ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT

METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE

& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

DRC– IRAQ

ZUBAIR OIL FIELD DEVELOPMENT PROJECT

Method Statement for Hot Insulation Works

Rev Issue Date Description Prepared by Reviewed by Approved by

s
Naveed Ahmed Mohammad Bagher Thamer Younes
00 04-08-2020 First Time

Naveed Ahmed Mohammad Bagher Thamer Younes

001 03-20-2022
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

REVISION HISTORY

Rev. Date Nr. of sheets Description

EXDE00 06/09/2014 12 For Approval

EXCO00 21/10/2014 13 For Construction

 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

INDEX
1 PURPOSE............................................................................................................................................ 5
2 SCOPE................................................................................................................................................. 5
3 REFERENCES..................................................................................................................................... 5
4 DEFINITIONS...................................................................................................................................... 5
4.1 Company.................................................................................................................................. 5
4.2 Contractor................................................................................................................................. 5
4.3 Subcontractor........................................................................................................................... 5
5 SUBCONTRACTOR RESPONSIBILITIES.......................................................................................... 5
5.1 Site Incharge............................................................................................................................ 5
5.2 Supervisor................................................................................................................................ 6
5.3 QC Incharge............................................................................................................................. 6
5.4 HSE Supervisor........................................................................................................................ 6
6 SPECIALIZED TOOLING AND EQUIPEMNTS..................................................................................6
7 Work Instructions............................................................................................................................... 6
8 MATERIALS FOR PIPING & EQUIPMENT......................................................................................... 7
8.1 Insulation Material for Piping, Fittings and Valve & Flanges.....................................................7
8.2 Ancillary Material for Piping & Equipment................................................................................7
9 BASIC PROCEDURE.......................................................................................................................... 8
9.1 Scope of Work & Explanation of Procedure.............................................................................8
9.2 Materials Receipts.................................................................................................................... 8
10 INSULATION SUPPORTS.................................................................................................................. 9
11 INSULATION OF PIPING.................................................................................................................... 9
11.1 Insulation Application............................................................................................................... 9
11.2 Insulation of Elbows, Tees, Reducers......................................................................................9
11.3 Insulation of Valve and Flanges.............................................................................................10
11.4 Weatherproofing Application.................................................................................................. 10
12 INSULATION OF EQUIPMENT......................................................................................................... 10
12.1 Insulation Application.............................................................................................................. 10
12.2 Weatherproofing Application.................................................................................................. 11
13 INSPECTION PROCEDURE............................................................................................................. 11
14 QA/QC RESPONSIBILITY................................................................................................................ 12
15 HEALTH & SAFETY.......................................................................................................................... 13
15.1 Material................................................................................................................................... 13
15.2 Equipment.............................................................................................................................. 14
15.3 Tool Box Talks........................................................................................................................ 14
15.4 PPE........................................................................................................................................ 14
15.5 Working on Height.................................................................................................................. 14
16 ATTACHMENT.................................................................................................................................. 14
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

1 PURPOSE
The purpose of this method statement is to define the guidelines/procedures to carry out
supply and application of Hot Insulation Works.

2 SCOPE
This Method Statement covers the procedure for the material and application
requirements for exterior thermal insulation system for piping and equipment located
above ground on Zubair Oil Field Development Project.

3 REFERENCES

This procedure is based on WFT technical specification for thermal insulation, Document
No. 00250621DVSG00002_EXCO01.

4 DEFINITIONS

4.1 Company

The Company means ENI Iraq B.V., the owner of this project.

4.2 Contractor

The Contractor is the employer for whom the sub-contractor is working in this case:
Weatherford Oil Tools Middle East Ltd.

4.3 Subcontractor

The Subcontractor is the organization that is responsible for material procurement and
installation of the insulation and weatherproofing materials as specified by the
CONTRACTOR. In this case Dr. Concrete

5 SUBCONTRACTOR RESPONSIBILITIES

5.1 Site Incharge

He will be responsible for overall control of work according to this approved method
statement in line with requirement of Health, Safety and Environment. Site Incharge will
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

coordinate with client for the scheduling and progress of work. He will assist his site team for
completing the scope as per project requirement.

