METHOD STATEMENT
FOR
FIRE FIRHTING SYSTEM
PROJECT NO. : 2240-2560 PROJECT NAME : STAR PROJECT CLIENT : STAR RAF?NER? A.?SITE : TURKEY
We concluded the years’ experience of similar domestic and overseas projects and put forward this plan. Maybe there are some methods which are not applicable to the Star Project, and we will improve & revise it according to tender’s specification if our bidding will be accepted...
1. Purpose
The main objective of this method statement is to describe in detail the sequence of work and make sure we can complete the project in time. This project has a heavy workload and the process of construction is also complicated, especially the Foam System, Deluge System and its supports clips. These works belong to work high above the ground and are easily affected by the wind climate of the sea, so the Fire Fighting System is a key point to the project that can be completed on time.
2. Scope
This document covers all Fire Fighting work (Including: fabrication, inspection, testing, cleaning, and erecting etc.)as detailed in AFC Drawings. Construction of fire line will be completed in accordance with the requirements detailed in this specification and STAR RAF?NER? A.? drawings.
The following are excluded from the scope of this document:
2.1 Fabrication of pressure vessels and/or other mechanical pressure containing
equipment unless specifically detailed in the applicable design documentation pertinent to the equipment.
2.2 Fabrication of material handling devices and ducts
2.3 Fabrication and/or assembly of instrumentation hook-ups and tube assemblies.
2.4 GRP piping
No deviation from this specification will be allowed without written approval from STAR RAF?NER? A.?.
3. Reference
ASME B31.1 Power piping
ASME B16.5 Pipe flange and flange fitting
ASME B16.9 Factory-made wrought steel butt welding
ASME B16.11 Forged steel Fittings, Socket –welding and Threaded
ASME B16.20 Metallic Gaskets for pipe Flanges Ring-Joint Spiral-Wound, and Jacketed
ASME B16.21 Non-metallic Flat Gaskets for pipe Flanges
ASME B16.34 Valves-Flanged, Threaded and welding End
ASME B16.47 Large Diameter Steel Flanges
ASME B36.10M Welded and Seamless wrought steel pipe
ASME BPV VIII DIV.1 Rules for construction of pressure Vessels
ASME BPV V Non-destructive Examination
ASME BPV IX Welding and Brazing Qualification
API526 Flanged steel safety Relief valves
API598 Valve Inspection and Testing
API600 Bolted Bow net steel Gate valves
API607 Fire Test for soft seated Quarter-turn Valves
MSS SP25 Standard Marking System for Valves Flanges Fittings and Unions NFPA 100 Edition Fire Prevention Code
NFPA1000 06 Edition Standard for Fire Service Professional Qualifications Accreditation and Certification Systems
NFPA 101 06 Edition Life Safety Code, 2006 Edition
NFPA 101A 01 Edition Guide on Alternative Approaches to Life Safety
NFPA 11 05 Edition Standard for Low-Expansion Foam
NFPA 13 07 Edition Standard for the Installation of Sprinkler Systems
NFPA 16 03 Edition Standard for the Installation of Foam-Water Sprinkler and Foam-Water Spray Systems
4. Planning and Deployment
4.1 Construction Sequence: Technological process of construction is that first finished
the work on the tank then completed the work above the ground.
4.2 Spray line, support and painting should be prefabricated, welded and marked on
the ground.
5. SHOP AND FIELD FABRICATION WORK
5.1 General
All drawing provided by STAR RAF?NER? A.?, and this document will be adhered to in completing all fabrication activities.
Where a discrepancy arises, SINOCONST will refer the discrepancy to STAR RAF?NER? A.? for a written clarification prior to proceeding with the work in the affected area(s).
Intermediate butt weld (BW) pipe joints are permitted for the purposes of maximizing available raw piping materials.
Where lengths of ERW or EFW piping are joined at a butt weld, the longitudinal seams in adjoining lengths must be staggered. Where possible the longitudinal seams should be staggered in the top half of the pipe.
A template will be used when laying out headers, mitres, laterals and other
irregular details to ensure accurate cutting and proper fit-up.
In fitting up, prior to welding, spacers will be used so that a proper gap is made for the weld. Spacers will be removed prior to the commencement of welding.
Pipe line-up clamps will be used. Tack welding of steel shapes to the pipe for line-up purposes is prohibited.
The use of permanent backing rings or consumable inserts is prohibited.
FW and FFW’s are detailed on isometric drawings, the Contractor will provide a minimum of 150mm extra length over the dimension nominated on the applicable isometric drawing.
Branches will be made in accordance with piping isometric drawings, branch connection tables for line classes and standard drawings (where applicable).
Materials will be in accordance with the material class data sheets.
