PIPING PRE-FABRICATION
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Contract No. MPP-ITB-11-05Jubail, Kingdom of Saudi ArabiaEngineering and Project ManagementMETHOD STATEMENT FOR PIPING PRE-FABRICATION11108-MS-PC-001Contract No. MPP-ITB-11-05I N D E X1.0 PURPOSE2.0 SCOPE3.0 REFERENCES4.0 DEFINITIONS5.0 RESPONSIBILITIES6.0 PROCEDURE7.0 DOCUMENTATIONContract No. MPP-ITB-11-051.0 IntroductionThis method statement covers basic requirements and procedures of piping and pipesupports prefabrication. It is to ensure that the methods and procedures shall be carried out for the fabrication of piping work in accordance with the Technical / Contractual specifications of Yanpet Benzene Mitigation Project.2.0SCOPEThis Method Statement describes the methods of identifying and executing thepiping fabrication activities within subcontractou’s scope of work for YanpetBenzene Mitigation Project.3.0 DEFINITIONSProject : Yanpet Benzene Mitigation Project (BMP)Location : YANBUCompany : Saubi Yanbu Petrochemical coContractor : WISONSubcontractor : China Eleventh Chemical Construction Co. Ltd. (ELECO)4.0REFERENCES4.1 Codes and StandardsASME B31.3 : Process PipingASME Sec IX : Welding and brazing QualificationASME Sec V : Non-Destructive Examination4.2 Sabic standards.4.3 Yanpet Standards.5.0 RESPONSIBILITIES5.1 CONSTRUCTION MANAGER shall be responsible for the implementation ofthis procedure who shall pass on instructions down the line to maintain the therequired quality level at each stage of fabrication.Contract No. MPP-ITB-11-055.2 PIPING ENGINEER shall be responsible for the execution of correct workingtechniques with strict adherence to this method statement and referencedocuments, and inspection.5.3 PIPING FOREMAN shall be directly responsible for the quality produced by theworkers under them. They shall confirm that latest drawings, sspecifications,grades of materidls, correct tools & tackles etc. are used.They shall also guide the workers in the interpretation of drawings / documents so that work is carried outin correct sequential manner, meeting the various in process inspection activities.5.4 WELDING FOREMAN shall be responsible for deployingQualified welders.They shall also be responsible for ensuring that the welderswithdraw electrodes as per WPS and that they work within the weldingparameters of approved WPS.5.5 QC INSPECTOR / WELDING INSPECTOR shall be responsible for carryingout the in process Inspection including dimensional check of fabricated spools,arrangement for NDT and relevant tests as per ITP’s. They shall also beresponsible for maintaining the documentation & records of inspection.5.6 RIGGING FOREMAN shall work in full compliance with Safety Procedures forsafe handling of materials during the process of piping fabrication works.5.7 SAFETY OFFICER shall ensure that all the Equipment, Tools and Tackles arecertified in accordance with the site HSE Requirement. All manpower, directly or indirectly involved in this activity shall be informed of the hazards and risk factor.All regular Safety Equipments(PPE) shall be used like helmet, goggles, workgloves, safety hamess etc.6.0 PROCEDURE6.1 Safety1) All equipment and accessories shall be verified and of adequate capcityacording to HSE requirements.Contract No. MPP-ITB-11-052) All personnel involved in fabrication works shall be informed of hazards andwill adopt preventive measures while using said substances.3) All electrical equipment shall be properly earthed and display appropriateinspection color coding.4) All the welders must use their safety equipment such as welder helmets, handgloves and personnel protective equipments (PPE)5) All the necessary safety precautions to be followed while carrying out NDT’ssuch as RT, PT, MT and UT as mentioned in the relevant procedures.6.2 Equipments & Tools / Tackles- Crane (With valid Certificate)- Trailer- Welding Generators- Cutting Machine- Gas Cutting accessories- Grinding Machines- Chain Pulley Block- Electrode Oven- Power Generators / Other hard tools.6.3 Sequences of operations6.3.1 Receipt of Material and StoragePipe materials including CS, LTCS and Stainless Steel, which are received, shall Be stored in the lay down area,They shall be stacked properly without touchingthe ground, placed on wooden rafters, Care shall be taken to stack materialssegregated as CS/LTCS/SS and each area shall be designated, LTCS shall have a designated colour code .6.3.2 Issue of Materials to Piping