and drilling machine.
6. Wire rope /nylon slings.
7. Ladders.
8. Fork lift.
5. RESPONSIBILITY
5.1 PROJECT MANAGER:

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

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

Project Engineer is responsible for the overall site operation and works. He shall
ensure that the appropriate procedure is followed by all the involved personnel taking
into consideration all relevant shop drawings, Reference drawings, statutory bench
marks and reference points and methodologies are correctly utilized. Responsible for
the overall fabrication installation, testing and commissioning activities. Responsible
for planning of site organization, resource mobilization, subcontracting, site operation,
construction methods and scheduling etc. ensure that proper approved documents are
in place prior to start of production activities.
5.4 SITE ENGINEER:-
5.4.1 Co-ordination with all site personnel & control of Labour.
5.4.2 Direct monitoring and supervision of work.
5.4.3 Tool Box talk to Labour.
5.4.4 Confirming Health Safety Environment.
5.5 SAFETY OFFICER: -(these responsibilities are included but not limited to):
5.5.1 Assists the Project Manager for implementation and monitoring of

the HSE system.
5.5.2 Carries out Hazard Risk Assessment for the site.
5.5.3 Ensures work site is in safe conditions.

5.5.4 Ensures calibration & approval of all lifting equipments and

machineries.
5.5.5 Ensures first aid and emergency procedures for the site are established and
maintained.
5.5.6 Coordinates with the client for any safety related requirements at site.
5.5.7 Arranges safety induction program for the site personnel as required. He ensures
that daily toolbox meetings are conducted by Site foremen/Supervisor.
(Refer H.S.E plan clause 8.6 Page no. 12 & 13 of 43)
5.6 QUALITY CONTROL:
Quality is a throughout process of installation, testing & commissioning of the system.

However following steps shall be followed.
1. QA/QC Engineer along with project engineer will monitor that all components are
installed as per contract specifications and approved submittals.
2. Works inspection shall be submitted to Main contractor/consultant for the

following stages of work as per ITP: a) material receiving/inspection. b)
Installation of valves. C) Testing and commissioning of valves.
6.0 SAFETY PRECAUTIONS:
All work shall be carried out in accordance with approved PETROSERV’s project
safety plan. All personnel shall be provided with necessary personnel protection
equipment (PPE) and given required training to ensure that all personnel involved in
the work are aware of importance of safety precautions, equipments and consequences
of abusing them. Excavation permits will be prepared to ensure that all necessary
precautionary measures have been taken and other requirements are fulfilled.
a) In deciding manning levels account must be taken of the location of manholes

and sewerage facilities in relation to availability of means of summoning
assistance in emergencies.
b) Unattended open manholes must be safely protected by suitable barriers.
Remember that some people are visually handicapped.
c) Whenever possible covers shall be lifted using lifting keys and proper lifting
and handling techniques or by the use of hydraulic or other approved manhole
lifting device.
d) Before entering the manhole ensure that the cover has been removed to give
natural ventilation for minimum of 5 minutes.
e) Before enter the drywell and wet well proper ventilation will be used.
f) Test for toxic and flammable gases, and oxygen deficiency, using approved
detector. If toxic and flammable gases or oxygen deficiency is detected do not
enter the manhole.
g) Before the any lifting activity the area is cordon off with safety ribbons/tape.
h) All machine, vehicles & equipments operator shall have valid licences or
certificate or approval.
i) Proper and safe support temporary supports, scaffolding, platform and access
ladders will be provided. Erect and inspect the temporary works by authorized
specialist.
j) The approved electrical lockout/tag out safety procedure (doc no. 729/2-gen-
doc-0055) will be fallowed strictly followed & also approved HSE PLAN.
k) Refer H.S.E plan clause and there sub classes 16, 17, 18, 19, 20, 21, 22, 23, 25,
26, 27, 33, 34, 36, 39, 40. Document No.729/2- GEN-
DOC-0019)
7. PREPARATIONS:
A. DOCUMENTS
a. Entry permits from Ashghal to enter pumping station.
B. Confined space permit.
C. Lock out/tag out (LOTO).
D. Permit of work.
8. SEQUENCE OF ACTIVITY FOR INSTALLATION:
1. Mechanical Screen.
2. Penstock.
3. EOT Cranes.
4. Ductile Iron Pipes & Fitting.
5. Valves and actuators
6. Dry Submersible Main Pumps.
7. Sump and Transfer Pump
8. Odour Control Unit.
9. High Pressure and Potable Pump
10. Air conditioning & Ventilation.
11. Instrumentation & control system.
12. Electrical items.
13. Civil work.
NOTE: 1) item no.1 to 10 will be covered under mechanical installation
9. (A) PRE-REQUIRMENTS:
1. Ensure that approved materials are available to carry out the work.
2. Valves are transported from stores according to good engineering practice and physical
verification.
3. Prior to commencement of work, areas and access will be inspected to Confirm that safety
precautions ensured.
4. All relative documents (approved shop drawing and approved method statement) will be
checked by site engineer prior to commencement of work.
5. Arrangements of suitable access / scaffolding for erection.
6. Tool box talk will be conducted with all the people involved in the operation and discuss
about the past lifts observations, assign individual responsibilities before starting the job.
(B) HANDLING AND STORAGE:
1. Manufacturer storage instructions will be strictly followed as applicable.
2. Valves to be transported/unload as per manufacturer recommendation and by the
recommended equipment.
3. Storage area for valves has to be arranged with leveled wooden platform, the area
should be barricaded with tape.
4. Valves are to be unloaded from the vehicle by crane only.
Ensure that the vehicle parked in a safe area and parking brake is applied.
5. The valves should be kept on the wooden platform only.
6. The valves should not come into contact with any contaminative substances prior to
installation.
7. Always use fork lift to transport the valves.
8. The valves should be protected from direct sun light or moisture.
9. Hand wheels, actuators and gearboxes should not be used as lifting or rigging
points for valves.
(PS-17,PS40 & PSW1) Page 10 of 38
10. ITP will be checked for storage and handling, refer the attached ITP
10 INSTALLATIONS OF VALVES:
We have different models of gate valves and non return valves (check valves).
1. Series 54 Gate Valves (size 700 mm to 450 mm)
2. Series 37 Gate Valves (Size 300 mm to 100 mm)
3. Check valves 41/36 (Size 600 mm to 500 mm)
4. Check valves V2-08 (size less than 300 mm)
1) INSTALLATION DESCRIPTION OF SERIES 54 GATE VALVES:
A) BEFORE INSTALLATION OF THE GATE VALVES:
1. Take the picture to the area of valves erections.

