method statement for prefabrication and erection-piping

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

Method Statement for Pre-Fabrication and Erection of Piping

CONTRACTOR : ADVANCED VISION CO.

PROJECT NAME : MASAA EXTENSION PROJECT

CONSULTANT : DAR AL HANDASAH

SITE : AL HARAM-MAKKAH-KSA

0 Issued for Approval

REV. DATE DESCRIPTION PRPD TPI APPD

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

INDEX

1. INTRODUCTION

2. DEFINITION

3. APPLICABLE DOCUMENTS

4. SCOPE OF WORK

5. PROCEDURE

6. MATERIALS RECEIVING & STORAGE

7. PRE – FABRICATION

8. PIPING ERECTION

9. MECHANICAL CLEARANCE AND PRESSURE TEST

10. INSPECTION AND QUALITY RECORDS

11. SAFETY PROCEDURE

12. ATTACHEMENT: SAMPLE OF WELD MAP

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

1) Introduction

The purpose of this method statement is to ensure that the methods and procedures

shall be carried out for the fabrication, erection and testing of piping work as per the

Technical / Contractual specifications of Dar Al Handasah.

2) Definitions

Project : Massa Extension Project – Makkah

Consultant : Dar Al Handasah

Contractor : Advanced Vision Co.

3) Applicable Documents

3.1 Codes & Standards

ASME B 31.3 ANSI B 16.25ASME SEC II Part CASME SEC IXASME SEC VAWS D 1.1

3.2 Ref. Project Specifications

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

4. Scope

The scope of this method statement is limited to Pre-fabrication, Erection and Testing procedures followed for Carbon Steel and Stainless Steel piping.

5. Procedure

The Engineering drawings and documents received from Consultant shall be clearly

understood to find out the service, material specification, size, thickness, NDT

requirements, PWHT requirements, pipe routings quantity etc. line wise and area

wise.

Ensure that the documents received bear the stamp “Issued for Construction” and are

of latest revision.

Make sure that all the Quality Control and Pre – Construction formalities, approvals,

and preparations are done sufficiently in advance to start the construction activity as

per the schedule.

6. Materials Receiving and Storage

1) Material Requisition form prepared by supervisor shall be forwarded to the

material controller who shall collect the piping materials as per the piping

specifications and drawings from Consultant, respecting the material issue

procedure of Consultant.

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

2) Handling and transportation of piping materials shall be done with utmost care

to avoid any damage.

3) Separate area shall be assigned for the storage of Carbon Steel and Stainless

Steel piping materials. Pipes shall be stored in open area resting on wooden

sleepers and small pipe fittings, bolts, nuts, and gaskets shall be stored in

shelved containers. Storage & issue procedure of piping materials shall be in

time with the requirements of Consultant.

4) Documents shall be maintained by the material controller till the end of the

project.

7. Pre – Fabrication

7.1 Replacement

1) Determine the safe location on the Rejected Fittings to start the cutting and remove the cut items to scrap area by safely procedure.

2) Select the proper cut method either flame cut or cut machine.

7.2 Cutting and Beveling

1) Pre-fabrication of Carbon Steel and Stainless Steel Pipes shall be done in

separate fabrication ways.

2) Proceed with cutting of pipes, edge preparation, joint alignment, and fit-ups

as per the WPS.

3) The edge cleaning and beveling shall be done using abrasive grinding disc/

beveling machines.

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

4) Line Number, Spool Numbers, and Joint Numbers are to be clearly

identified and marked on the spools with the welder identification for

each joint.

7.3 Fit – Up and Tack Welding

1) Fit-up assembly shall be carried out by using locally prepared couplers.

All the required pipe holding work benches, assembling brackets, ‘U’

bolts etc. would be made in house to suit the pipe sizes.

2) For butt welds a uniform root opening as specified below shall be

maintained.

1.5 mm for pipe diameters < 50 mm

1.5 / 2.5 mm for pipe diameters 50 mm to 250 mm.

2.5 / 3.5 mm for pipe diameters > 250 mm

3) For all socket weld joints the pipe end shall be free from cutting burrs. A

clearance of 1.6 mm shall be provided between the end of pipe and

bottom of socket.

4) Internal misalignment shall be limited to

1.6 mm for pipe diameter 24” and below.

3.2 mm for pipe diameter 26” and above.

5) The pipes shall be tack welded in three equidistant positions. Tack Weld

shall be done as per approved WPS by a qualified welder.

7.4 Welding

1) Welding procedures and welders shall be qualified as per Project

Specifications and relevant codes, prior to start of the welding.

2) Ensure that the edges are free from dirt, rust, oil, grease, paint etc.

