Doc. No.: Method Statement for Piping Fabrication & Installation Rev. No. : Sheet 1 Doc. No. : Method Statement for Piping Fabrication & Installation Rev. No. : Sheet 1 A) FABRICATION 1. PURPOSE This procedure describes the general requirements for shop & field fabrication, installation and inspection including, carbon steel and stainless steel for Integrated Gas Development (IGD) Project, Das Island (except for FRP piping and HDPE piping). 2. SCOPE It should be noted that this document is intended to present CONTRACTOR's plan for accomplishing the work but is not intended to provide every detail on how the work will be executed. In addition to the information contained in this procedure, CONTRACTOR will carry out fabrication and installation work to meet the requirements of drawings, technical specification, standards and codes as set out in the contract. In case there are any conflicts between this procedure and contract document, the later shall govern. 3. DEFINITIONS Company: Project: ADGAS / IGD Das Island Project. This shall refer to the subject contract for Integrated Gas Development (IGD) Project. Hyundai Heavy Industries. Include output in the form of hard copy, drawing, tracing, reproducible, & field inspection reports. Contractor: Document: Doc. No. : Method Statement for Piping Fabrication & Installation Rev. No. : Sheet 1 4. RESPONSIBILITIES 4.1 Construction Manager Constructions Manager has the overall responsibility for this Method Statement and is responsible for supporting it and for ensuring that all entitles at the Worksite actively participate. 4.2 Deputy Construction Manager (Piping) Deputy Construction Manager (Piping) has the responsibility for compliance with this Method Statement and shall ensure that review contract documents and provide all resources necessary to effectively implement throughout the construction period. Deputy Construction Manager (Piping) shall review the construction details and specification with piping Engineers & ensure they should fully understand the requirements of the job. Deputy Construction Manager (Piping) shall ensure that all personnel involved in the project are fully aware of all quality control requirements. Deputy Construction Manager (Piping) shall monitor the quality and progress of the work plus ensure project Schedules are achieved. Deputy Construction Manager (Piping) shall identify any problem, which may affect completion or progress of the job & produce proposals for submission to ADGAS / IGD Construction Manager for resolving the problem. 4.3 Piping Engineer / Supervisor Piping Engineer / Supervisor shall ensure that relevant quality control check sheets / report formats are available and duly completed where identified on Inspection and Test Plans (ITP). Piping Engineer / Supervisor shall report any problem that may affect quality, completion or progress of the job to the Deputy Construction Manager (Piping). Piping Engineer / Supervisor shall give support to QC Inspector for ensuring that required inspection and tests are attended and any defects noted are rectified to the satisfaction of the Company. Piping Engineer / Supervisor shall coordinate receipt of materials with Material Controller and supervise lifting and offloading to the site. Piping Engineer / Supervisor shall ensure that the equipment and tools required for carrying out the job are available, maintained and used in safe manner. Piping Engineer / Supervisor shall produce all necessary records / diaries for the confirmation of works completed and pass to QC inspector as required. Doc. No. : Method Statement for Piping Fabrication & Installation Rev. No. : Sheet 1 4.4 QC Manager QC Manager has overall responsibility for all QC activities of the project. He shall be interacting with related to all Piping QC activities. He shall be responsible for Non conformance management and Quality Audit. 4.5 QC Engineer QC Engineer shall be responsible for the QC activities, material control and traceability, Nonconformance management and compilation of test packs for Hydro / Pneumatic Test. 4.6 QC Inspectors QC Inspectors shall be responsible for Site QC activities, co-ordination with HSSE authorities for NDE works, Piping/Welding department for inspection activities and NDE sub contractor for NDE works at site. 4.7 Welding Engineer Welding Engineer shall be responsible for welding control activities. He shall be responsible for the execution of correct welding techniques / control with strict adherence to this Method Statement and reference documents. 4.8 HSSE Officer HSSE Officer shall monitor the HSSE aspects of the work and ensure that they are carried out, and advice supervisors for corrective measures, if required. He shall ensure holding of pre task TSTI covering details of specific tasks and specific job risks involved to the work force involved. He shall also ensure appropriate mode of communication in case emergency. Doc. No. : Method Statement for Piping Fabrication & Installation Rev. No. : Sheet 1 5. RELEVANT SPECIFICATIONS AND CODES HHI (and subcontractors) shall apply the most recent applicable standards and codes issued by the following associations and approval bodies as part of this specification. 5.1 Specifications 1) GD-100-A4L-5-94043: Specification for piping design 2) GD-100-A4L-5-94097: Specification for pipes 3) GD-100-A4L-5-94099: Specification for flanges 4) GD-100-A4L-5-94098: Specification for fittings 5) GD-100-A4L-5-94100: Specification for Bolt/nut 6) GD-100-A4L-5-94101: Specification for gaskets 7) GD-100-A4L-5-94096: Specification for valves 8) GD-100-A4L-5-94049: Specification for hot insulation 9) GD-100-A4L-5-94050: Specification for cold insulation 5.2 Codes 5.2.1 American Petroleum Institute (API) API RP14: Recommended practice for design and installation of offshore production platform systems API SPEC 5L: Specification for line pipe API STD 590: Steel line blanks API STD 598: Valve inspection and testing 5.2.2 American Society of Mechanical Engineers (ASME) ASME B1.1 Unified Screw Threads ASME B1.20.1: Pipe Threads, General Purpose ASME B16.5: Pipe Flanges and Flanged Fittings ASME B16.9: Factory made Wrought Steel BW Fittings ASME B16.10: Face to Face & End to End dimensions of valves (for Dummy spools) ASME B16.11: Forged Fittings, Socket Welded and Threaded ASME B16.20: Metallic Gaskets for Pipe Flanges ASME B16.21: Non Metallic Gaskets for Pipe Flanges ASME B16.25: Butt-Welding Ends ASME B16.36: Steel Orifice Flanges ASME B16.47: A Large Diameter Steel Flanges 10) GD-100-A4Z-5-90504: PWHT procedure for Piping. 5) GD-100-A4Z-5-90107: Material Identification and Traceability procedure. 11) GD-100-A4Z-5-90505: Flushing and HYDRO test Procedure for Piping.10M: ASME B36. 13) GD-100-A4Z-5-90507: Chemical cleaning and Oil-flushing procedure. No.3: ASME B36. 8) GD-100-A4Z-5-90116: NDE procedure for piping. .3 Project Documents 1) GD-100-A4L-5-94045: Piping Material Classes. 4) GD-100-A4Z-5-90105: Non conforming item control procedure. : Method Statement for Piping Fabrication & Installation Rev.19M: ASME Part A: ASME : ASME : Process Piping Carbon Steel Pipe Stainless Steel Pipe Materials-Ferrous Materials Specifications Non-Destructive Examination Welding and brazing qualifications 5. 7) GD-100-A4Z-5-90110: Qualification procedure for welder and welding operator. : Sheet 1 ASME B31. 14) GD-100-A4Z-5-90013: Painting procedure. 9) GD-100-A4Z-5-90121: Inspection and Test Plan for Piping. No.Doc. 2) GD-100-A4Z-5-90102: Project quality Audit Procedure. 6) GD-100-A4Z-5-90109: Welding consumable control procedure. 3) GD-100-A4Z-5-90104: Material Receiving Inspection Procedure. 12) GD-100-A4Z-5-90506: Bolt tightening procedure for piping. 2 Fabrication Area Fabrication of different materials like carbon steel and stainless steel materials will be carried out in separate designated areas in the fabrication yard.Doc. : Sheet 1 6. cutting tools for facing machines will be identified by color codes for carbon steel. 6. stainless steel materials as per the material control procedure. stainless steel and high alloy materials and low-alloy ferrite steel will be fabricated in separate areas. No. : Method Statement for Piping Fabrication & Installation Rev. Stainless and high alloy materials will be stored in separated areas on the timber lined floor of the stock area and will be moved by the use of web slings or by hand into clean timber/rubber lined trestles/work benches. at least 1800 mm high to ensure that all possibilities for contamination of stainless steel and high alloy materials with ferrous materials i. carbon steel grinding particles are eliminated between carbon steel and stainless steel.e. . No. Tools for use on stainless steel and high alloy materials will be kept in separate tool boxes under the control of the material controller and foreman. Carbon steel. Welding of carbon steel and stainless steel shall be kept separated by using cubicle type isolation. All tools such as wire brushes. It does not apply to FRP and HDPE piping or to instrumentation piping and tubing downstream of the first block valve. There shall be no direct contact between carbon steel and stainless steel material under any circumstances.1 General The procedure applies to all piping fabrication including carbon steel and stainless steel within packaged units or other sub-assemblies. 3.1. etc. All flange faces including gasket grooves in ring joint flanges shall be prevent direct contact with foreign materials 6. . Material control department shall control and issue the material in accordance with the COMPANY approved material control procedure. 6.3. : Sheet 1 6.3. (GD-100-A4Z-5-90104) All materials. fittings and others.Doc. No. No. Carbon steel and non ferrous materials will not be transported stored in such a way as to cause cross contamination of the materials as per the material control procedure. 6.3.4. whether loose or prefabricated will be stored as per the material control procedure.5. : Method Statement for Piping Fabrication & Installation Rev. All materials. Any re-facing that reduces the flange thickness to less than minimum thickness allowed by the relevant code or standard will be rejected.3 Material Control In regard to the material control. Edge thickness of flange will be checked after re-facing.3. 6. separated from accepted material with sufficient safeguards to preclude it being used.3.) shall be received separately from the material control department as specified on the material requisition sheet. issued by the production design department. Materials (pipes. HHI and subcontractors will refer to the material receiving inspection procedure. whether loose or pre-fabricated will be stored as per the HHI material control standards Material found to be defective or incorrectly marked or lacking relevant documentation shall be immediately placed in a quarantine area. 6.2. No.2 Stainless steel.2. A) Large sized pipes (above 28" NPS) and holes of branch connections shall .Doc.4.4.2. : Method Statement for Piping Fabrication & Installation Rev. tagging (Aluminum strip with punch marking) shall be used. 6. For small bore Piping. Saw blades used for cutting carbon steel are not to be used for cutting non-ferrous material.2 Cutting and Edge preparation: 6. : Sheet 1 6.1 Carbon steel shall be cut by of flame cutters.4. where spool size permits.4 FABRICATION SEQUENCE Spool Fabrication Flow: Note: Insulation for Welded joints should be carried out after the Hydro Test. high alloy steel shall be cut by high speed cutters. 