All sharp edges and burrs will be removed.
5.2 Tolerances and Dimensional Accuracy
For butt welding of all piping components, pipe ends, fittings and weld neck flanges, the root opening and weld bevel alignment will be in accordance with ASME B31.3 and PFI-ES21.
Linear and angular dimensional tolerances during fabrication will be in accordance with PFI-ES3.
The inside surfaces of component ends to be joined by girth or mitre groove welds will be aligned to within the dimensional limits of the welding procedure.
Flattening/ovality of the pipe will not exceed the requirements detailed in the applicable standard for the manufacturing process.
5.3 Fitting-up
Flange bolt holes are to be oriented as follows, unless otherwise indicated on the piping drawings.
Flange bolt holes are to be oriented as follows, unless otherwise indicated on the piping drawings.
?Flange face vertical - bolt holes to match vertical centerline.
?Flange face horizontal - bolt holes to match north-south centerline.
?Caution: The fitter will exercise care to ensure that required information is
included on the shop drawings.
When assembling flange connection, approval paste will be applied to the gasket and bolt/nut, except austenitic steel, for prevention of seizure, leakage, or adherence. Especially, for asbestos sheet gasket sufficient paste will be applied.
5.4 Threaded Connections
All pipe threads will be cut after any required bending, forming or heat treatment.
Where this is not practical, suitable protection will be applied to protect the threads.
All threaded connections will be gauge checked or chased after welding or heat treating.
Openings for threaded thermowells and other inserts are to be drilled through
and be free from obstructions or burrs.
Where threaded flanges are specified, the pipe will terminate 1.5mm short of the flange face.
5.5 Specific Details for Galvanised Carbon Steel Materials
All aspects relating to fabrication, fabrication tolerances, cleaning and testing of galvanized piping and piping components will be the same as carbon steel pipe.
No bolted type joints (i.e. flanged joints) will be assembled prior to hot-dip galvanizing.
All spooled piping will be fabricated within an envelope size capable of being handled by the galvanizing plant/facility. The spool envelope size must be confirmed by the galvanizing plant prior to the start of fabrication.
All fabricated piping will be left open and free of obstruction to enable full and proper pickling, fluxing and coating of all surfaces of the pipework.
Where pipe supports and other attachments have been made to the piping, appropriate measures will be taken to ensure full and proper venting during pickling, fluxing and coating of all surfaces. This may include the provision of openings and weep holes of sufficient size on the attachment if they have not already been included in the attachment design. Some general guidelines governing this are presented in ASTM A385.
Precautions will be taken to ensure minimal warpage and distortion of the piping during galvanizing operations. Guidelines on this are presented in ASTM A384.
Where applicable, precautions relating to fabrication processes as detailed in ASTM A143 will be taken into account to protect against embrittlement of the galvanized coating.
All pipe threads will be NPT type in accordance with ASME-B1.20.1.
Threaded joints will not be assembled prior to hot-dip galvanizing.
All threaded pipe and fittings will be inspected following hot-dip galvanizing to ensure that the thread form has not become overfilled with galvanizing metal.
Where it is found that a thread form has become over filled with galvanizing metal, the thread form will be recut or cleaned with a tap and die set or similar machining technique.
All recut threads will be coated with approved white spirit soluble rust preventive.
5.6 Storage and Handling
All openings in pipe work, whether vents or drains to atmosphere or openings for onsite hook up of modules etc., will be adequately sealed to prevent the ingress of foreign matter. End protectors applied will not be capable of passing into the bore of the pipe.
Exposed machine surfaces such as weld bevels and flange facings will be covered with approved white spirit soluble rust preventive.
Plastic end caps and thread protection plugs will be secured with an approved tape.
Flange covers of metal (minimum 5mm thick) or wood (minimum 20mm thick) will be used, c/w gasket. The covers will be of the same outside diameter as the flange and held in place with 50% of the required bolts for the joint (minimum of 4 bolts). Covers held on with wire, steel or plastic straps are not acceptable.
Pipe spools will be protected from damage and contamination during handling and storage. Piping items (e.g. spools and loose fittings) will be stacked to prevent excessive loading on each item. All pipe work will be examined to ensure that no deterioration has occurred during storage.
Where stored on the ground in an unsheltered location, piping will be stacked up off the ground surface using dunnage or spacers in a location with good drainage and rainwater runoff.
Silica gel will be placed inside spools to remove air humidity and reduce the onset of corrosion.
All manually operated valves included in spools as part of the fabrication process (i.e. SW end valves) will be cycled from fully open to fully closed and back again to ensure operability. Gate and globe valves will be stored closed.
Ball and plug valves will be positioned either fully open or fully closed, and diaphragm valves opened.
