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Project Package Originator Discipline Doc. Type Unit n° Serial n°

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RAPID P03 VOR CON MST 0004 1004

PETRONAS RAPID PROJECT

(P3-DIESEL HYDROTREATING UNIT)

METHOD STATEMENT (MST) PIPING AND EQUIPMENT

INSULATION

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 Rev. Page

Document Number

Project Package Originator Discipline Doc. Type Unit n° Serial n°

0 /8
RAPID P03 VOR CON MST 0004 1004

PETRONAS RAPID PROJECT

(P3-DIESEL HYDROTREATING UNIT)

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DATE
WRITTEN BY CHECKED BY APPROVED BY
REV. STATUS – REVISION MEMO
DD-MMM-YY (name & signature) (name & signature) (name & signature)

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 HOLD’s

HOLD No. REF. § DESCRIPTION ACTIONS

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 TABLE OF CONTENTS

1. PURPOSE…………………………………………………………………………………………………………4
2. SCOPE……………………………………………………………………………………………………………..4
3. RESPONSIBILITIES…………………………………………………………………………………………......4
4. WORK METHOD……………………………………………………………………………………………..…4-9
5. SAFETY INSTRUCTION…………………………………………………………………………………………9

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1. PURPOSE
This is method statement for process pipeline and equipment of insulation and cold
insulation which is under Vorplex's scope in PETRONAS RAPID project, it is prepared
according to work characteristics and design requirements of this work. This insulation
procedure is to assure that the relate insulation work will be in compliance with the
engineering specifications, execution plans, HSE system and provide adequate operation
environment & quality during the construction period.

2. SCOPE
2.1 This procedure is applicable to the insulation work for the equipment including
material claim, storage, application, and inspection.
2.2 All the applicable project specifications, standards, procedures (including HSE
requirements) and drawings shall be followed.

3. RESPONSIBILITIES

3.1 Insulation Supritendant

4.1.1 Assist the Site Manager to prepare and execute the Insulation Construction Plan
4.1.2 Preparation of requisition for construction work.
4.1.3 Supervision of the insulation construction work to ensure that its quality will meet the
contract requirements and the specification.
4.1.4 Preparation and mobilization of facilities, equipment, tools required for insulation
construction work.
4.1.5 Plan the required manpower and assign the workforce for the insulation construction
work.
4.1.6 Supervision of the performance of all the Insulation Construction Engineers

3.2 Insulation supervisor

4.2.1 Responsible for the execution and management of the construction safety, quality,
progress control and follow-up of all the relevant plans.
4.2.2 Assist in compilation of Insulation Construction Procedure.
4.2.3 Check the issuance of the equipment and materials.
4.2.4 Supervise the subcontractors' construction execution.
4.2.5 Supervise the execution and reporting for inspection and testing required during each
phase of the construction.
4.2.6 Control of drawings, which are used by his group and ensure the latest drawings are made
available to the subcontractors.
4.2.7 Responsible for the work mentioned in Paragraph 4.3 if Insulation Inspection Engineer is
not assigned for the project.
4.2.8 Assist in the interpretation of the drawings and solve the problems including the
interfaces with other activities, if any, by providing the suggestions due to the design errors or
inconsistencies.

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 4.2.9 Responsible for the drafting, confirmation and the checking of the material take off in the
event that drawings have to be modified.
3.3 Insulation inspection
3.3.1 Integrate and summarize the quality inspection and records for the insulation
construction work.
3.3.2 Responsible for each inspection and testing work for insulation construction
work.
3.3.3 Responsible for the inspection of the insulation facilities and materials.
3.3.4 Review and check each inspection and testing report and records.
3.3.5 Supervise the labeling for the situation of each variety of the equipment /
materials and product during construction phases.