6. and grinder or band saw machines.4. grinders or band saw machine. 6.1 Marking: Marking shall be clearly painted in characters 50 mm high. high speed cutters. No. The application of the compound is applied completely around circumference. : Sheet 1 be cut by a plasma arc cutting machine. A detailed sketch / drawing is shown in Figure 1 B) If the cutting area is inaccessible. the anti-spatter compound shall be removed by cloths or other methods. : Method Statement for Piping Fabrication & Installation Rev. All materials cut by a flame or arc shall have the edge ground back to clear the affected zone. .Doc. dedicated to stainless steel and high alloy materials. The grinding wheel is marked by an impregnated red dye in the make-up of the disc which denotes chloride and sulfur free material when used for stainless steel and high alloys. No. No. a spatter compound is applied to the inside cutting area by brush. Certificates for chloride and sulfur free construction materials. After cut. a receiving basket for spatters shall be inserted in the inner cutting area of the pipe to avoid adherence of spatters to internal wall of pipe. Files for use on stainless steels and non ferrous alloys shall be new and dedicated to a particular alloy only. a minimum of 200mm on each side of the cutting area.4.4.3. When cutting starts.4 All edges shall be accurately maintained as per design requirement with a smooth even surface with all slag removed. if access permits. 6. Wire brushes with stainless steel bristles will be used. (Doc no: GD-100-A4Z-5-9________) 6. roller or swab. scale or internal burrs . Alignment for the fit-up of the piping components shall be executed on a steel floor or steel jack stand for carbon steel spools.4. No. : Method Statement for Piping Fabrication & Installation Rev.4. high alloy & non ferrous materials shall be allowed to come into contact with carbon steel. All flanges. 6. The number of welds in a spool shall be in accordance with approved spool drawing. Inspection of fit up assemblies shall be done and the relevant reports shall be duly filled in. Fit up. Stainless steel and high alloy pipe shall be beveled by a grinding or beveling machine only. whichever is greater. machining may be conducted to improve root alignment providing the taper is not steeper than 1 in 4.4.1.5.5.P. For stainless steel and high alloy spool fabrication.5.3 paragraph 335 shall apply. Edge Preparation for Welds 6. No. All stands will be insulated with clean rubber sheet to prevent contamination of the spools. If exceed. fittings and pipe to be welded together should be provided for same internal bore. However internal radial alignment due to differences in tolerances for bore up to 100mm should not exceed 1.5. The surfaces of the edge shall be free from tears.3. 6.5. : Sheet 1 6. oil slag.5. 6.S & ASME B 16. Misalignment may be alleviated by the use of hydraulic or screw type clamps except where ASME B 31.5.0 mm.4. Under no circumstances stainless steel. The minimum spacing between circumferential weld joints shall be 2³ or 6 times the wall thickness of the pipe. Fit-up inspection of assembly. unless otherwise approved by COMPANY. 6. it shall be taper-trimmed.1. Pipe lengths less than 3 m long shall not normally be welded together. (DOC No: GD-100-A4Z-5-9________) 6. Edge preparation shall be performed in accordance with the approved W. Separate machines will be used for carbon steel and stainless steel.Doc.5.4. the floor will be covered with wooden planks or rubber.2. The preparation of edge for welding shall be done by machining or grinding.4. . grease.25 6.2. After completion welding of W1. shall have the opening contoured to the branch to provide a good fit. W4 and W6 joints of above sub spools cannot be welded by automatic welding process (1G). No. The bolt holes of flanges shall straddle the normal horizontal and vertical centerline of pipe. So. W3 and W5 of each sub spool shall be welded by 1G as per approved WPS by COMPANY. W3 and W5 joints. Fit-up for maximization of auto welding (1G) The above spool shall be separated into (1).Doc. The above method is established for maximum utilization of automatic welding (Doc No. which abut the outside surface of the pipe wall. At the welding area.5. the spools shall be transported to the fit-up area for completion.e.5. : Sheet 1 If component ends must be trimmed to correct internal misalignment. No. After completion of fit-up (1). Hammering. 6. these joints will be welded by a manual welding process i. or which are inserted through an opening cut in the pipe wall. W2.W1 of (1) spool and W3 of (2) spool and W5 of (3) spool shall be fitted up by GTAW process as per approved WPS (Doc No. (2) and (3) sub spools.: GD-100-A4Z-5-90511) . jacking or heating the pipe is not permitted. Welded branch connections including integrally reinforced branch connection fittings. corrosion and erosion allowances.. (2) and (3) spools shall be transported to welding area for automatic welding (1G).2. Holes for attachment of weldolets and nippolets shall be made using drills or hole saw and all burrs shall be removed. W1. : Method Statement for Piping Fabrication & Installation Rev.1. GTAW + SMAW or GT+SM+FC or GT+FC as per the approved WPS by COMPANY.2.: GD-100-A4Z-5-90511) by COMPANY and taped-up to prevent contamination.2. 6. it should not reduce the finished wall thickness below the required wall thickness for the pipe or fitting including all mechanical. 4 Maximum fabricated spool dimension shall be 12 m x 2.2.3 ³Chemical Plant and Petroleum Refinery Piping´.25 and approved WPS. Stainless steel wire brushes shall be used for all other materials except carbon steel and low alloy steel 6.5 m or the largest transporter available on the site. scale. In the case of submerged arc welding of carbon steel and low alloy steel. unless specifically authorized in writing by COMPANY and in accordance with ASME B31. All welds shall be performed in accordance with the approved WPS which shall be displayed on a notice board close to the work. : Sheet 1 6. oil or contamination due to flame cutting or machining. Cleaning must be carried out just prior to tacking and repeated just prior to welding. The welding grooves shall conform to the ASME B 31.6. 6. grease. If the above work flow requires inspection. 6. Any cracks. slag.6. which shall be cleaned out by grinding to shiny metal. flux.6. All edges of surfaces to be welded shall be cleaned to a bright metal finish.4. Welding shall not be allowed on piping after Post Weld Heat Treatment.5.6. or other impurities that appear on the surface of any welding bead shall be removed by grinding or chipping before depositing the next successive bead.1. cold laps.5 m x 2. in a manner suitable to remove any oxides. blowholes. No.3. 6. No. 6. . unusual irregularities.3 and ASME B 16.2. 6.Doc. Welding All root runs in non ferrous pipe to be done by the GTAW process and carbon steel where cleanliness is concerned. 6. : Method Statement for Piping Fabrication & Installation Rev. Oil paint and dirt shall be removed from the pipe surface for at least two inches from the bevel before welding is started. Longitudinal weld seams shall be located to clear openings and external attachments. No sealing or back-up rings shall be used. the removal method used may be air arc gouging.6.2.3.5.5.6. the component spools are inspected by inspection as per approved ITP. The remaining wall thickness shall not be less than the stipulated minimum.9. whichever is the less.6mm. as stated in specification ASME B 31. Pipe longitudinal seams shall be positioned in the upper half of the pipe circumference. alignment may be achieved by tapering the thicker pipe at a gradient of not steeper than 1 in 4. Internal purge of argon shall be used for the GTAW process root pass on stainless steels and non-ferrous alloys as specified by WPS. The requirement of the finished weld reinforcement for all materials should comply with ASME B 31. The offset shall not exceed 1. 6. If arc strike occurs. Longitudinal weld seams on seamed pipe shall be out of phase at inline butt welds. The ground area shall be inspected by MT (carbon steel & low alloy) or PT (stainless steels & non-ferrous alloys). for area welded. For pipes of the same grade and diameter.7. The alignment of the abutting ends shall minimize the offset between surfaces. The sketch below demonstrates: .6.9.3.8.D No. : Sheet 1 6. No.Doc. to be marked with welder's I.1. 6. the damaged part of the pipe shall be removed. Purging will be carried out by using the best method for the particular application during welding and shall be maintained until 6 mm of weld material deposited. If pipe is ground severely to repair. : Method Statement for Piping Fabrication & Installation Rev. 6. Adjacent pipe seams shall be separated by 90° or by a distance of 250mm. instrument connections or pipe support attachments shall not bisect any seam welds.6. and any welded attachments such as branches. The minimum rotation for welded long seams shall be 10 times the wall thickness of the pipe or 90 deg out of phase.6. whichever is less. Two welders may be required on pipe ij400 mm and above pipe. No.6.3 specification for piping. 6.6. but different wall thickness.6. this shall be removed by grinding with COMPANY's prior approval. 4The GTAW process shall be used for root pass of all diameters.Doc. No. No.6. 6.5. Each end of the pipe adjacent to the weld of tie in spools shall be dammed by using water soluble paper or sponges at a distance of 150 mm from the weld prep. : Sheet 1 6. . : Method Statement for Piping Fabrication & Installation Rev.3 For all materials.6. Where purge dams are used a register of dams installed should be maintained and signed off when dams are removed particularly during spool erection.9. 6.9.6. pipe butt joint of 2 inch and below shall be made 6.6.2.9.9. 8.2. No. Preheating and inter pass shall be maintained as per approved WPS.9. B. C. in lieu of marking the weld.6. Attachment welds of non-pressure parts by welds. testing and final reinstatement of stainless steels and .6.6.7. D. : Sheet 1 6.Doc. low chloride marking pen (less than 100 PPM) or engraving. 6. : Method Statement for Piping Fabrication & Installation Rev. The specification for weld projection and depression should be in accordance to ASME B 31. The method will be used for the permanent marking for welder identification. 6. G. Reinforcement pads or saddles required by specifications and drawings shall be of the same material as the main pipe (unless specified otherwise) and shall be formed and countered to provide a good fit to both main and branch pipe.6.0 mm drilled and tapped hole (hole to be filled with silicone or grease after testing to prevent ingress of moisture) prior to fitting to the pipe .6. 6. If unavoidable the area to be welded over shall be subject to 100% radiographic or MPI as directed by CONTRACTOR and witnessed by COMPANY. 