Dissimilar metal piping and piping components will be segregated during storage, handling and transportation to avoid metal contamination and corrosion issues (i.e. stainless steel will not be stored or handled with carbon steel or galvanized components).
Coated piping will be handled so as to avoid damage to the protective coating(s).
6. Piping Installation
6.1 Receival, Storage and Handling
Pipe spools and valves will be protected from damage and contamination during handling and storage.
Piping placed in storage will be stored off the ground using padded bolsters and plain timber under the uncoated ends.
Suitable wedges will be used to preclude rolling.
Pipe will be stored on flat well drained ground whenever possible.
Piping items (eg spools, valves, loose fittings) will be stacked to prevent excessive loading on each item.
All pipe work and valves will be examined to ensure that no deterioration has occurred in storage with particular attention to valve internals.
Where not provided, silica gel will be placed inside spools to remove air humidity and reduce the onset of corrosion.
Contamination of the surfaces of the pipes by corrosive or other detrimental substances, particularly non-ferrous metals, halogens and sulphur will be avoided.
Adequate measures will be taken to prevent sulphur pick-up.
Paint, markers labels or tools containing lead, copper, zinc or tin will not be used.
All manually operated valves will be cycled from fully open to fully closed and back again to ensure operability.
Adjacent valves and instruments will be protected against welding or cutting splatter.
Gaskets will be stored in a warm dry enclosure, protected from direct sunlight.
Gaskets will be kept clean and away from oil, grease, gasoline and solvents.
Lifting and slinging operations will be carried out using nylon slings or straps.
Metal chains and galvanised wire slings will not be used.
6.2 Piping Installation
All pipe will be installed in accordance with the Piping Design Criteria, Piping and Isometric Drawings, P&ID’s, Line Designation Table and Specification.
Modifications necessary to remove interferences will be discussed and agreed with TECHNIP prior to any action by SINOCONST. All modifications will be noted on “as-built” drawings prepared by the SINOCONST.
SINOCONST will use temporary supports where necessary, during assembly of the piping system/s, to ensure that no unacceptable stress or deformation occurs in the piping and connected equipment as a consequence of the cantilever effect of unsupported weight distribution.
Special operations such as balancing will be completed under instructions submitted by the SINOCONST and approved by STAR RAF?NER? A.?.
All pipe work, valves, and piping specialty items will be inspected before installation to ensure that protective packing, covers, wrapping and internal protectives, such as silica gel bags etc are removed.
Protective covers attached to piping and equipment will not be removed until immediately prior to installation.
Any material soiled or damaged in the execution of the work will be thoroughly cleaned, repaired or replaced.
Pipe internals will be free from mill scale, dirt and foreign material when installation is completed.
On galvanized piping all damaged and exposed surfaces will be cleaned and prepared as per Specifications, and coated with an TECHNIP approved galvanizing method and/or compound.
All closing FW or FFW’s on galvanized piping will have all surfaces affected by the welding operations cleaned and prepared as per Specifications, and coated with an STAR RAF?NER? A.? approved galvanising method and/or compound.
When a work period ceases before completion of all installation work scope, any open pipe ends will be protected with securely closed, tight fitting covers.
Passageways, access ways, manholes, clean-outs, inspection points and reserved spaces will be kept unobstructed from piping and pipe fittings.
6.3 Piping Support
Piping will be supported as indicated on the isometric drawings and piping support drawings. When temporary supports other than those shown on these drawings are required to facilitate installation, they will be of the removable type and will be indicated as such.
Temporary supports will not transfer detrimental reactions/loads to piping, structural members, or equipment.
Temporary supports will be completely removed upon completion of testing and prior to commissioning.
Galvanized material will not be welded to austenitic stainless steels or nickel alloys under any circumstances.
Where piping is supported using spring supports the locking pins will be in place during installation and hydrostatic testing the piping system. Locking pins/stops will be removed prior to system start-up.
Spring supports will be installed to ensure that the identification, load and travel scales are readily visible.
All threaded parts will be fully engaged, and locking nuts tightened.
Variable spring and constant load hangers will be locked during the installation and assembly of the piping unless otherwise specified in the design instructions.
If supports are unlocked for specially controlled operations such as balancing or cold pull, they will be relocked prior to any hydrostatic pressure tests and chemical cleaning.
The installer will ensure that the load setting of spring supports is pre-set to the design requirements.
If adjustment of the load is required, the installer will ensure adjustment does not prevent or reduce the anticipated support travel.
Support for pipes larger than DN50 will not be located more than one pipe diameter from the specified position on the piping drawings. Where necessary, the fixing of the support to the structure will be adjusted to ensure that the orientation (direction, angle, etc) of the support is in accordance with the specified limits.