4. WORK METHOD

4.1 Insulation work procedure flow the insulation construction .

4.1.1 It is required to apply insulation on the Dress up equipment in prior to the
commencement of lifting activity, Insulation shall be started only when the
equipment supports, monkey ladder and pipeline of auxiliary tower have been all
wholly installed and in addition ,the pressure test of the pipeline of auxiliary tower
has been done. The double —row scaffolding platform shall be erected before
application of insulation for the purpose of keeping some reasonable distance
between the work platform and the exterior surface of the equipment. The
scaffolding platform shall be 150 -200mm away from the exterior surface of the
equipment to create favorable conditions for applying insulation.
4.1.2 It is technically impossible to insulate the bracing parts. However, partly insulation
can be done before the lifting activity gets started. It shall be guaranteed that work
has been all done and furthermore passed the inspection before lifting the equipment.
Proper care and attention shall be given to protecting the finished insulation the
surface of the equipment.

4.2 Preparations prior to the construction

4.2.1 The Insulation Supervisor shall review and study thoroughly the provisions as
stipulated in the Contract and Construction Specifications and prepare the
Construction Procedures accordingly.
4.2.2 The Insulation Supervisor shall prepare "Table for Equipment Insulation","Table for
Insulation MTO", and " Piping Isometric Drawings". The first two Tables will be
used as the basis for the insulation materials and thickness while the Isometric
Drawings will be used as the basis for checking the field construction location.
4.2.3 The Insulation Supervisor shall prepare Insulation Construction Planning Schedule
based on the Master Schedule and equipment construction schedule, and manpower
and equipment/tools mobilization plan based on the construction period and work
quantity.
4.2.4 Insulation Supervisor shall review the Temporary Facility Plan, including material
storage, pre-fabrication shop and yard, scrape storage, and material supply plan, etc.,
prepared and submitted by the subcontractor based on the space provided for the
storage. This Plan, if approved, can be executed accordingly.

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 4.2.5 The material certificate and inspection records shall be attached to the materials
along with the delivery. For the materials supplied by client, the Insulation
Inspection Engineer shall assist the Material Warehousing Group to review the
above-mentioned documents. Materials for which the inspection by third party is
required, the Insulation Inspection Engineer shall prepare the sample on the spot
together with client and sub-contractor.
4.2.6 The Insulation Supervisor shall, coordinate with the HSE Group, advocate the affairs
with regard to HSE and security.
4.2.7 Operations prior to Construction:
A. The Equipment Supervisors shall prepare and submit the application form which lists
all the equipment and pipe lines for which the insulation can be applied next week
for the Inspection Engineer's review and confirmation. All the endorsed relevant test
and inspection records shall be in place prior to the commencement of the insulation
works.
B. The Insulation Supervisor shall supervise the subcontractor to prepare the three-
weekly schedule and manpower planning, review and check the materials required,
stock materials, and arrange the purchase of materials.
C. Equipment or Piping flanges and valves, which are temporarily not necessary to be
insulated, shall be executed in accordance with the Contract and specification. In the
event that the Contract or the specification, shall be noted on the application form or
field marked and the application shall be carried out after the confirmation of the
Insulation Supervisor.
D. The existing scaffolding shall be inspected in advance for its safety. All the other
required scaffolding and personal protective equipment required for each worker
shall be erected and prepared by the subcontractor respectively. All works to be
carried out as per the approved MS and JHA.
E. With regard to weather condition, materials shall be delivered to site daily located on
owner requirement. No excess materials allowed at site, to protect the materials and
provide enough access around site place.
F. Subcontractor shall clean and remove the foreign matters on the equipment
surfaces such as dust, oil, etc. with compressed air or cloth. In the event that anchors
are loosen or fallen off shall bere-welded just after confirmed by the equipment
supervisor. The Insulation Supervisor shall coordinate and resolve problems, if any,
found during the survey for the interference with equipment insulation construction
such as insufficient gaps of the opening on the operating platform.
G. To prevent the corrosion under insulation, the following shall be checked;
a. Insulation material shall keep dry during insulation;
b. Water shall be isolated well after insulation finish.
c. Pipe painting must painted well.
H. Insulation Support rings : Make sure the insulation supports for all vertical items is
installed already. If not, fabrication and installation refer to the specification for
insulation, PTS or other technical query which is confirmed by Contractor of Owner.