2. Area of installation will be in the clean condition.
3. Installation will be carried according to manufacturer installation.
4. Check the weight of the valves to be handled safely.
5. All special packing material will be removed.
6. Ensure that the pipeline is completely free of debris or foreign matter.
7. Check the direction of operation/orientation of gearbox spindle.
8. Check the valve, by operating it two or three times to ensure freedom of spindle
rotation and movement of wedge (gate).
9. Check the EPDM gasket (4mm thick).
10. Check the gasket for freedom from injurious defects or damage.
11. Check the flow direction arrows particular on parallel faced valves or valves
having bearing plates on the wedge.
B) INSTALLATION OF THE GATE VALVES (ACTUATED & NON ACTUATED):
1. Use the correct bolts (diameter, length and material).
2. Prepare the concrete base for valve support

(PS-17,PS40 & PSW1) Page 11 of 38
3. Ensure that the seats and flange faces are clean.
4. The valves inside the chamber a crane is used for lowering the valve to position.
4.1 Inside the pump station fork lift will be used for transportation and
chain block will be used for positioning.
5. Place the valve between pipe flanges, and insert the bolts.
6. Wooden blocks will be used as temporary supports below the flanges.
7. Gasket will be inserted between the flanges and hold in position.
8. Bolts and nuts will be inserted on all holes of the flanges.
9. Tighten the bolts in a diagonal sequence to ensure flanges are pulled parallel.
10. Adjust the jack screw if required.
11. Finally tighten bolts to correct torque levels.
12. Remove the temporary supports.
13. Once the valves will be installed, check that the valve still functions correctly by
operating it for a minimum of five turns.
14. Inside the chamber extension spindle and stem cap will be installed as per approved
drawing.
15. Extension spindle support will be provided.
16. Proper Hand wheel will be installed for hand wheel operated gate valves.
17. For actuators valves connection will be provided as per electrical method statement.
18. All the external debris will be cleaned off from the external surfaces of the valve.
Same procedure will be followed in the installation of series 37 gate valves.
2. INSTALLATION DESCRIPTION OF SERIES 41/36 CHECK VALVES :

(PS-17,PS40 & PSW1) Page 12 of 38
A) BEFORE INSTALLATION OF SWING CHECK VALVES:
1. All the packing will be removed.
2. Valve direction will be corresponded with the direction of the flow.
3. Ensure that the pipeline is completely free of debris or foreign matter.
4. Check the foundation of the valve.
5. Check the EPDM gasket (4mm thick).
B) INSTALLATION OF SWING CHECK VALVES:
1) Prepare the concrete base for valve supports.
2) Use the correct bolts (diameter, length and material).
3. Ensure the valve interior through the end ports to determine whether it is reasonably clean and
free from debris.
4. Ensure the mating flanges facings for correct gasket contact face, surface finish and condition.
5. For external chamber the crane is used for lowering the valves to position.
5.1 For inside the pump station use fork lift to transport the valve and chain block to position
the valve.
6. Wooden block will be provided below the flanges for temporary support.
7. Care will be taken that the lever and weight will be free of obstruction in its path of
movement.
8. The weight will be installed at the end of lever and the bolts of weight will be tightened.
9. Place the valve between pipe flanges.
10. Insert the gasket between flanges and insert the bolts in the all holes of flange.
(PS-17,PS40 & PSW1) Page 13 of 38
11. Bolts will be tightened in a systematic manner to avoid undue stress in the body valve.
Same procedure will be followed in the installation of check valve V2-08.