Department from Subcontractor’s StoreContract No. MPP-ITB-11-05As per progress schedule, Piping Engineer shall draw the required material fromstores through Material Issue Voucher.6.3.3 Receipt Inspection of MaterialsOn receipt of materials, Piping Superintendent / Foreman shall check thematerial class, size, schedule and heat nos. Discrepancies shall be reported toQA/QC department. Due Instructions shall be given to workers to transfer all the necessary information before cutting pipes.6.3.4 Cutting of Pipes as per drawingsPipes shall be cut to lengths as specified in isometric drawing taking in toaccount of minimum wastage.During fabrication of pipes, care shall be taken totransfer all the identification details such as Isometric drawing number, spoolnumbers,pipe material identification and heat number on marked area beforecutting, Heat numbers of other items like flanges, elbows, tees, o-lits etc. will beavailable on material itself.6.3.5 Edge PreparationCutting and edge preparatin shall be in accordance with project specificationwith approved Welding Procedure Specification (WPS)All paint, rust, grease etc. shall be cleaned for a distance of 25 mm from theweld edges from inside and outside of pipes and piping components.6.3.6 Cleaning:Prior to Piping Fabricaton, all pipes / spools shall be cleaned by air blowing orManual cleaning as mentioned below.1 ) Pipe diameter less than 24”-cleaning to be done by air blowing.6.3.7 Fit up of assemblyBefore fit up, the pipe and fittings shall be visually checked for insidecleanliness. The fit ups shall be carried out as per the requirements of WPS &drawing. Fit up shall be carried out by root tack welds using qualified weldersContract No. MPP-ITB-11-05and approved welding consumables as per approved WPS. The root tack weldsshall be ground to a taper edge to fuse smoothly with the root pass, Arc shall bestruck inside the groove and not surfaces of pipe or fittings.During Fit-up of large bore piping joints, bridge tack outside the groove on pipe, may be permitted ,subject to Company’s approval, In such case, DP or MPI is to be carried out after removal of bridge.Longitudinal seams shall be located to clear openings and extemal attachments.Longitudinal seam shall be locatedin top quadrant of pipe to extent possible.After completion fit-up, groove shall be protected by masking tape.Qc lnspector shall conform material type and heat number marked on each itemduring fit-up inspection and verify with respect to QC lsometric drawing. Fit-upinspection clearance shall be signed off near the weld joint numbering, markedadjacent to fit-up.In Socket Fit-up assembly, 1.5mm to 3mm gap shall be maintained between thebottom of socket between pipe and valve, fittings of slip-on flange.Weld joint number, Welder no .and all identification marking shall be writtennear the joint by solid paint marker. The metal marker with low chloride shall be used for stainless steel materials and shall be approved by Contractor.6.3.8 Inspection of assembly.The spool identification tag shall be tied up on each piping spool prior toinspection of assembly.Inspection of fit up assemblies including dimensional check of fabricated spoolsshall be carried out prior to release for welding.6.3.9 welding of jointsRequirements of the WPS (i,e, Type of consumables, pre-heating, weldingprogression, etc.),specification of piping and HSE practices shall be followed.Only qualified welders shall be used for Tacking & welding, All the temporaryContract No. MPP-ITB-11-05tacks/bridge shall be removed one by one (by grinding) as the weldingprogresses. Before leaving any joint in partially welded conditions, a minmum 3runs of welding must be completed. Each pipe spool shall be thoroughly cleaned from inside after completion of fabrication and welding and the ends shall becovered with suitable plastic sheet covers ofr hard boards in case of flange faceprotection.Temporary bracing to be given with bracket arrangement wherever needed toavoid distortion during welding, same should no be welded on bare pipe.6.3.10 Visual Inspection of Joints Before, During and After Welding1) Qc Inspectors shall perform in-process visual inspection before, during andafter completion of welding of the joints, as per approved Inspection .2) The accepted joints shall be marked as “VT OK”near the weld joint by solidpaint marker.6.3.11 Identiflcation of joints and execution of NDE1) The QC / Welding Inspector shall