4.3 Application of the Insulation Layer

4.3.1 Check the insulation type and thickness. The insulation shall be applied such that two
pieces of the insulation are joined closely without gaps. The insulation shall be then
tightened using galvanized steel wire (stainless steel wire shall be used for stainless

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 steel piping) approx. every 30 cm longitudinally. Large gaps or seams, if any, shall
be sealed with the insulation. 1/2" bands shall be used for tightening the insulation on
pipelines larger than 24' (not inclusive).
4.3.2 Insulation for reducers, tees, flanges, and valves shall be performed by cutting the
pipe covers directly at the angle required (not 90 deg.). Joints of them shall be
contacted closely with each other. Large gaps or seams, if any, shall be sealed with
the insulation. The insulation shall be tightened afterwards using the wire or bands.
4.3.3 If pipe protruding from iron support or equipment, the excess of insulation materials
shall be trimmed. So that the smooth appearance of insulation material. Excess
trimmed material to be disposed immediately and seperated with other materials
before display.
4.3.4 Insulation for the flange joints shall be so applied that a space will be spared for
dismantling the flanges during maintenance, if required
4.3.5 Transverse joints and all the joints for multilayer insulation shall be staggered with
each other.
4.3.6 Surfaces and joints of the insulation materials for cold insulated equipment shall be
entirely sealed with insulation adhesives. The sample and the type of the adhesive
shall be in accordance to the specification
4.3.7 Equipment having skirt shall be applied with the insulation blanket, and covered with
hexagonal eyed steel net.
4.3.8 Remaining materials or scrapes, after performing the cutting in the field, shall be
collected immediately to avoid messing up the environment and collection bin shall
be provided to store all these scraps.
4.3.9 Prior to the application of the weatherproofing layer, the insulation shall be protected
temporarily from getting damped by using the plastic cloth as the cover during
construction stage.
4.3.10 The materials use for insulation work, should follow the type of base metal, owners
specifications with manufacturers through the product catalog description, given
construction procedure, and different levels to apply various types of glue, caulk or
mastic and soon.

4.4 Inspection of Insulation

4.4.1 After the completion of inspection by Insulation Construction Engineer (Supervisor),
Inspection Engineer shall be notified for witness.
4.4.2 Inspection Items:
A. Type of materials and their thickness are correct.
B. Whether the joints are staggered? The joints are tight? The gaps have already been
sealed with insulation.
C. Gaps between the surfaces of the parts to be insulated and insulation are evenly
applied using vapor barrier mastic.
D. Perform the remedial work for those not acceptable and can be modified immediately.
For those cannot be modified immediately, self-stick tapes shall be used to mark the
locations and modify it as soon as it is available and inspect together with Insulation
Inspection Engineer after its completion.
E. The Insulation Inspection Engineer shall issue a NCR for parts whose specifications
are not mentioned or not clear. Perform the work in accordance with the conclusion of
the NCR.

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4.5 Application of Waterproofing Layer
4.5.1 The insulation, after the inspection and acceptance, shall be wrapped generally with
one layer of asphalt paper. The surface of the paper shall be very smooth and without
any wrinkles. The overlap of two pieces of paper shall be at least 50 mm.
4.5.2 The bottom end plate of the insulated equipment having skirt shall be applied with
one layer of the vapor barrier mastic afterwards on the outer surface of the hexagonal
eyed steel net.
4.5.3 If the vapor barrier mastic is specified as the waterproofing layer by the
specification, right after the first layer of the mastic is applied, glass cloth fabric shall
be embedded with trowel without wrinkles when the mastic is in fresh state. Glass
cloth joints shall have an overlap of 50 mm minimum. Apply the second layer only
after the first layer is dry.
4.5.4 The total dry thickness of the mastic shall be kept within the range specified by the
vendor.