5.2 Supervisor

He will be responsible for day to day activities as per planning and instruction of Site
inchrage. Manpower and equipment planning, daily progress of work shall be his main
responsibilities. Site Supervisor will comply all safety and QA/QC requirement as per project
requirement.

5.3 QC Incharge

He will be responsible for maintaining the quality of work as per project specification. He
shall be following ITP and maintain all inspection records due signed by all parties for final
hand over. He will be responsible for coordination with Contractor & Company Inspection
Group.

5.4 HSE Supervisor

He will responsible for safe implementation of this method statement for completing the
scope as per project health, safety, and security & environment requirement.

6 SPECIALIZED TOOLING AND EQUIPEMNTS

- Rolling Machine

- Grooving Machine

- Lock Forming Machine

- Bending Machine

- Shearing Machine

- Drilling Machine

- Flat Cutting Machine

- Decoiler

- Hand tools
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

7 WORK INSTRUCTIONS

 The Insulation Thickness for all Insulation works for this scope of works shall be as per
drawing.

 Workmanship – All steps proceeding during and after installation of insulation will be
carried out strictly in accordance with project specification.

 Surface to be insulated should be inspected for application of paint system as per project
specification. Insulation to commence after such inspection. The surface should be clean,
free from moisture, oil, grease and foreign matter.

 The required scaffolding is to be erected as per project requirement.

 Scaffolders and Scaffolding Inspectors should be certified by Third Party.

8 MATERIALS FOR PIPING & EQUIPMENT

8.1 Insulation Material for Piping, Fittings and Valve & Flanges

 Rockwool Pipe Section, unfaced, having density 100 kg/m³ will be used for pipes and
fittings upto 1.5” NPS..

 Rockwool Blanket, unfaced, backed one side with GI Wiremesh, wire dia 0.6-0.8 mm , 25
mm wire mesh, hexagonal pattern, density 100 kg/m³ will be used for pipes and fittings
above 1.5” NPS, Valves and Flange

8.2 Ancillary Material for Piping & Equipment

The following ancillary materials shall be used:-

 SS wire 1mm (304) diameter will be used for securement of insulation at every 300mm
distance for pipe size upto 6" NPS.

 SS304 Bands 12mm x 0.6mm with SS304 Bands Seals will be used for securing
insulation for pipe size greater than 6" NPS at every 300mm distance and at every
250mm distance for equipments. It will be used for securing cladding on equipments at
every 1000mm distance.

 GI wire 1.2mm diameter will be used for lacing of blankets.

 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

 SS304 Self Tapping Screws, 4.8mmx16mm with Nylon Washer will be used for
securing of cladding at every 150 mm distance for pipe & equipment.

 SS304 Toggle Clips 40mm Length with SS304 Poprivets and Aluminium
Poprivets, 3.2mm x 5mm will be used for removable boxes.

 Flashing Compound, TIC 70-30 will be used.

 GI Flat Bar (30mm x 3mm) along with GI Flat Head Rivets, 3.5mm x 16mm, GI Nut and
Bolt, M6 x 40, ISOPLAN and Corroplast Tape, 30 mm wide will be used for ring
supports.

9 BASIC PROCEDURE

9.1 Scope of Work & Explanation of Procedure

The total process consists of surface check, fixing of insulation material, securing and
cladding activities. This procedure covers stage wise activities including quality control
checks for insulation work.

9.2 Materials Receipts

Material shall be received by Subcontractor Site Incharge and shall be checked for
following:–

 Packing & Damage during transit.

 Specification and grade

 Quantity and Batch No.

 Manufacturer Certificates

 Material Expiry Da

All information shall be recorded in Material Receipts & Storage and signed by
representative of Subcontractor & Contractor and kept in the Subcontractor site file.
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

10 INSULATION SUPPORTS

The insulation of stretches of vertical piping shall be supported every 4 meter for pipes up to
6", and every 3 meter for pipes 8" and over.