identify the joints to be offered for NDEas per requirement & the applicable piping specifications.2) The idetified piping spools will be shifted to designated place for RT.3) NDE shall be carried out by the NDE subcontractor in accordance withapproved NDE procedures.4) QC Inspection / NDE coordinator shall organize for RT, MT, PT and UT asper the requirement of Piping Specification, He shall also organize for NDT’srequired ofter repairs, The QC Inspector / NDT coordinator shall be responsiblefor Interpretation and Reporting of NED’s and also for co-ordination of NDEwith contractor’s QC Representatives.6.3.13 Pneumatic TestPneumatic testing of RF pads & pad segments on pressure connections shall becorried out as per ProjectContract No. MPP-ITB-11-056.3.14 Control of Non-conformance or non-compliance are fonud, will be dealt asper approved Procedure;1) After completion of pre-fabrication, the spools shall be cleaned by airblowing and be free from weld spatters, arc strikes and foreign materials onoutside and inside pipes.2) Flange face and threads shall be protected from rust by applying suitablerust preventives as applicable. Where wood covers are used, a polythene sheetshall be placed between the coated flange face and the cover to prevent thegrease from soaking in to the wood, Flange gasket surfaces shall be protected byplywood tied to the flange face.3) All open ends shall be blanked properly to prevent entry of foreign materialsand damage to bevel ends, during transportation and storage.4) No spool shall be released from fabrication shops to lay down yard or toPainting or to Coating & Wrapping before being fully inspected and released byQC department.5) Prior to dispatch of the pre-fabricated materials to site, Spool ClearanceRecord shall be checked,6) Pipe spools shall be carefully stored in their designated area in accordancewith area identification numbering.7) The spools shall be laid on wooden sleepers or other suitable materialabove ground level and chocked to prevent movement8) The movement of spools shall be controlled in order to have fulltraceability till it gets installed at its final position9) QC Inspector shall verify the piping spools and piping components by thespool identification tag attached, prior to installation.10) Subcontractor and Contractor together shall offer a demonstration of Jointpreparation of Pipe, Flange etc to Company prior to commencement of actualContract No. MPP-ITB-11-05work, Information about time and venue shall be passed to company 24 Hrs in advance.7.0 DocumentationContract No. MPP-ITB-11-05PROJECT :Document NO. 11108-MS-PC-001. Rev: B0 11Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 12Contract No. MPP-ITB-11-05PROJECT :Document NO. 11108-MS-PC-001. Rev: B0 13Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 14Contract No. MPP-ITB-11-05CHANGING CONDITIONS & EMERGENCY Stop Work, Switch off equipment, Supervisor directs personnel to nearest and safest.Muster point Considering Wind direction, supervisor accounts for all Workers,Missing persons are reported to WISON EHSS Dept, When all clear is given check with WISON EHSS before resuming to work.NOTE: If any of the tasks involves biological, physical or chemical hazards,Then WISON Industrial Hygienits must also approve the work use additional sheets as necessary.Details on safety (PPE, Hazards etc) and environmental requirements can be found in WISON and Ras Gas Safety and Environmental procedure.Document NO. 11108-MS-PC-001. Rev: B0 15Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 16Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 17Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 18Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 19Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 20Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 21Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 22Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 23Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 24Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 25Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 26Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 27Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 28Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 29Contract No. MPP-ITB-11-05Document NO. 11108-MS-PC-001. Rev: B0 30Contract No. MPP-ITB-11-0531 Document NO. 11108-MS-PC-001. Rev: B0Method Statement for Piping Pre-fabrication。