6. Branch reinforcement pads or each segment thereof shall be provided with a minimum 6. The threaded opening shall be sealed with a piping plug after hydro test. All welded branch connections shall be as allowed by the project piping material class and be welded with full penetration welds. marking shall be done with weather proof chalk (chloride free crayon). All sealing tape used shall be of a kind that is safe to use on stainless and alloy steels. E. After spool installation.9.10.9.9.9.3. After welding the welds an adjacent area shall be similarly examined. Branch connections and outlets A.3.6. F.9. as applicable.9. appropriate records shall be filed as per approved inspection procedure. 6. No. In case of stainless steel. No undercut or overlapping (cold lap) is permitted. Peening and hammering of weld runs are prohibited.6. which cross existing main welds or for which the distance between the attachment weld toe and existing main weld is less than 50 mm should be avoided. Table 341. Stub-in connections shall be set-on type as per ASME B 31.3.11. All welding procedures.8.7.5. all markings shall be removed using an appropriate solvent or pickling paste.7. Performance qualifications will be carried out for all welders and welding operators in accordance with the requirement of ASME IX. 6.7.4.7. 6.1. Storage and issue of consumables shall be done by COMPANY approved procedure. 6.7.7. Please refer the Doc no«««««««««««««««. 6.8. Tack Welds 6. . number. Tack welds shall be made by qualified welders. 6.ferrous alloys. 6. preheating shall be performed in accordance with WPS.1. tack welds shall be done by either GTAW or SMAW as determined by the approved W. 6.8.3. For acceptability of the test weld shall be judged. No.8. the preheat temperature shall be 25 ° C h i g h e r than the preheat temperature for the weld joint. Prior to performing main welding.2 and ASME IX articles II and IV. 6.4. For tack welds. No. Where tack welds are made. photograph signed by CONTRACTOR surveyor.3. All welders should always keep their identification cards at all times with their name.P. 6. The length and number of tack welds for the diameter of pipe being welded shall be specified as follows (see table): .8.9. : Method Statement for Piping Fabrication & Installation Rev. Qualification of welders and welding operators: 6. The qualification limits and ranges for WPS / PQRs and welders will to be based on ASME IX.11.S.3 paragraph 328. 6.Doc.6.. welders & reference to be used shall be qualified in accordance with ASME B 31.2.2. : Sheet 1 non . 9.8. No. with certification material same type & grade as parent material. The use of cleats. Initial fitting up can be achieved using temporary bridge tacks across the groove. 6.1. : Method Statement for Piping Fabrication & Installation Rev. the cut shall be such that 3 mm of the temporary attachment is left for final removal by grinding.T.9. etc. bridge pieces. fixtures. Where removal is by air-arc gouging or flame cutting.Doc. Permanent tacks of the desired penetration and workmanship. without welding to the pipe or fitting.7.2. Temporary Attachment Piping fabrication and installation shall be achieved by use of clamps. Jigs.5. (Length of Tack) Min 10 mm 10-15 mm 20-25 mm Number of Tacks Min 3 3-4 4-6 6. . Removal by hammering or bending is not permitted. and conforming to 3. 6. Temporary attachments shall be completely and carefully removed prior to any PWHT that may be required. tacking strips or other attachments welded temporarily to pipe work to facilitate fabrication shall be of the same or equivalent material as the pipe work to which they are supposed to be attached.. Any crack tacks will be completely removed by grinding and grinding areas to be checked by MPI or PT. No. : Sheet 1 DIA (mm) Up do 50 mm 50 -150 mm Over 150 mm L.1 ~ 4 need not be removed before welding unless handling may have caused the tacks to crack. 10.10. Unless otherwise stated on approved drawing or specifications. cover all threads using the GTAW process with a minimum of two passes and be done with electrodes not to exceed 1/8" inch (3. Material Segregation All material coming shall be segregated at site. Screwed connections subject to seal welding shall be made without the use of sealing compound. No. tapped and cleaned out. Screwed or threaded connections shall not be used on process piping.3. shall include the first block valve. 6. where no seal welding is provided. with a safe manner (Before construction.11.6 mm) away from the "bottom" of the socket. per ASME B 31.10. The joint shall be cleaned of all cutting oil and other foreign material and made up dry to full thread engagement.10.5.7. when specified. Minimum gap is to be 3/64 inch (1. 6.2 mm). 6. : Method Statement for Piping Fabrication & Installation Rev.10. 6. When socket weld fittings are used.3.Doc. before seal welding.1 and ASME B16.10.2. 6.4.8. No.2 mm) and maximum gap to be 1/8 inch (3. Seal welding of threaded connections.11.10.2ij) in diameter. 6. oxide and grease shall be removed 6.10.10.6. shall be packed with fiber reinforced gasket-seal compounds (Loctite 577 or equal). pipe threads shall conform to ASME B 20. : Sheet 1 6.10. 6. 6. Thermo wells shall be attached as per approved spool drawing. All threaded joints.10.9. and any dust. All surfaces of threaded joints shall be checked before connection. Threads shall be concentric with outside of pipe. pipe shall be spaced approximately 1/16 inch (1. during construction and before removal for installation all material will be staging at site As per requirement) .10.1. Seal welded and threaded piping shall not be substituted for socket weld piping connections without prior written approval by COMPANY. Threaded and Socket Welds 6. 6. Doc. : Method Statement for Piping Fabrication & Installation Rev. Flattening measured as the difference between maximum and minimum outside diameter at any cross section of bent pipe shall not exceed 8% of the nominal outside diameter.3.5 mm + 3 mm + 0. flange faces shall be aligned to the design Plane.25º . measured across any diameter within: Flange bolt holes shall be aligned within: Specified angles for bends or branches shall be within: +1.1.12. Before bolting up. Linear tolerances are ±3/32´ (3mm) for line sizes NPS 10´ (DN250mm) and under. The alignment and fabrication tolerances for piping butt welds shall be in accordance with Figure 3 attached.12.12. Tolerance 6.4 mm) for line sizes over NPS 24´ (DN 600 mm) Linear dimensional tolerances shall be applicable to dimensions measured from a common datum for the relative locations of branches. flanged or butt-weld ends and shall not be cumulative. The inside wall thickness shall not display any curling or cracks. 6. No. ±3/16´ (5mm) for line size NPS 12´ (DN300mm) through NPS 24´ (DN 600 mm) and +1/4" (6. The pipe wall thickness on the outside of the pipe bent shall remain within the specified pipe wall thickness schedule manufacturing tolerance as per applicable ASTM.12. No.2. 6. The dimensional tolerance should be in accordance with Figure 2 attached. : Sheet 1 6. : Method Statement for Piping Fabrication & Installation Rev. No. No. : Sheet 1 Application of Pipe Fabrication Tolerances Figure 3 Alignment and Fabrication Tolerances for Piping Butt Welds .Doc. : Sheet 1 .Doc. No. : Method Statement for Piping Fabrication & Installation Rev. No. 6.13.2. Flanged openings shall be sealed with steel flanges at least 5 mm thick with oil resistant rubber gaskets and at least four full diameter bolts. Undercut shall be limited to 0. No. : Method Statement for Piping Fabrication & Installation Rev. the spools shall be stored on pallets as per the pallet control system.(before finalizing we need confirmation fro Mr HHKim) 6. : Sheet 1 6.14.13.13. NDE and visual inspection should be performed in accordance to ASME B 31.14.5 mm occasional. After completion of painting. all flanges and gasket surfaces shall have all openings suitably sealed. No internal undercut is allowed.3 table 341. Extent of welding test shall be examined in accordance with the approved NDE procedure for piping.6.2.13. NDE for final acceptance shall only be accomplished after the weld is complete. When welding is carried out under a WPS which has been qualified with PWHT. the weld is not complete until the PWHT is complete. Root concavity shall be accordance with the ASME B 31. No.1.5.14.13. 6. The surface of repair welding will be cleaned thoroughly before welding in accordance with applicable W. STORAGE / STAGGING 6. All repairs and initial NDE will be completed prior to stress relieving of the pipe spools.13. For preservation. spools should be blown thru or internally swabbed to remove contaminants. Before delivery. intermittent. 6.4.13.3 for piping.3. 6.2. Studded opening shall be secured with all nuts needed for the intended service and rubber . After final completion of carbon spool fabrication.S. checks will be made to ensure that all end covers are in place on piping spools to prevent ingress of dirt and moisture. 6. carbon spools will be transferred to the painting area. Before transfer to painting area. After gouging for removal of defects the area shall be ground smooth and shall be tested by MPI (carbon steel) or PT (non-ferrous steel) 6. NDE and Repair of defects 6.P.Doc.1.3. high alloy & Non Ferrous spools are transferred to the pipe stock yard directly and segregated from carbon steel spool 6. Inspection. ««««««««««. No.). The Piping Fabrication will fabricate the spools as per the line system 6.4.. All threaded nipples and bosses shall be protected using waterproof tape or equivalent material to prevent damage to the threads.3.6. 6.14.14. no. Painting A protective coating will be applied in accordance with the COMPANY specification and approved painting procedure. 6. Cleaning and Testing Inspection will be done in accordance with the COMPANY specification («««««.5. touch up & insulation of the field welded joints can be carried out after the successful completion of hydro Test. Spools for yard installation and off-shore hook up and all pipe ends will be protected by caps.) and Material Control Procedure (Doc No.14.16.). GD-100-A4Z-5-90xxx After the installation of piping spools . Procedure for Painting Doc.Doc. Cleaning shall be carried out in accordance with COMPANY specification («««««. : Method Statement for Piping Fabrication & Installation Rev.. After completion of fabrication. The Engineering Department will sort and select the spool as per the line system in order to install the spools on the equipment or part or equipment conveniently.15. plywood or equivalent methods attached to flanges to prevent ingress of dirt etc. No. 6. 6. stainless steel. : Sheet 1 gaskets.) and testing shall be carried out in accordance with the COMPANY specification (««««««««. The threaded openings shall be sealed with solid-shank threaded plugs before moving the pallets. .14. : Sheet 1 6. . Each end shall be protected by a closed type plastic protector securely held in place with a minimum of three layers of waterproof tape. including gasket grooves in ring joint flanges. Stainless steel. Carbon steel spools with beveled or grooved ends shall be thoroughly cleaned and coated with rust inhibitor to prevent rust fabrication.1. shall be cleaned of all mill scale.17.17.Doc. Preparation for Shipment (Ship loose) Polythene sheet will be placed between the flange and the plywood to prevent the cover absorbing the grease. No. High alloy & Non Ferrous material All beveled and grooved ends shall be prepared as per the paragraph above.2. 