4.6 Inspection of Waterproofing Layer

4.6.1 The Insulation Construction Engineer (Supervisor), after performing the self-
inspection, shall notify the Insulation Inspection Engineer for witness inspection.
4.6.2 Inspection Items
A) Waterproofing is evenly applied or not.
B) The overlapping is adequate or not.
C) Randomly inspect the thickness of the waterproofing layers, two points at least
for each pipeline or equipment.
D) Mark the location not accepted with the color marker, and re-inspect after the
modification by the Subcontractor.

4.7 Application of Weatherproofing Layer

4.7.1 Prior to the application, the material, coating, and thickness of the metallic outer
cover for the insulated equipment shall be confirmed carefully.
4.7.2 Cutting of the metallic cover shall be adequately arranged so that the waste will be
minimized.
4.7.3 Joints mentioned above are not necessary, if corrugated metallic jackets are used.
However, those joints shall be overlapped longitudinally and circumferentially a
minimum of two corrugations and 75 mm respectively.
4.7.4 The metallic jackets for the reducers and tees shall be closely fitted with the
insulation pipe cover, being truncated at the inclined angle, to avoid the existence of
any gaps.
4.7.5 The metallic jackets used for the end plate of equipment shall be developed and cut
in accordance with its size. Lap joints shall be used to join any two pieces of the
jackets by seaming and connecting their edges and the flat head wood screws shall be
used to fasten to prevent them from loosening and slipping.
4.7.6 In the event that protrusion exists, the metallic jackets shall be so cut and assembled
smoothly that no any gap is found.

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 4.7.7 Finishing of the metallic jacket edges
A) Vapor barrier mastic shall be used to seal the edge of metallic jackets and
locations where the water will seep into the insulation
B) The mastic shall be applied evenly, smoothly, and neatly. In the event that the
cracking found after the drying due to shrinkage, the modification work by the
Subcontractor shall be done accordingly
C) After the completion of the insulation application, the remaining materials and
scrapes shall be collected and placed into the boxes separately and delivered to
the designated areas. Cleaning of the site shall be performed immediately right-
after.
D) A placard marking with" Extreme care shall be taken to avoid the damage to the
insulation already applied" shall be placed at the conspicuous location (for
example: the entrance and exit)

4.8 Final inspection

4.8.1 The Insulation Construction Engineer (Supervisor) shall perform the preliminary
Inspection with Subcontractor and then inspect together with the Insulation
Inspection Engineer. If required, the Insulation Inspection Engineer shall notify the
client to witness the final inspection.
4.8.2 Inspection Items
A) Check if the material of the aluminum sheet is correct or not.
B) Check if the appearance of the aluminum sheet is smooth or not and the method
for fixing is adequate or not.
C) Are there any possibilities of the water seeping into the insulation, The amount
of the vapor barrier mastic applied is enough or not.
D) The Insulation Inspection Engineer shall prepare the Punch List, which itemizes
the remaining works and items to be modified or corrected. TheInsulation
Construction Engineer (Supervisor) will supervise the Subcontractor to carry out
the listed work accordingly until their completion.
E) The Insulation Inspection Engineer shall coordinate and confirm the disputes for
item listed, if any. In the event that the specification is not clear, the Inspection
Engineer shall prepare NCR and the remedy work shall be carried out in
accordance with the conclusion.
F) After the modification, the Subcontractor shall prepare the inspection report and
submit it to relevant personnel for his signature. This report will be filed by the
Inspection Engineer and handed over to the Site Quality Control Manager after
its completion as a part of the turn over documents.

4.9 Integration of Inspection Report

After the completion of the construction work, The Insulation Construction Engineer
(Supervisor) shall submit all the inspection report and relevant documents to Site Quality
Control Manager for the integration

5. SAFETY INSTRUCTION
5.1.1 All required work permits and documents will be obtained and kept available at site in
permit boxes.

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5.1.2 All personnel involved will wear necessary PPEs at all time.
5.1.3 The workers will be made aware of safety requirements related to this activity through
Tool Box meeting.
5.1.4 Good housekeeping should be maintained at all time.
5.1.5 Fire extinguisher and fire hose shall be available at working area.
5.1.6 When working at height, fall protection measures shall be taken.
5.1.7 Remove all materials and tools from site after completion of job

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