11 INSULATION OF PIPING

11.1 Insulation Application

 Before installing insulation clean the pipe and ensure that it is free from dust, oil,
grease, mill scale etc. Preformed Rockwool pipe insulation shall be applied in a
minimum number of layers. When the insulation thickness required is above 100 mm,
the insulation shall be applied in multi layers.
 Single layer pipe insulation shall be applied in a staggered circumferential joint
arrangement. Multiple layer pipe insulation shall be applied with all joints staggered.
 SS wire 1mm diameter will be used for securement of insulation at every 300mm
distance for pipe size upto 6" NPS.
 SS304 Bands 12mm x 0.6mm with SS304 Bands Seals will be used for securing
insulation for pipe size greater than 6" NPS at every 300mm distance.
 Circumferential joint between segments in adjacent length shall staggered.
 Where flanged joints are concerned, the insulation shall stop at a suitable distance to
allow the bolts to be extracted without damaging the adjacent insulation.

11.2 Insulation of Elbows, Tees, Reducers

 Same insulation as used on the adjoining pipe line shall be used over the fittings
(elbows, tees, reducers) after fabrication in required shape.
 SS wire 1mm diameter will be used for securement of insulation at every 300mm
distance for pipe size upto 6" NPS.
 SS304 Bands 12mm x 0.6mm with SS304 Bands Seals will be used for securing
insulation for pipe size greater than 6" NPS at every 300mm distance.
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

11.3 Insulation of Valve and Flanges

 The insulation shall be of the same type and thickness as the adjacent pipe or
equipment insulation.
 The insulation thickness over Valve and Flange shall be equal to that of the associated
pipes
 The boxes shall be constructed of Flat Aluminum Sheet ASTM B 209 type 3003-H14
alloy with polysurlyn moisture barrier. Thickness of sheet will be 0.6 mm for pipe sizes
upto 12" and 0.8mm thick for pipe sizes greater than 14" and above.
 Aluminum boxes in two dismountable parts shall be constructed to the size of item's
overall dimensions. All insulation boxes shall be designed utilising quick release
toggles to fasten the component parts tightly together but also be easily removable.

11.4 Weatherproofing Application

Sheet jacketing shall be erected in such a way to adhere perfectly to the insulation beneath.
The longitudinal joints of the jacketing shall have a 50 mm. minimum overlap, with the free
edge beaded for reinforcement and shall be placed sideways on the piping and fixed with
SS304 Self Tapping Screws, 4.8x16 with Nylon Washer at every 150 mm center to center.
Peripheral joints shall have a 50 mm minimum overlap with male-female type beading on
the edges. They shall not be fixed with screws, in order to give free play to the thermal
expansion. Peripheral joints on vertical piping shall be installed with the upper section
overlapping the lower. All cladding sheet joints shall be waterproofed by sealing with
flashing compound.

12 INSULATION OF EQUIPMENT

12.1 Insulation Application

Before installing insulation clean the equipment and ensure that it is free from dust, oil,
grease, mill scale etc. Insulation on equipment shall be applied in a staggered joint
arrangement and to fit the contour of the equipment so that no gaps are evident. Equipment
Shell insulation shall be secured with SS304 Bands, 12mm x 0.6mm with SS304 Bands
Seals spaced at every 250 mm.
Insulation over the heads of horizontal equipment and top & bottom heads of vertical
equipment shall be as follows:
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

Insulation shall be suitably shaped and fastened to the heads by SS straps. The joints
between mattresses shall be closely aligned and the edges of the wire mesh sewn
together with 1.2 mm. galvanized steel wire.

12.2 Weatherproofing Application

Cladding sheet shall be fixed each other and to the support by means of SS304 Self
Tapping Screws, 4.8x16 mm with Nylon Washer at every 150mm. Longitudinal and
peripheral joints shall be overlapped, not less than 50 mm and the overlap edges shall be
beaded. All cladding sheet joints shall be waterproofed by sealing with flashing compound
Equipment shell & Head cladding shall be secured with SS304 Bands, 12mm x 0.6mm with
SS304 Bands Seals spaced at every 300 mm.