6.1.2. Each flange face shall be covered with a plywood cover held in place by hot dip plated bolts of at least 1/4" diameter. except that ends do not require the rust preventive coating. 6. Up to 50% bolting may be used with a minimum of four bolts or tie-wraps. 6. Carbon steel flange face. : Method Statement for Piping Fabrication & Installation Rev.17.1. No. rust etc and shall be coated with rust inhibitor to prevent rust formation.17. Carbon steel & Low-alloy ferrite steel 6.17.1. Doc.18. 6. The following equipment may need to be used for this work A) Cranes B) Compressors C) Welding Generators D) High Frequency sets for Welding E) Welding Sets F) Gas Cutting Sets G) Grinding M/Cs H) Hand Tools I) Propane Heating Torches J) Gas Cylinders (Argon. No. All Construction Equipment shall be inspected and approved by ADGAS /IGD Third Party Inspection in accordance with Equipment Check List prior to work inside ADGAS / IGD Area.18. Acetylene.2. : Method Statement for Piping Fabrication & Installation Rev. Oxygen.18. No. INSTALLATION TOOLS AND EQUIPMENT 6. Propane) K) Pick-Up L) Trailers .1. : Sheet 1 6. Implement equipment pass system 1.1.1 Safety Audits and Unsafe act auditing 2.1 Ensure Lifting slings and tested / Inspected and correct color coded 3.3.2 Emergency communication telephone numbers issued to site staff 2. Job Hazard Analysis JOB HAZARD ANALYSIS Job / Task: Shop /Field Fabrication of Piping Job Step No. 3. 2.2.3.1 Unauthorized Lifting Cranes 3.1 No personal are allowed to stand on trailer before the piping materials reaching to the trailer deck or while lifting the material from the trailer deck. No.3 Injury accidents due to improper handling of tools and equipments 2 TSTI 2.2.1 Engaging unskilled and in-Experience workers 1.1 Use local language and to be simple and concise 2.1 People not familiar with the Job and Hazards involved.1 First aider on site Emergency response plan in place 1.2 Use of defective tools and Equipments 1. : Sheet 1 ATTACHMENTS 1.2.1 Ensure Lifting crane is inspection and certified by ADGAS / IGD 3. : Method Statement for Piping Fabrication & Installation Rev.4.4 Too many signal confusing the operator 3 Loading /Unloading the Pipes 1.3.2 All workers will be inducted by ADGAS /IGD for safety 1.2. Description Hazard / Potential Incidents Control Recovery / Measures 1 Mobilize Men and Equipments 1.1 Engaging trailer & Approved Rigging person as banks man for signaling .Doc.1.1 Conduct tool box talks by line supervisor and safety offices (Confirm understanding) 2.1 Counseling and Training Disciplinary action as last result 3.2 Failure of Lifting slings and dropping the materials 3.4.2 All equipment will be certified by ADGAS /IGD with third party certificate for all lifting equipments 1. No.3 Personal standing on the trailer while Loading/ Unloading 3.1.4 Subject matter incomplete 3.1.1.2.1.2 Poor understanding of workers 2. Ensure by visual inspection lifting slings are in good condition and free from damage 3. Engage skilled workers for the work 1.2.3 Poor safety attitudes of workers 2.3. 2.1 Damaged wiring may cause shock or electrocution 7.3. leggings. color coded lifting equipments regular maintenance and third party inspection to be carried out 6.1 To use certified .1.1 Observe proper lifting posture.3.1. Use hand gloves 5.2. Description Hazard / Potential Incidents 4.1 All machinery will be certified by ADGAS / IGD 4. signaler and bankman 7. : Method Statement for Piping Fabrication & Installation Rev.1 Carry out housekeeping daily before shift end Inform supervision any obstruction in work area 6 Mechanical Lifting 6. eye goggles to be used 4.1. Dark glass. : Sheet 1 Job Step No.Doc. Electrocution 4.2 Untrained personnel unsafe crane positioning . No.1 Lifting equipment (Faulty slings & cranes defects) 6.2 Proper ventilation to be provided 4.1 To deploy trained operator.1 Handling with improper Posture may result to back injury 5.3.3 Use fire blanket to cover pipe coating 4.3 Use double insulation type tools 7.2. use lifting equipments Provide proper access to work place and ensure constant supervision 5.2.1.2 Defective or incorrect use 4. long sleeve cotton coverall.apron.2.1.1 Report to dress up sharp edges on work piece .Electric shock.2 Check Electric cable for damage and replace any defective material 4.2 Report defect to supervisor 7.2 Work piece Sharp edge on work piece may cause injuries or hot work piece may cause burn 5.3 Slippery surface or obstruction at walk ways may lead to falls or trips resulting to injury 6.1.2 Welders gloves .5 Due to sound Control Recovery / Measures 4 Welding of Carbon Steel & LTCS Piping 5 Manual Handling 5. lifting load 7.3.1 Inspect electrical tools prior to and during use 7.2.4.4 Emergency medical evacuation facility to be available 4. ground condition.4 Fire extinguisher to be provided near welding 4.4 Wear hand gloves 7 Electrical Operated hand tools .5.1 Earth welding generators 4.1 Check the permit to work 4. No.1.3.2 Electricity. face shield.3 Cool drinking water to be provided at all times 4.1. welding mask.3 Confined space working 4.1 Proper PPE will be ensured 5.4 Defective tools and machine 4. Minimize manual lifting .1 First aider in site Emergency response plan in place 4.1 Face injury / Skin burns while working 4. 1 Readymade pocket sized card with emergency numbers to be provided .4.2. No.1 Inadequate ER Plan 8.3.g.Doc. hand phone provided to essential field supervisor staff 8.1 Adequate communication equipment e.4 Emergency contact numbers not available 7.5 Deficiencies shall be rectified immediately 7.2.1.2. : Sheet 1 of hand tools leading to personal injury 7.1. grinding 8 Emergencies 8.1.3 Do not defective tools 7.2.1 Inspect electrical tools prior to and during use 7.6 First aider on site Emergency response plan in place 7.2 Poor emergency response for workers 8.6 First aider on site Emergency response plan in place 7.2.4 Deficiencies shall be rectified immediately 7. weld spatters.3 Inadequate communication Equipment 8. protective cloth and face shield attached with helmet 7.3.3.1 Wear safety goggles. : Method Statement for Piping Fabrication & Installation Rev.3 Flying metal fragments.1 Scheduled for emergency exercise / Drills to be carried out 8.5 Correct tool usage shall be supervised 7.3 Install safety sign / protection cover First aider on site Emergency response plan in place 8. Report defect to supervisor 7.2.3.2.2.1.2 Inspect grinding disc for damage before use 7. No. Follow ADGAS /IGD Emergency response plan 8. Piping Manager shall monitor the quality and progress of the work plus ensure project schedule are achieved.2. PURPOSE The purpose of this Method Statement is to ensure that define the general sequence of events. DAS Island Project.Doc. No. 9. Piping Manager Piping manager has the responsibility for compliance with this Method Statement and shall ensure that review contract documents and provide all resources necessary to effectively implement throughout the construction period. Piping Manager shall review the construction details and specification with Piping Engineers and ensure they fully understand the requirements of the job. .1. SCOPE The scope of this Method Statement covers to the objective and requirement of steps to followed and applicable to Above Ground Piping Field Installation for the IGD DAS Island Project. interfaces and responsibilities relating to Above Ground Piping Field Installation works for the ADGAS / IGD. No. Construction Manager Constructions Manager has the overall responsibility for this Method Statement and is responsible for supporting it and for ensuring that all entitles at the Worksite actively participate. : Method Statement for Piping Fabrication & Installation Rev. 10. : Sheet 1 B) INSTALLATION METHOD 8. 10. Piping Manager shall ensure that all personnel involved in the project are fully aware of all quality control requirements. RESPONSIBILITIES 10. Piping Engineer/Supervisor Piping Supervisor shall obtain the required clearance from IGD regarding completion of above ground field installation in accordance to lines and levels within the permitted deviations stated in the Reference documents as described in Chapter 4. Piping Supervisor shall coordinate receipt of materials with Material Controller and supervise lifting and offloading to the site. maintained and used in safe manner. which may affect completion or progress of the job and produce proposals for submission to Construction Director for resolving the problem.3. MS ITP. : Method Statement for Piping Fabrication & Installation Rev. No. No. Welding Procedure Specification (WPS) schedules.Doc. Piping Supervisor shall give support to QA/QC Inspector for ensuring that required inspection and tests are attended and any defects noted are rectified to the satisfaction of the client Piping Supervisor shall ensure that quality levels are maintained. completion or progress of the job to the Piping Manager. 10. Piping Supervisor shall check that welders and fitters are working to the current approved editions of Drawings. . Piping Supervisor shall produce all necessary records / diaries for the confirmation of works completed and pass to QA/QC inspector as required. : Sheet 1 Piping Manager shall identify any problem.0. Piping Supervisor shall ensure that relevant quality control check sheets / report formats are available and duly completed where identified on Inspection and Test Plans (ITP). Piping Supervisor shall ensure that required daily check sheets are completely signed off and maintained. and that obsolete information is removed from the place of work. Piping Supervisor shall report any problem that may affect quality. Piping Supervisor shall ensure that the equipment and tools required for carrying out the job are available. Rigging Manager Rigging Manager/Supervisor shall physically examine the job site and the equipment to be used prior to the lift. He will be responsible for checking the lifting tools such as slings. QC Inspectors QC Inspectors shall be responsible for Site QC activities.8. : Method Statement for Piping Fabrication & Installation Rev. non conformance management and compilation of test packs for Hydro / Pneumatic Test. He will conduct tool box meeting to riggers and discuss launching plan before any launching commences. . 10. 10. and chain blocks.9. 10. HSSE Coordinator HSSE Coordinator shall be responsible for monitoring all site activities and ensuring compliance to safe work procedures and best practices.4. QC Manager QC Manager has overall responsibility for all QC activities of the project.7. He shall be interacting with related to all Piping QC activities. material controller and traceability. He shall be physically present to supervise all lifts that requires his expertise.Doc. shack. QC Engineer QC Engineer shall be responsible for the QC activities. Piping/Welding Department for inspection activities and NDT work at site. Piping Foreman The Pipefitters¶ assigned will follow the procedures for fitting random pipes on the pipe rack.5. 10. No. : Sheet 1 10.10. 