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

3) Welding shall be done as per approved WPS for the particular piping. Pre

heating and welding consumable shall be checked before starting of

welding.

4) Each weld layer shall be cleaned before starting to weld next layer. The

cleaned area shall be free from slags. Any visual defects like cracks,

pores, spatters weld shall be removed by grinding before the next layer is

applied. The ends of weld layer shall be removed by grinding at tack

points of each weld. Any possible weld excess layer will be removed by

grinding.

5) For the fabrication & welding of Stainless Steel pipes, only Stainless Steel

tools & consumables (Wire Brush Chipping, Hammer, and Abrasive

disc) shall be used.

6) Appearance of finished weld shall be as even as possible and free from

spatter, under cutting, cracks, excess reinforcement etc.

7.5 Non Destructive Examination

1) The extent of NDT will be in accordance with Project General Specification

for different piping systems. The acceptance criteria shall be in accordance

with ASME B 31.3.

2) If PWHT is applicable for any piping system, NDT shall be carried out after

completion of PWHT.

3) Welding record shall be maintained with proper identification of joint,

welder etc. for all joints.

4) NDT shall be carried out as per approved procedure and the results shall be

recorded properly.

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

8. Piping Erection

1) The Pre-Fabricated spools shall be identified by spool and line numbers before

and after priming.

2) Care shall be taken while handling and stacking of spools to prevent any

possible damage.

3) Open ends of spools shall be covered by caps after thorough cleaning.

4) Erection of spools shall be carried out area by area as per piping layout drawing

and Isometric drawings.

5) Scaffolding and temporary platforms shall be arranged to carry out fit up and

welding of field joints at elevated positions.

6) Pre-fabricated spools shall be shifted to site carefully as per daily erection plan.

7) Before erection of spools ensure for inside cleaning of the spools and their

items.

8) Erect the spools in position using crane or other lifting devices as per the

drawings.

9) Supports to be welded on to the pipe (shoes or saddles) shall be done before

erection.

10) Check the pipe supports details in the piping layout drawings and Isometric

drawing for location and type of supports.

11) Install the pre-fabricated supports as per drawings.

12) Joints shall be aligned and complete the fit-up / welding as per applicable WPS.

13) NDT and other inspection shall be completed for the field joints and recorded

properly.

9. Mechanical Clearance, Inspection & Pressure Testing

1) Identify the test loops for the completed line system wise.

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

2) Upon obtaining mechanical clearance, Hydrotest shall be carried out as per

project specification.

3) Arrange for Hydrotest Pump, Calibrated Pressure Gauges, Test medium (Water)

etc.

4) Blind flanges shall be installed on all required locations and items which are not

to be included in pressure testing, shall be isolated.

5) Water shall be filled and vented properly before pressurising.

6) Line shall be pressurized to the required pressure of that piping class and hold

the pressure till the inspection is completed.

7) Pressure Test shall be witnessed by contractor representative.

8) On satisfactory completion of test, pressure shall be released and line is to

drained off completely.

9) Reinstate the line with all the permanent items and remove all the blinds.

10) Inspection and Quality Records

Inspection, Testing and Recording shall be in accordance with the approved

Inspection & Test Plan.

11. Safety Procedure

Prefabrication and Erection of Piping and Pipe Supports.

Equipment and tools

1) Portable cranes, column cranes. 2) Scaffoldings 3) Small items (lifting jacks, slings, chain block, D-shackles, etc.)4) Oxygen Acetylene Cutting, Portable Power Tools, and Welding units.

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING

Safety Measures

Protective Clothing

1) Helmet 2) Gloves 3) Safety shoes4) Full Body Safety Harness5) Face shields

Accident Prevention Safety Procedures

1) Area shall be barricaded adequately with warning barriers prior to any lift.

2) All Equipment shall be checked for good conditions before commencing the work.

3) Unauthorized persons shall be excluded from the area.

4) When lifting, the personnel shall not remain in the lifting equipment work area.

5) Adequate caution boards and warning signs shall be provided.

6) Only trained and authorized personnel shall operate the hydraulic lift.

7) Observance of the lifting equipment capacity.

8) Electrical installations and equipment shall conform to standards.

9) Application, maintainence, storage of electric, and oxygen cutting welding units

shall conform to applicable standards.

10) Do not stand under suspended loads.

11) On Completion of job, the area shall be cleared of any materials and kept clean

and tidy.

12) Hazard analysis for hazardous operation shall be carried out prior to commencing

the works.

Advanced Vision Co Ltd..

Massa Extention Project Al Haram- Makkah- KSA

METHOD STATEMENT FOR Replacement, PRE-FABRICATION AND ERECTION OF PIPING