13 INSPECTION PROCEDURE
The insulation shall be inspected during the following stages:-
 At the time of material receipt
 Before applying the insulation
 During insulation application
 Before and during application of weatherproofing
Quality control activities shall include at least the following activities at the time of receipt of
the materials:
 Appropriate checks shall be made to verify materials received at the site are the
same as the specified or approved materials. Such checks shall include verification
of labels, material safety data sheets, delivery receipts, and thicknesses. Damaged,
unspecified, or unapproved insulation materials shall be removed from the site.
 Ensure materials are protected from being damaged by moisture, temperature,
wind or any other atmospheric factors.
Quality control activities shall include at least the following prior to insulation application:-
 Obtain written approval of Field Management in case that welding of
insulation supports is to be applied.
 Verify that pressure tests have been completed.
 Verify that painting at protrusions through insulation has been done.
 Ensure that protective coatings, over stainless steel surfaces to prevent external
stress corrosion cracking, have been applied.
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

 Revert also to applicable quality control plan for additional requirements.

Quality control activities shall include at least the following during insulation application: -
 Make sufficient checks to verify that the material applied are the same as the specified
or approved materials.
 Verify the insulated item and insulation code are the same as marked in the P&IDs and
related drawings.
 Inspect the insulation supports for correct location, type, width and length.
 Verify that the insulated surface is uniform without gaps and voids.
 Inspect the tightness of joints and fasteners.
 Verify the location, width and installation of insulation expansion joints.
Quality control activities shall include at least the following prior to and during
weatherproofing: -
 Ensure that the insulation is clean, dry and fit for its intended purpose before
weatherproofing is applied.
 Inspect for proper overlaps of metal and flashing.
 Verify that the location of bands, screws, S-Clips, J-clips and breather
springs.
 Ensure that moisture protection and weatherproofing at cutouts, protrusions and
locations where moisture could enter the insulation has been appropriately installed.

14 QA/QC RESPONSIBILITY

All the insulation works on the project will be under QA/QC Incharge
 Ensure all the materials for the project are strictly in accordance with the specifications.
 Ensure correct materials are used for application. Delivery notes & Test Certificates
should be available at the site for Contractor & Client’s inspection.
 Ensure all materials are installed as per the manufacturer’s
recommendations and approved Inspection & Test Plan.
 Inspect workmanship of work in progress including general cleanliness and
appearance of the working area.
 Ensure all tools and equipment is in good working order.
 Co-ordination with Contractor/Client inspection department and appraise them of daily
inspection requirements and necessary follow-ups.
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

 Organize the inspection of the completed work after joint inspection with the Site In-
charge and satisfy himself that the work offered for inspection has been completed in
accordance with the relevant specifications and ITP.
 Responsible for recording on inspection findings and maintaining them for each item to
obtain final completion certificate.

15 HEALTH & SAFETY

15.1 Material

Insulation and ancillary materials used on this project contains no asbestos and cause no
known health hazards either during or after installation. During application, however the
following precautions will be taken.
 Protect skin from irritation by wearing loose clothing; wash work clothing separately
from other garments.
 Protect eyes and respiratory tract from airborne product by wearing dust masks and
goggles / safety glasses or eye shields as necessary.
 Eyes and skin areas that come in contact with Metal sealant, will be rinsed with clean
water.
 Follow the safety instruction given in material safety data sheet.
 All waste to be disposed off in safe manner to client designated area within the project
premises.

15.2 Equipment

All equipment used for the Insulation work should be well maintained and safe to use. All
equipment shall be cleaned and routine maintenance done periodically.

15.3 Tool Box Talks

Tool Box Talks will be held on regular basis and details will be recorded.

15.4 PPE

All personnel will be equipped with safety gears including coverall, safety shoes, safety
helmet, cut resistant gloves, Dust mask and safety goggles.
 ZUBAIR OIL FIELD AND DEVELOPMENT PROJECT
METHOD STATEMENT FOR INSULATION & JACKETING FOR PIPE
& EQUIPMENT
Doc. No.: DRC-MS-00-01-122 Date:- 22/03/2022 Rev. 001

15.5 Working on Height

All personnel will be using full body safety harness / safety belts (lanyard) when working on
scaffolding.

16 ATTACHMENT
1- Insulation inspection report : (One sheet).