10. No. Rigging Foreman The Lifting Foreman is responsible for lifting and ensures the lifting procedures for pipe launching is followed to the fullest directives of ADGAS / IGD regulations.6. 10. coordination with HSSE authorities for NDE works. He shall be responsible for Non conformance management and Quality Audit. He shall assume full responsibilities for the rigging works. shackles. Controls the movements of equipment by giving signals to the operator. . etc. Banksman .Must stop operator by using whistle and hand signals if there is any danger which concerns people or other machine.Assists operator to safety maneuver the equipment in congested areas where people are working. Pipe Fitter The Pipe Fitters groups including Helper helps the riggers in hauling or moving the pipe. . .Erects necessary barricades to control access of vehicles and to clear out all people from the equipment.12. 10. people. . excavations. He will conduct tool box meeting to the pipe fitters and discuss proper fit-up for random pipes.Always stay behind the operator¶s view or otherwise machines can be dangerous to Banksman as well as to the workers. No.Banksman is the eyes and ears of the operator of the machine wherein he sees nothing (blind spots). raising or lowering chain blocks and monitoring every aspect of pipe installation. trenches. .14. No.13. Welding Foreman Welding Foreman is responsible for all welding works base on Welding Procedure Specification and conducts daily TSTI for all welders. Riggers The Riggers will follow the lifting procedures as planned by the lifting foreman. 10.11. : Sheet 1 10. . 10. .Checks the area for any obstacles like other equipments. : Method Statement for Piping Fabrication & Installation Rev. .Controls the movement of people while the equipment is in operation.Doc. 2.. This plan details the guidelines to be utilized for carrying out all field activities directly related to construction of the permanent facilities. Specially. : Method Statement for Piping Fabrication & Installation Rev. construction Equipment. grinding wheel. welding and testing: that comes under the overall execution plan for the project.Doc. Construction Operation Support Detailed planning will begin for all temporary facilities. No.1. Construction consumables Construction consumables such as welding rod. construction utilities. are as follows. 11. The activities coming under the construction plan are interrelated. No. . consumables and miscellaneous services required to support construction operations. The plan will commence during mobilization and will continue in effect until permanent facility construction is completed and demobilization well in advance. logical and practical construction plan. : Sheet 1 11. arranged alphabetically by subject. CONSTRUCTION PLAN 11. shall be correctly stored at site and stock records will be provided at site.2. welding rods will be controlled by QC Inspector welding rod control procedures. 11. Issuance of construction consumables will be closely controlled to ensure that wastage is minimized and that adequate quantities are always available to provide proper and continuous support of construction operations. cutting wheel.1. Introduction The successful completion of construction in accordance with the approved schedule and contract requirements will be dependent upon a through. tools. Preliminary plans regarding the various construction operation support requirements. All such requirements will be frequently reviewed throughout the course of the work to ensure that all items of construction operations support are adequately provided as required to properly maintain the construction efforts. etc. This construction plan must be compatible with the associated plans such as piping installation. Doc.2.3. 11. It is intended that adequate warehouse stocks of tools will be maintained on site. . It is intended to establish facilities at site for performing of normal serving. House Keeping Construction areas will be kept in a neat orderly and clean manner so as to maintain good. However. Construction Equipment All construction equipment will be brought on board and when required and will be available on site for the estimated periods indicated in the construction equipment schedule.4. : Method Statement for Piping Fabrication & Installation Rev. No. Frequent HSSE inspections of individual tools will be made to ensure that all tools are in safe working condition. equipments requiring major repairs or overhaul will be sent off from the site and will be replaced. maintenance and minor repairs of construction equipment.2. Trash will not be permitted to accumulate throughout the work areas but will be continually removed to designated temporary trash storage areas. 11. The supervisor will frequently monitor job site cleanliness activities in his assigned construction area to ensure that accumulations of waste materials and rubbish are minimized. with ones in good condition.2.2. Rigorous initial inspections will be performed to ensure that all arriving equipment are in good condition and suitable and safe for the intended use.3. No. Construction Personnel Support At an early arrangement will be finalized for the provision of all job site support required ensuring the efficient and safe performance of all personnel. Before Installation (Erection) & after Installation the area where to be installation carried out should be kept clean & clear. efficient working conditions and reduce safety hazards and sanitation problems. 11. Tools To maintain high efficiency. : Sheet 1 11. all craftsmen will be outfitted with suitable tools. if required. arranged alphabetically by subject.3. 11. They verify and document that welding.4.3.4. dirt. : Method Statement for Piping Fabrication & Installation Rev. . 11. construction drawings and WPS. procedures and established quality requirements. To this effect. All piping material & welding consumables shall be conforming to specifications.4. as follows. piping installation works done comply with the approved WPS. 11. 11. etc. grease. He also carries out his own inspections to verify compliance with Specifications.1. Drawings and ITP¶s as follows. No.4. contractor shall embrace the whole range of the project activities. Technical supervision. Enclosure shall be used for welding works when there is wind or dust of unacceptable nature. 11. No. conducting the inspections as per the ITP. The criteria to be followed in order to ensure the compliance of construction works with the established quality requirements will be indicated in proper procedures to be prepared during the engineering stage. Quality Control To obtain the maximum advantage from an effective Quality Control Plan.4. All measuring Instruments shall have valid Calibration Certificates.4. : Sheet 1 Preliminary plans regarding the various construction personnel support requirements.2.4.Doc. Area to be welded shall be cleaned of paint. 11. As a part of the construction temporary facilities an equipped first-aid box will be provided. it is essential to maintain the continuity of responsibility between the various phases of the project. Conform availability of the latest revision of drawings. 11.5. Conform that the ITP for piping prefabrication work is in place. inspection and testing at site are the responsibility of each supervision and his team.4. Plot Plan drawings and P & ID to the Piping Manager and Piping supervisor. : Sheet 1 11. Welders will be qualified as per Welding Procedure Specification (WPS) 12. 11. No. All material test certificates will be verified by Material Controller QA/ QC Engineer prior to issue for construction.5.1. Preparation Bevel end/edges on pipes and fittings shall be prepared by means of the thermal cutting and grinding to provide a reasonably smooth true weld surface. No. . Materials will be inspected by QA/QC engineers to ensure that they are not defective and are incorporated with Contract Requirements. all oxides and traces of previously melted and notches will be removed from edges by grinding or machining. All materials used for fabrication and installation shall be prior inspected and released by QC Inspector as per the requirements of related Standard and as per Codes described. Installations 13. Whenever cutting is employed. Cutting will be made considering suitable allowance taken into account for shape of connections and shrinkage due to cutting and welding. Preheat may be applied during bevel edge preparation and while thermal cutting.6. : Method Statement for Piping Fabrication & Installation Rev.Doc. 12. Drawings Document controller will distribute all relevant Company approved drawings (Approved for Construction) such as Isometrics. Welding Procedure and Welders Qualification QA/QC engineer will ensure that all welding procedures are approved by Company in accordance with the Contract requirements. (GD-100-A4Z-5-90511) 13. Welding Consumables All welding consumables will be controlled as per WPS. if required. prior to commencing any welding works.1. Materials The materials to be used will comply with Contract Requirement & applicable Standards/ specifications. . Bevelling and welding end preparation will be in accordance with specifications and approved welding procedures. Bevel face to be welded and HAZ will be smooth.. : Sheet 1 Special care will be taken to remove internal burrs resulting from cutting. All the transported spools will be covered by polyethylene papers/plywood pieces on both sides of the spool and also any other opening like vent. No. painting and spool tags. lamination. instrument tapping. branches.Doc. 13. Handling. During installation pipe should be warped rubber tape on the section of pipe passing through sleeve. material damages. Surface and end preparation for welding will be as defined in the applicable qualified WPS (Welding Procedure Specifications). Cleaning Requirement The external and internal surface at the cutting edge of the pipe joint will be cleaned by a hand brush and or mechanical wire brush (buffing wheel) for a minimum distance of 2´ (50mm) from the fusion face to prevent contamination in Heat affected Zone(HAZ) of the weld area. Wherever possible spools fabricated in the piping shop will be transported from storage area to the site area and installed. or other defects which could adversely affect the quality and strength off weld. drain. and free from fins. : Method Statement for Piping Fabrication & Installation Rev. during resting. etc. 13. uniform. All fabricated spools shall be protected properly from the damage of material. tears. Storage and Transportation All spools will be handled by means of wide sling bands or belts to prevent damage to the painted piping. Pulling/Dragging activities of spools are prohibited to avoid the damage of painting. especially on Pipes 2´ Diameter. Pipe spools will be stocked in designated areas as possible to the installation area.3. cracks.2. No. 4. ISO-drawings and or other related drawings prior to installation of piping components. : Sheet 1 Also bevel face and HAZ will be prepared free from loose or thick scale. Piping foreman shall make arrangements of transportation of the pipe spools to field as per the requests received by the field piping supervisors. which do not require any prefabrication in the shop.Doc. No. piping installation shall be started. All permanent supports as per piping isometric drawing shall be installed along with piping installation. The dimensional tolerance for finished piping will confirm to the followings: . rust. In case of prefabricated spools from lay down area a Spool Request Form shall be used for the request and intimated to piping spool coordinator at the spool lay down area. (Temporary supports shall be provided and shall be removed when permanent supports are in place) 13. If supports are to be welded at the field for the purpose of any field adjustments the supports may be tack welded at the fabrication shop and forwarded to the field. All necessary NDT shall be completed as per the specification.5.4. Tagging / Marking Pipe racks/tracks/equipment and routing shall be tagged or marked with respect to piping GA drawings. No. moisture and any other materials that would prevent proper welding. The straight lengths of pipes. : Method Statement for Piping Fabrication & Installation Rev. Accuracy and Tolerances Accuracy and dimensional tolerances of pipe spool shall be checked and assured as per the detailed drawings and applicable to Field Fabrication of Piping specification and ASME B31. will be shifted from the paint shop after the painting. grease oil paint. After rectification and instruction from QA/QC Engineer for released for piping. the site location where it will be directly installed with the mention area. 13. supports to be welded on the pipe shall be completed prior to installation work at the fabrication shop. Where possible. The availability of a pipe bends as a measured difference between the maximum and the minimum diameters at any cross-sectional area of a bend will not exceed 8% of the nominal outside diameter of the straight portion of the pipe.Rotation of flanges from the indicated position measured as shown will be within 1/16´ (±1.7.Doc. ends and changes in direction will be maintained within ±1/8´(±3mm) . No. . Piping connections to equipment shall be properly aligned without imposing any stress on equipment nozzles.75mm (1/32´) . etc) The flange face alignment check shall be performed with bolting inserted loosely.5 mm) .2 mm 0.All angular dimensions of bends and branch will be maintained so that out of alignment will be within the tolerance. Flange face alignment Flanges connecting to rotating equipment (pump.1.6.5 mm 13. Flanges.All linear dimensional involves in the relative position of branch connections.Lateral transition of branch connection will be ± 1/8´(± 3mm) . compressors.2. and the acceptance criteria shall be as given below Flange Diameter at OD <300 300 to 600 600 Maximum misalignment at OD of flange 0. No. 13. : Sheet 1 . : Method Statement for Piping Fabrication & Installation Rev.3 mm 0.7.7. Following pre-alignment of the equipment to the required elevations as per relevant drawings the pipe work shall be connected to the equipment nozzles within the manufacture's tolerances or within the following. 13.Alignment of flanges and branch-welded ends measured across any diameter will not deviate from the indicated position more than 0. . Tie -In 13. 7.5.6. 13. The bolting torque shall be per ASME B 16.5.Doc. Flange bolting shall be carried out using a calibrated torque wrench to bolt manufacture¶s recommendation. Except as noted. 13.4. No. plus space for gasket ±1/8´ ±1/16´ ±1/64´ 1/8´ 1/64´ 1/16´ 1/64´ 1/64´ 1/64´ 1/8´ 1/16´ 1/64´ 1/8´ (3mm) < 22´ (560mm) 1/16´ (1.7.Once the nuts are tightened per the required torque.7.5mm) < 24´ (600mm) 1/64´ (0. 13. a minimum of three (3) threads shall protrude from each nut. Final bolting of the flanges shall be carried out after completion of coupling alignments. : Sheet 1 NPS Description < 12´ (300mm) Vertical bolt hole offset Horizontal bolt hole offset Rotational offset Flange face parallelism Flange face separation. . Flanged connections shall be tightened diagonally in counter clockwise direction to obtain an even gasket contact on the flange faces. : Method Statement for Piping Fabrication & Installation Rev. No.7.4mm) 13. The length of the stud bolt shall be as per ASME B16.3. for all piping system fastening shall be with stud bolts.5. Prior to pipe alignment. each pipe or fitting will be inspected to ensure that the outside and/or inside surfaces and bevels are free from foreign materials. .8. the internal surface of the thicker part will be tapered and chamfered to meet the wall thickness of the difference in wall thickness of the two parts in accordance with ASME B31.4 Special care will be taken in order to avoid a reduction of all thickness in the part having the lowest yield strength. : Method Statement for Piping Fabrication & Installation Rev. Qualified fitters have to take care for proper alignment of flanges to pipes and connecting equipments including connection to relief and control valves is of great importance to keep equipments stress free for trouble free operation of the system. : Sheet 1 13. Welder will be advised to get help of fitter to check the right angle/parallelism of flange etc. in between different passes to minimize the bulking effect. Qualified welder will carry out before welding of joints. No. Welders will be instructed to weld both sides of pipe alternatively so that welding shrinkage is made most minimum. Special care will be taken regarding internal misalignment which must not exceed 1/16´ (±1. Piping components will be adequately supported and aligned through the use of jig clamps. or other suitable devices as required in order to avoid deformation and to minimize strains during tacking. On joining pipes or fittings of different wall thickness. Also temporary stoppers/restraints will be provided before starting of welding to avoid distortion/cambering during welding. vessels will be aligned so that no stress is induced on the equipment.Doc. Pipe Fit-up and Alignment Pipe fit-ups shall be prepared by tack welding. Piping connecting to the nozzles of the equipment such as pumps. No. Ends of pipe-to-pipe or pipe-to-fitting joints will be aligned accurately.5mm) in order to facilities welding of the root pass. All flanged joints shall be made with proper sized bolts(as per drawings/ specification)for that flanged end with uniform bolts stress and the gasket properly compressed in accordance with the design principles applicable to the type of gaskets used. the temporary pipe pieces or spools with the same length as the piping component shall be installed instead of piping components.9. : Sheet 1 13. Prior to installation. Pipe Spool Installation Piping spools shall be positioned in the location & slope (if any) to be maintained as shown on the approved construction drawings. Excess pipe lengths shall be cut as per site requirement and checked as per isometric drawings.Doc. or other unbalanced displacement exists. Supports Pipe supports for shop-fabricated spools will be installed based on the construction drawings. Temporary covers made of plywood or metal sheet will be used to cover manholes and flanged connections. all access openings. No. : Method Statement for Piping Fabrication & Installation Rev. During installation of piping all openings (small bores) for pipe connections. If needed to install piping components (valve or other inline components) later. No. bolts. During installation we will warp rubber tape on the section of pipe passing thru¶ sleeve. nuts and gaskets shall be visually exanimate to verify that they are undamaged and corrosion free. 13. Rigging of piping spools shall be performed in a manner that will not cause any damage to the surface of the material. and all ended pipe (small bores) shall be covered with weather proof covers whenever work is not actually in progress. . Flange face must be square with the pipe.10. Temporary support can be used during installation so that no bowing/sagging/ overhanging deficiencies. Installation of pipe spools on the Pipe racks Lifting study shall be carried out by rigging foreman and piping supervisors for the spools to place on pipe racks of higher and lower elevations.1. : Method Statement for Piping Fabrication & Installation Rev. Care shall be taken to avoid any undue strain on the piping components during installation works. geometry of the spool. No colour is applied on Tools used for Carbon steel or Low temperature carbon steel materials. The next spool is placed in the similar way. Check the dimensions as per QA/QC ISO drawings and cut the excessive length and prepare weld edges of the spools to be joined. Installation of piping Components Lifting and access studies shall be carried out when component to be lifted is more than 15 tone in weight and or when free access is not available.2. fittings. : Sheet 1 13. Consider the weight of the spools. Tools used for Stainless steel shall be identified with red paint markings and blue paint marking for alloy materials. boom length and radius and study the load charts. No. Accordingly select the capacity of crane. elevation and location.10. Scaffolding shall be erected as required by Scaffolding procedure the others as per v requirements. Permanent and temporary supports as required will be installed on the rack. No.Doc. . Piping components shall be lifted and placed in a safe way with the least damage to painting and no damage to nearby components. Place the pipe spool on the rack and ensure proper supporting. 13. and flange and valves shall be done as per the requirements of related WPS. Weld edge preparation on the pipe spools.10. The spool pieces may be fabricated using temporary piping materials. level glasses/gauges etc to be checked properly for its location. tag no etc with the drawings to prevent installation on the wrong equipment. Special attention has to be paid to reinstall all internals of non return valves or any other valve. In addition to the welding requirements of ASME B31. shall be installed to confirm pipe fit up configuration. etc. plugs etc for proper seating. : Method Statement for Piping Fabrication & Installation Rev. All necessary measures shall be taken to prevent stainless steel piping components getting into contact with carbon steel and alloy material. then removed and replaced by piping spool pieces (Dummy or Pup spools). For stainless steel piping and Alloy Piping without back welding of the internal side. motorised valves relief valves etc.12. Alloy Piping 13. Installation of Stainless Steel. Dedicated trained crew shall be deployed for reinstalling process. tight shut off valves.g. No. the root pass shall be carried out by the GTAW process (GD-100-A4Z-5-90511) The fit up of the assembly shall be as per WPS & Drawing requirements. : Sheet 1 Before installing the pipe spools it shall be ensured that there is no foreign material (debris.12.12. emergency shutdown valves. Qualified fitters with correct tools will carry out repacking of valves if damaged/worn out any other components e. Pipe fit up / Alignment. strainers. grinding wheels. 13. dust.1.11. Installation of Critical Valves Critical valves such as Control valves. if any. gaskets. Root run of all welds on process pipe line to be made by TIG welding to avoid internal slag generation unless access to back weld is possible.Doc. wire brush etc. sight glasses. shall be used for Stainless Steel and other alloy piping material with suitable colour markings..3 13. 13. Inert Gas Purging. Also ensure its bolts. but must be sufficiently strong to maintain the piping geometry around the valves. Paper dams with sticky taps .) inside the pipe material. No. glass.2. tightening and have no damage. cutting wheels. Separate tools like grinding machines. one spool piece will have a plain end.13.Doc.4 13. which are to be protected properly by means of suitable coverings or any other means. Branch Connections All welded branch connections will be joined to the header with full penetration welds as per approved WPS. Ends Connections End connections of fabricated spool pieces will be in accordance with the following criteria: Before preparing the fit-up of any field weld of two pre-fabricated pipe spools or pipe with fitting/flange. cables etc.13. Connection between Underground and above ground piping (If Required) The connection between the A/Ground piping and U/Ground piping will be flanged connections as shown on the piping drawings (Using Insulation Kit Assembly). Before carrying out any welding. The adjacent spool piece will have a bevelled end and will be installed to the dimension indicated. : Sheet 1 shall not be used. it shall be minimum to ensure internal cleanliness of pipe following proper procedure to remove weld dams. . Low Chloride Masking tapes shall be used for sealing the root gap. No. it is the responsibility of the fabricated to ensure that both adjacent ends are bevelled for field welding and are installed to the drawing dimensions. Soluble dams will be held in place with soluble adhesives. Piping supervisor shall instruct to welder to be aware of nearby/adjacent instruments. if used at all. 13.13.13. Connection 13.2. Inert Gas Purging shall be controlled by both the welder and piping supervisor. 13. end caps and hardboard dams. : Method Statement for Piping Fabrication & Installation Rev.3.1. Branch connections will comply with the requirements of ASME B31. No. Where a field fit-up is required. valves. or Heat treatment.4.13. Teflon tapes to be used for making all threaded connection to ensure leak proof joints. The socket/seal welding will be of minimum 2 runs. it shall be performed after the approval of the Company 13.Doc. 13. Ends will be reamed to remove burrs. . the threaded ends of piping will be protected by threaded caps or plugs to avoid any damage to threads. During storage. The last three threads of the joint shall not be gauged. Sealant approved by the Company will be applied on the outside of male thread and inner side of the female thread before tightening the pipe/fittings. : Sheet 1 Before the installation of Insulation Kit Assembly. transportation and field assembly. Alloy and Stainless Steel Piping: It is to be ensured that minimum 2mm gap is maintained between the pipes a fitting. flange parallels¶ will be checked test lugs will be welded on either side of the Insulation flange joint. all threads will be tapered on Nominal Pipe Thread (NPT) and concentric to the outside of the pipe. Where seal welding is required. Threaded ends of pipe will be clean out without burrs or stripping of threads. thread must be protected.5. When this is not possible. all threading of pipe will be carried out after bending. The connection flange connecting the underground and above ground piping will be protected against possible damage. No.13. No. forging. Normally. etc. : Method Statement for Piping Fabrication & Installation Rev. Threaded Connections Unless otherwise indicated on the drawings. Care will be taken that minimum of 300 mm of above ground piping is wrapped and coated above the finished floor level (FFL) of that specific location where there is a connection between Underground and above ground piping works. All damaged pipe ends shall be re-cut and bevelled.Doc. All required bevels on the piping and tie-ins shall be done by automatic flame bevelling devise. paint by use of brush. Welding shall be carried out with single pipes lowered in and joined one after the other. 13. : Method Statement for Piping Fabrication & Installation Rev. : Sheet 1 13. 14. grinding or approved solvents. Long seams of the straight pipe shall be positioned such that weld is located in the upper half of the pipe circumference and not matching one another but having minimum offset of 50mm. tiein. rust adhesions. this shall be applied prior to tack welding and maintained until the joint is completed Ach welding incorporated into the final weld shall be ground to a feather edge at each and to ensure adequate fusion on the root pass. Prior to fit-up and welding. The root gap shall be checked accurately and shall be as per WPS. Root gap shall be maintained by taper wedge at six locations and same shall be removed on aligning pipe with the clamps.14.15. the bevelled ends of joint of pipe for minimum distance of 50mm shall be thoroughly cleaned of coating paint. the groove face and adjacent face shall be cleaned to remove all grease. Line-up and Clamping External line-up clamp shall be used for line-up all bore pipe. oil. Pipe end preparation Immediately prior to alignment pipe for welding. and elbow and others. No. rust. Welding Where preheat is required for the root run. No. When the re-cut is located at a distance of more than 25mm from the original bevel. . then the re-cut ends shall be ultrasonically inspected for lamination over a zone extending 100 mm from the newly prepared bevel end. except at other piping. dirt and any other foreign matter by use power brush or disc wheel. While carrying out welding of valves care has to be taken to keep its closure in open condition to prevent damage to the internals. shocks. 14. 14. Preheating (if required) and inter-pass temperature shall be maintained during all weld repairs. Welds made by more than one welder shall be marked by each welder in a similar manner and daily welding report will be maintained. the joints surface shall be dried by a flame torch or by other approved methods. No.Doc. . If moisture is present. rust. The cut of the pipe in case of cut-out weld joints shall be re-bevelled Only two attempts per repair shall be permitted.1. Any kind of movement of components. weld joint number using a paint marker. : Method Statement for Piping Fabrication & Installation Rev. The root gap shall be accurately checked and shall be as per approved WPS. Also to check inside surface of valves remain clean (free from dirt. vibration. Welding Joint Numbering All welds shall be identified with the welder¶s number. burrs and any foreign materials) Distance between welds shall not be less than 2´ (50mm) or 5 times the thickness of the thicker component which ever more is unless otherwise. Final NDE for repair welding shall be performed in accordance with NDE requirements for the original welding. Welding Repair Welding repair shall be performed as per approved WPS. Welding shall not be interrupted during a pass and shall be completed with a speed as mentioned in the approved WPS. : Sheet 1 The welding joints surface shall be visually checked for the presence of moisture before Welding. bumping stress and other stresses are prohibited while welding is in progress. No.2. increasing the load uniformly each time until the sequence is completed. bolts shall be installed with the exception of one or two. The pin wrench shall then be removed and remaining bolt tightened by gradually working around the flange until all bolts are tight with equal tension on each bolt. The spiral wound type gasket joints. 15. : Method Statement for Piping Fabrication & Installation Rev. bolt positions. One bolt shall then be tightened sufficiently to keep the gasket seated. After cleaning the flanges for make-up. Radiographic testing percentage required and PWHT requirements will be indicated in the isometric drawings.1. Also. Foreign material and protective grease shall be removed from flange face prior to assembly. When are aligned. 9 o¶ clock. both horizontally and vertically.Doc. welding spatter will be removed by chipping and wire brushing. and faces are parallel. Inspection After welding is completed. In one of the holes left open. Bolts shall be long enough to show one to three full threads after proper tightening. Bolts shall be tightened until the flanges are uniformly seated on the gasket centring. : Sheet 1 15. No. the bolting sequence shall consist of a series of uniform loadings starting with the flange bolt in the 12 o¶ clock position. rust. No. and nuts hand tightened. . dry gaskets shall be cantered by the flanged bolts. etc. Assemble of flange to piping. a pin wrench may be inserted to rise or lower either flange as required to ensure proper alignment. dirt. then transferring successively to the 6 o¶ clock. Cantering of spiral wound type gaskets shall be properly centred. All bolts and nuts shall be thoroughly cleaned before assembling joints. slug shall be removed to provide clean weld bead for inspection and NDE. Completion Checks 16. 16. P & IDs / Isometric. : Method Statement for Piping Fabrication & Installation Rev. it will be ensured that the line is completed in all aspects as per the approval drawings. : Sheet 1 15. 16. Suitable temporary gaskets are also to be provided during testing of lines to isolate pumps and any connecting equipments.2. The line will be checked by the Piping Supervisor/QC Inspector for any missing supports. Pressure testing of piping systems (ISO 14692) Inspection clearance will be documented in the Punch list and reviewed by the QC Inspector prior to hydro testing. Category of Punch Punch ³A´: As per site Condition Punch ³B´: As per site condition .1. No. prior to Commissioning. Punch Clear After installation of the piping. inline instruments. Also. instrument tapping etc. Temporary Gaskets All permanent gaskets will be installed during the work where the flange assembly need not opened. Inspection Clearance QA/QC Engineer will ensure that all NDT and destructive testing are completed. Gasket will be protected from damage until final installation is completed.2. Temporary gaskets shall be replaced with permanent gasket during reinstatement phase. Blinds made of thin aluminium sheet with blind neoprene gaskets between pump suction and discharge flanges and piping counter flanges to be provided at the time of pipe welding for isolation of pump casing to prevent damage to bearings. system shall be inspected for Punch Clearing prior to hydro testing. No.Doc. : Method Statement for Piping Fabrication & Installation Rev. No. etc.GZ-100-A4Z-5-90xxx) as per contract specifications Pressure testing of piping systems. after draining. the piping will be flushed and dried Doc No.1. The system will be boxed up with proper size bolts. All gauges and instruments will be re-installed to original position. Construction areas: Fire points will be established where fire extinguishers will be stored and kept ready for use. The risk assessment will also have the details of emergency services like hospital. (Doc No GZ-100-A4Z-5-90xxx) 17. HSSE Piping installation procedure shall be executed in conjunction (but not limited) with the rules and precautions mentioned in HSSE plan. . Additional fire extinguishers will be provided for immediate work areas during certain phase of work that are particularly susceptible to fire. etc. : Sheet 1 17. ambulance.. The approved Risk assessment will be issued to contractor and the HSSE Officer will ensure that contractor explain every risks involved during the job execution to each and every workman through the daily tool box talks. Contractor will evaluate and prepare Risk Assessment / Job Hazard Analysis of each and every activity involved in the job. HYDROTEST Hydro test will be carried out as per the project specification and Method statement for the Hydro & Pneumatic Testing. gaskets. It will be approved by HSSE Officer. No. Fire fighting equipment: Fire fighting equipment will be provided as per requirement following the CHC HSSE standards throughout the construction areas and temporary facilities areas as follows. 9.Doc. fire services. Temporary facilities areas: Fire extinguishers will be located in areas which are easily accessible in case of emergencies. REINSTATEMENT After hydro testing. Doc. FORMATS AND REPORTS All the formats and reports will be utilized from approved ITP and Procedures. No. : Sheet 1 Equipment: Fire extinguishers shall be provided for each working equipment at site such as welding machines. All the fire extinguishers will be inspected on a monthly basis.Welder Certificates and cards . 10.Pressure Test Certificate. 3. Never put your hands in between pipe ends while pipe launching to prevent entrapment. maintained in good working order and recharges when necessary to ensure continue serviceability. The proximity of distance or height in between the load and the structure should be in minimum to prevent swinging of the pipe. Records of all testing will be kept by the QA/QC Inspector for inclusion in the Construction Certificate of the materials shall be reviewed and included in the Dossier Records.Pre-Fabrication Daily welding reports . : Method Statement for Piping Fabrication & Installation Rev.Approved WPS and PQR . compressors.PWHT Report & Hardness Test . Minimum piping/fitting crew consists of pipe fitter. . RESTRICTIONS: 1. generators. No. Never to allow pipe launching at a distant level.RT and MPI Reports (If available) . semi skilled pipe fitter and helpers. cranes etc. . 2. No. No. 1 Description Hazard / Potential Incidents Unfamiliar with local situation Control &Recovery Arrival of Personnel on Site 2 3 4 Check Work Location for space & Obstacle Enter Work Location Rig Crane of Lifting Location Insufficient Space Obstacle Present Collide with the equipment In adequate ground Incorrect Crane Configuration Incorrect Position Collide With Equipment Unauthorized People in Work Area Site Induction cause. Man Basket With . Use Only Certified & Tested Lifting Gears Approved Procedure & Independent Checks Clear Instruction & Communication and Use of Stairs/ Scaffold or Sky Lift. : Method Statement for Piping Fabrication & Installation Rev. All personnel to fully understand to tasks & responsibilities with the use of PPE Cordon Off Area Have Obstacle Removed Follow the approved lope Follow Approved Procedure Follow Rigging Study Approved Procedure &Independent Check Clear Instruction & Communication Cordon-Off Area & Remove Unauthorized People 5 6 Load Position Beneath Crane Hooks Attach Lifting gears with Hand Lines to Head Trunions & Tailing Attachments ( Sling & Shackles) See Transport Risk Analysis Wrong Lifting Gear Danger Crush Work at Elevation Follow Approved Lifting Study. : Sheet 1 ATTACHMENT Job Hazard Analysis Job / Task: Pipe Launching / Installation Job Safety Analysis: A/G Piping Field Installation Supplier Location: Date: Job Step No.Doc. 1 Engage skilled workers for the work 1.1 Counseling and Training Disciplinary action as last result 3.3.3 Injury accidents due to improper handling of tools and equipments 2 Tool Box Meeting 2.1 People not familiar with the Job and Hazards involved.1 Safety Audits and Unsafe act auditing 2.4 Too many signal confusing the operator 3 Loading /Unloading the Pipes 1.2 All workers will be inducted for Safety by ADGAS 2. : Sheet 1 Safety ATTACHMENTS Job Hazard Analysis Job / Task: Pipe Launching / Installation Job Safety Analysis: Piping Field Installation Job Step No.1 Engaging unskilled and inExperience workers 1.1 Ensure Lifting slings and tested / Inspected and correct color coded 3.2.Doc. 2.1 Conduct tool box talks by line supervisor and safety offices (Confirm understanding) 2.1 Engaging trailer & Approved .2 Emergency communication telephone numbers issued to site staff 2.2. 3.1 Unauthorized Lifting Cranes 3.3 Poor safety attitudes of workers 2.1 Use local language by selecting foreman of same nationality of the workers or by using interpreters 2.3 Personal standing on the trailer while Loading/ Unloading 3.2 Use of defective tools and Equipments 1. 1 Hazard / Potential Incidents Mobilize Men and Equipments Hazard / Potential Incidents Control Recovery / Measures 1.2 Poor understanding of workers 2.1 First aider on site Emergency response plan in place 3.2. No. Implement equipment pass system 2.4.1.1 No personal are allowed to stand on trailer before the piping materials reaching to the trailer deck or while Lifting the material from the trailer deck.2 All equipment will be certified by ADGAS with third party certificate for all lifting equipments 3.2.1.1 Ensure Lifting crane is inspection and certified by ADGAS 3.2 Failure of Lifting slings and dropping the materials 3. No.4. : Method Statement for Piping Fabrication & Installation Rev.1. Ensure by visual inspection lifting slings are in good condition and free from damage 3.3.4 Subject matter incomplete 3. 5 Confined space working 4.2 Constant supervision Induction and Refresher Training must be provided to train them on the proper method of wearing and safe use.2 Welders gloves . : Method Statement for Piping Fabrication & Installation Rev.1 All machinery will be certified by ADGAS Proper PPE will be ensured 5.2 Vertigo Rigging person as banks man for signaling 4.. No.5.3 Fire aider on site Emergency response plan in place 4.apron.1 First aider in site Emergency response plan in place 4.1. eye goggles to be used 4. leggings.3.2 Report any oil leakage and authorized disposal 4.1.3 100% Tie-off policy Every personnel must be provided Full Body Safety Harness with Double Lanyard attached to separate pieces of Shock absorbers.3 Use fire blanket to cover pipe coating 4.3 Cool drinking water to be provided at all times 4.1 Inspection /Maintenance of equipment 4.1 Face injury / Skin burns while working barricades on grade under the area where welders are welding 4.7 Defective tools and machine Due to sound 5 Working at height 5.2.2 Electricity.1 Fire-retardant sheets to be provided for sun shade 4.1 Earth welding generators 4. long sleeve cotton coverall.5.5. Dark glass.1 Certified lifting equipment to be used 4.1 Use proper scaffolding materials.1 Check the permit to work 4.3 Engine oil. Electrocution 4.4 Safety nets will be utilized in the pipe racks . 5. Use trained & experience personnel inspect and ensure 5.4.Doc.2 Proper ventilation to be provided 4.7.Electric shock.4 Lifting Load 4.1.2 Full-line supervision by experienced personnel and a trained firewatcher to be present 4.leak 4.4. Check Electric cable for damage and replace any defective material 4.2. face shield.3.6 Heat-Heat stroke 4.1.2 Emergency medical evacuation facility to be available 4. : Sheet 1 4 Welding of Piping 4. 5.4.1 Incorrect use of defective Scaffolding 5.4 Fire extinguisher to be provided near welding 4. No.2.6.6.1.2. welding mask.1.2. 1 Report to dress up sharp edges on work piece .1 To deploy trained operator.1 Damaged wiring may cause shock or electrocution 8.2 Hazard falling objects: calls for barricading of crane flight area.2.6 First aider on site Emergency response plan in place 8.2. boom angle and follow approved lifting procedure and apply lifting plan all jobs above 15t weight 8. lifting load 7.1.1 Wear safety goggles.1 To use certified .3. Those with phobia or afraid of height must not be used 6.Doc.1 Carry out housekeeping daily before shift end Inform supervision any obstruction in work area 7.4 Deficiencies shall be rectified immediately 8.3.6 Projected at upper step off point 5.1 Inspect electrical tools prior to and during use 8.2 Defective or incorrect use of hand tools leading to personal injury 8.1 Limit lifting to SWL of crane .5 Overload Secure ladders at max. signaler and bankman 7. 7. : Sheet 1 6 Manual Handling 6.2 Untrained personnel unsafe crane positioning .1. color coded lifting equipments regular maintenance and third party inspection to be carried out 7.5 Deficiencies shall be rectified immediately 8. 15 deg to vertical and one meter 5.2 Work piece Sharp edge on work piece may cause injuries or hot work piece may cause burn 6.1.1.7 First aider on site Emergency response plan in place.1. protective .3 Slippery surface or obstruction at walk ways may lead to falls or trips resulting to injury 7.3.3 Use double insulation type tools 8. grinding disc may caused injury 5. : Method Statement for Piping Fabrication & Installation Rev.2.3 Do not defective tools 8.1.5 Correct tool usage shall be supervised 8.2 Report defect to supervisor 8.2 Report defect to supervisor 8.1 Lifting equipment (Faulty slings & cranes defects) 7. ground condition. 5.6 First aider on site Emergency response plan in place 8.1.1 Observe proper lifting posture.1.1 Check for the fitness of persons working at height. use lifting equipments Provide proper access to work place and ensure constant supervision 6.2.1 Handling with improper Posture may result to back injury 6. weld spatters. No.2. No.1.1.2.3 Flying metal fragments.2.3 Above SWL of crane(wrong procedure) 7 Mechanical Lifting 8 Electrical Operated hand tools 8. Minimize manual lifting .2.1.1 Inspect electrical tools prior to and during use 8.1. Use hand gloves 6.2.4 Wear hand gloves 8. 3 Install safety sign / protection cover First aider on site Emergency response plan in place 9.3 Inadequate communication Equipment 11.3 Wear sun glasses 9. do not get exhausted 10.1 Oxygen deficiency / Asphyxiation 10.1.1.1. 9.6 Take intermittent rest during hard work.1.2 Poor emergency response for workers 11.1 Adequate communication equipment e.4 Emergency contact numbers not available cloth and face shield attached with helmet 8.2.1 Provide access ladder / scaffolding or platform 11. : Sheet 1 9 Environment 9.2 Use coveralls of 100% cotton with long sleeves 9.1 Scheduled for emergency exercise / Drills to be carried out 11. No.3.1.1 Inadequate ER Plan 11.1 Provide air circulation .g.3.1 Provide lighting (24W explosion proof cable) 10..2 Poor visibility / Injury 10. No.1.Doc.5 Discuss tips on heat stress with subcontractors.2.2 Inspect grinding disc for damage before use 8. : Method Statement for Piping Fabrication & Installation Rev.4.4 Trench / fall injury 11.1 Provide shed where ever possible 9. gas testing 10. hand phone provided to essential field supervisor staff 11.3 Fire burn / Injury 10.1 Readymade pocket sized card with emergency numbers to be provided 11 Emergencies .1 Follow ADGAS Emergency response plan 11.1.4 Ensure adequate drinking water at site 9.1 Provide fire watcher / Extinguisher 10.1 Continuous exposure to sun/ Heat stress 10 Confined space 10.3.4.3. standby person.1.