12. Valve manufacturer representative will supervise the installation.
11. FINAL CHECK:

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

S.NO LOCATION DESCRIPTION DIA (mm) Weight (kg)
1 PS-17 ,PS-40 Gate valve Rising stem, with 700 1700
and PS-W1 Gearbox/Actuators
2 Gate valves non rising stem with 700 1650
spur gear box
3 Gate valve Rising stem, with 600 850
Actuators
4 Gate valve Rising stem, with Spur 500 640
gear box
S.NO DESCRIPTION DIA (mm) Weight (kg)
5 Gate valve Rising stem, with 500 670
(PS-17,PS40 & PSW1) Page 14 of 38
Actuators
6 Gate Valves Rising stem, with Spur 450 520
gear box
7 Gate valves Rising stem, with 450 540
Actuators
8 Gate Valves Rising stem, Hand wheel 300 270
9 Gate Valves Rising stem ,with Spur 200 150
gearbox
10 Gate valves Rising stem ,Hand wheel 150 80
11 Gate valves Rising stem ,with spur 150 100
gear box
12 Gate valves Rising stem ,with Bevel 150 100
gear box
13 Gate valves Rising stem ,with 150 100
PS-17 ,PS-40 Actuators
14 and PS-W1 Gate valves Rising stem ,Hand wheel 100 60
15 Swing Check valve with lever, 600 1070
weight, guard and proximity switch
12 (B) LISTS OF VALVES TO BE INSTALLAED:

Detail of valve for each pumping station please refers the Page No.30 to 38.
13. HSE PLAN:

(PS-17,PS40 & PSW1) Page 15 of 38
Emergency plan (Section 40) covers all the potential emergencies as per Do. No. : 729/2-
GEN-DOC-0019
(1) .Emergency Evacuation Procedure:

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

Police Civil Defense and Emergency -999
Water and Electricity Emergency - 991
Accident and Emergency – Hamad Hospital - 44392111
Telephone Directory - 180
Construction manager: Mr. Amr Gamal - 66237128
Project Engineer- Mr.Suneed SubairKutty - 66834721
Safety Officer – Mr. Jithin S. - 55363249
14. ATTACHMENTS:
a) Risk Assessments (Page No.19 to 22)
c) Contract Drawings no. (17-W356, 40-W357, W1-W358) (Page No.23 to 25)
d) Installation inspection checklist valves (Page No.26)
e) Approved ITP for valves (Page No.27 to 28)
f) RFI Form (Page No.29)
g) Valves schedule ((Page No.30 to 38)

h) Approved shop drawings (to be attached once getting approved).
i) Approved P &ID (to be attached once getting approved).
j) Approved valve foundation (concrete base) drawings (to be attached once getting
approved)
k) Valid calibration test certificate for the devices (to be provided prior the start of
installation)
(PS-17,PS40 & PSW1) Page 16 of 38
l) Operation and maintenance Manual.

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PROJECT TITLE : REFURBISHMENT & UPGRADING WORKS FOR

VARIOUS PUMPING STATIONS (PHASE – 8)

PROJECT NUMBER : CP 729/2

CONSULTANT : PARSONS INTERNATIONAL LIMITED

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

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

METHOD STATEMENT FOR

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

CONTENT TITLES PAGE NO.

2.0 Scope of Work 4

3. REFERENCE & ATTACHMENTS

5.1 PROJECT MANAGER:

5.2 CONSTRUCTION MANAGER:

5.3 PROJECT ENGINEER:

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

5.4.2 Direct monitoring and supervision of work.

5.4.3 Tool Box talk to Labour.

5.4.4 Confirming Health Safety Environment.

5.5.1 Assists the Project Manager for implementation and monitoring of

5.5.2 Carries out Hazard Risk Assessment for the site.

5.5.3 Ensures work site is in safe conditions.

5.5.4 Ensures calibration & approval of all lifting equipments and

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

5.6 QUALITY CONTROL:

Quality is a throughout process of installation, testing & commissioning of the system.

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

6.0 SAFETY PRECAUTIONS:

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

8. SEQUENCE OF ACTIVITY FOR INSTALLATION:

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

(B) HANDLING AND STORAGE:

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

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

should be barricaded with tape.

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

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

7. Always use fork lift to transport the valves.

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

1) INSTALLATION DESCRIPTION OF SERIES 54 GATE VALVES:

A) BEFORE INSTALLATION OF THE GATE VALVES:

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

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

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

2. Prepare the concrete base for valve support

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

chain block will be used for positioning.

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

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

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

10. Adjust the jack screw if required.

11. Finally tighten bolts to correct torque levels.

12. Remove the temporary supports.

operating it for a minimum of five turns.

15. Extension spindle support will be provided.

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

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

A) BEFORE INSTALLATION OF SWING CHECK VALVES:

1. All the packing will be removed.

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

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

4. Check the foundation of the valve.

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

B) INSTALLATION OF SWING CHECK VALVES: