QA/QC Comments

Review of Method Statement for Underground (Carbon Steel) Piping Construction and Installation.
Note : The following comments are guidelines only and are not instructions from TECHNIP. Descons Method statement for Underground (Carbon Steel) Piping Construction and Installation is their full responsibility.
Material Handling Will the large diameter pipe be fabricated in situ? Suggest:For the general large diameter of spools and fittings no shop prefabrication will be attempted to minimize handling. All spools will be delivered to place of erection and prepared. Any of pipe elements or branch connections will be done either next to the trench in moveable temporary shelters or inside the trench in situ conditions. Care will be taken to avoid fitting branches to spiral weld seams and spools will be turned to offer maximum interference. Where compensation pads fit over spiral seams same will be ground flush and inspected for any cracks or other defects prior to fitting pad. T weld connections will be subject to X-ray inspection to prove compliance. Note: Clarification is required on where the medium and small bore pipe will be fabricated / stored. a) RECEIPT & STORAGE OF PIPE RAW MATERIAL The piping raw material received from Technip shall be offloaded in designated lay down yard or Near the Site where piping will be installed. Specify the transport. During offloading, pipes shall not be dropped off the transport. A crane & nylon slings shall be used to handle CS pipes & fittings. More details required for

the handling. How to remove the slings, will pipe be on sandbags for easy removal? The pipes shall be placed with suitable material in place to ensure that no damage to pipe or paint occurs. They shall be adequately supported to minimize sagging. The piping end covers shall be kept in place to prevent foreign particle entry into the pipes. All material shall come with color-coding as per size, material & schedule. The piping material shall be segregated accordingly to facilitate location of items. Small-bore pipe fittings, less than 2, shall be stacked on racks in warehouses. They will be segregated accordingly to material, size, and rating & by tag number. Suggest: A maximum of one week spool requirement will be stockpiled on site to avoid congestion.

( New Heading) SPOOL BREAKDOWN The piping isometrics shall be marked into number of spools to facilitate the fabrication & erection works. Each spool shall be marked with a unique number. Each joint on the isometric will be given a unique number preparing a welding map for traceability. Separate numbering system will be followed for butt welds & fillet welds. The details of piping isometric breakdown into spools and joints will be recorded for reference. b) PIPING FABRICATION

As per the relevant isometric drawings material will be shifted from lay down area to fabrication shop or to the place of erection.

The carbon steel & low temperature carbon steel pipe fabrication work will be done in separate areas. The cutting and beveling of pipes shall be done by mechanical means like flame cutting machine. Pipes for socket weld joints shall be cut square. Reinforcement pads shall be installed only if required in the isometric. The material for reinforcement pad shall be same as that for the pipes unless otherwise authorized by Technip. The pad size & thickness of the pad will be specified in the isometric. It is preferable that the pad shape is circular, however the pad size may be altered provided equivalent crosssectioned area is maintained as per ASME requirement. The pad shall have a 1/8 NPT vent hole, drilled & tapped to NPT prior to installation of reinforcement pad.

IDENTIFICATION OF SPOOLS Heat No of Pipe shall be transferred on each cut length of Pipe spools by Permanent Paint Marker. Spool identification shall be done by marking spool no, Isometric No/Line No of Pipe spools with Permanent Paint marker. FIT UP BUT WELDS The fit up of pipe ends, fittings & weld neck flanges shall be done to obtain uniform root opening. The criterion given in related WPS shall be followed.

The primer paint coat on pipes & fitting ends required to be welded shall be removed. What distances from the end of the pipe will the paint is removed? The pipes shall be tack welded by qualified welder with

approved wire /Electrode. Where bridge tacks are deemed to be required it will be in the form of tack welded wedge clamps (strong backs) in area requiring adjusting. After fit up strong backs will be removed, area ground smooth and MPI carried out to verify integrity of pipe. It will require conformation from TECHNIP QA/QC to apply bridge tack method. If the pipes are of different thickness, the larger thickness will be tapered in compliance with the standard to match the smaller thickness. The adjacent section of longitudinally welded pipes that are to be joined by butt-welds shall have longitudinal welds seam positioned such that they are at least 30 apart from horizontal center line Ref Fig NoX. The fabricator will also not locate longitudinal weld seams on top or bottom of the pipes so that branch connection is not located on the seam. Tack weld for fit up joint shall be done by using a bridge Clit of same material in such a way that it will not disturb the root face of the weld joint Ref Fig No2X: SOCKET WELDS The pipe for welded sockets joints shall be ground to remove burrs due to cutting. A gap of approximately 1.6 mm between ends of the pipe & bottom of socket will be provided Ref Fig N o:3X How will this be achieved and what inspection will be undertaken to verify? WELDING All welding work will be according to approved WPS, B31.3 and Technip piping welding

specification. Only qualified welders shall be employed. All welders will carry an approved weld identification badge when welding. Before welding of joint following information shall be provided at adjacent of pipe joint. a) Piping Class b) WPS NO. c) Pipe material (CS) d) Welding Process (GTAW/SMAW) e) Tig wire for Root (ER70S-6) f) Welder Stamp NO g) Electrode (E7018-1) The welding work piece will be shielded against high winds and rain. The wind speed exceeding 10m/sec and 3 m/sec for SMAW & GTAW respectively. The weld surface shall be cleaned with the wire brush or grinding prior to welding operations to give a surface free from rust, scale or mill cutting. Between each layer of welding any cracks, pores or welding spatters shall be removed by grinding the surface before application of next layer. The appearance of finished welds shall conform to ASME B 31.3 codes & WPS and shall be free from any under cuts, spatters & cracks. All branch connections shall be joined to header with full penetration welding. The bore side shall be ground smooth, free from rust.

For flange to pipe connections if welding shrinkage can lead to misalignment, two similar flanges shall be joined by inserting a temporary gasket and then welded.

Above Sequence shall be followed for heavy wall thickness for avoiding after or during weld distortion.

The flange indicated on isometric to be supplied loose shall be tack welded with the pipe. Full welding shall be made after site checking.

For socket welding the pipe ends shall be cut straight.

THREADED JOINTS In case of threaded pipes (for Potable Water Line) screw threads shall be concentric with axis of pipes with no burrs or stripping. The Threading dies shall be sharp & properly designated for piping material. GALVENIZED PIPES The pipe work up to 2 shall be threaded & galvanized by hot dip process to both inside & outside. The pipe work 3& larger shall be fabricated in flanged spools as per design. The size of spools shall confirm to dimensions of hot dip galvanizing bath. The same shall be galvanized from both inside & outside.

The threaded joints of galvanized pipes shall not be seal welded. A PTFE tape will be used as a sealant.

c) INSPECTION The fabricated pipe spools shall be checked against TECHNIP drawings to verify its compliance. The dimensions angle and direction of bent portions and allowances for field welding shall be according to ASME B 31.3 (Chapter V). NDE shall be performed as per ASME section V after PWHT if specified on isometric drawings. The acceptance criteria for visual inspection shall be done according to ASME B 31.3(Chapter V). Visible small transverse cracks & star cracks of limited thickness shall be removed by grinding & repaired by welding. However circumferential cracks shall result in weld rejection. The defective material will be cut out & re welding shall be performed. NDE (RT/ UT/MPT) will be requested as per piping specification of welding provided by Technip. NDE results shall be interpreted by qualified inspectors (level II) & if resulted in defect, repair of the same joint shall be done & Re inspection shall be offered. After NDE clearance in all respect Pipe spool shall be released for Painting/Storage/Erection. Branch connection shall be examined by dye penetrate or magnetic particle or ultrasonic methods. Where the header thickness exceeds 16 mm, this type of examination shall be made for every 9 mm thickness of weld built up. All welding records for each joint shall be maintained throughout the fabrication work.

Low temperature carbon steel material traceability shall be maintained through out the fabrication work such that location & heat numbers of all welded pressure retaining pipe component is maintained. Permanent marker will transfer the heat number to all pieces cut from pipe.

d) IDENTIFICATION Each fabricated spool shall be clearly marked with a number. This number shall include line number & spool number as shown on the piping isometric. For piping up to 6 it will be hard marked on to a steel plate 2 x 3 x 1/16 which shall be securely wired to the pipe. However for piping greater than 6, the number will mark on inside of the pipe using a permanent marker. e) STORAGE The pipe spool complete in all respect shall be stored separately. All spools shall have their piece number clearly designated on each spool. The spool will be cleaned in an inclined position by tapping so that all foreign materials are removed. The spool shall be placed on wooden baton to avoid direct contact with soil. The open ends shall be securely covered by polyethylene sheets or end caps. In case of flanged spools the same shall be covered by securely tied wooden blanks to avoid foreign material entering the pipes. The spool shall be handled using nylon lifting slings.

PIPING ERECTION The fabricated piping spools of random length After the Trench acceptance related for piping

shall be shifted to site near the Trench. erection piping will be lay down on the sides of the trench on wooden sleepers or sand bags. A detailed planning schedule will be prepared to cover the order of work which will include any tie-ins with other contractors. The detail plan will be approved by TECHNIP before any work commences. Piping slopes shall be maintained as per isometric. The pipe spools requiring field joints shall be

welded at site. The pipe ends shall be prepared for welding after site checking the dimensions. A procedure similar to that described under

fabrication will be followed for welding. Not enough detail for site welding. Suggest: Sandbags will be used when placing the pipe in the trench. The height of the sandbags will be determined by depth of excavation versus the required BOP elevation. Welding on the bottom of the pipe will be achieved by trenches dug at weld seams coordinates as instructed by TECHNIP. The piping shall be erected & supported plumb &

level such that there will be no undue strain on corresponding equipment flange. The alignment of flanged joints shall be according to the ASME B.31.3 (chapter V). For fit-up of spools, sections will be adjusted by hydraulic jack if minor adjustment is required. Where spools require being brought closer together this will be achieved by moving with crane.

In case of flanged connections, the surfaces in

contact with gaskets shall be checked before assembly and all traces of dirt oxides & grease shall be removed. The flanges shall not be joined together without All temporary gaskets shall identify by color-coding All bolt heads shall be assembled from the same the insertion of gaskets. on their handles exposed. side. A logical sequence of bolt tightening shall be followed to evenly tighten the flanges. The Screwed joints shall be thoroughly cleaned for dirt or any other foreign matter. Teflon tape shall be used for all screwed connections. The tape will be wound in correct direction. All excess Teflon tape shall be removed. Care shall be taken that the tape does not enter inside of pipe. Seal welding of screwed joints shall not be Cathodic protection work will be carried out as per performed unless specially permitted. Project Specification and approved by other discipline (Electrical) as per schedule and in coordination with piping and civil departments. Visual / NDE will be done as per piping class Suggest: The NDE activities shall be carried out in requirement. accordance with the relative line class designation and as per the QCPs for Radiography, Magnetic Particle Inspection and Dye Penetrant Inspection by appointed sub contractor and monitored by Lehoud. Touch up coating and corrosion protection of pipes shall be completed as per manufactures recommendations. This may be accomplished while temporarily supported

on sandbags ensuring a sufficient distance is maintained between the pipe and the trench bottom at the area where the inspection and the repairs are to be completed. Piping will be inspected for cleanliness and swept clean by means of compressed air or other means if required. Lehoud will ensure that all coupons and debris deposited in the new lines during cutting and grinding shall be removed and the affected area cleaned. Cleaned sections of piping will be closed with a temporary wooden blank to prevent foreign particles entering. The blank will be moved as the next section of pipe is cleaned. Cleanliness records will be kept and updated as work progresses. A joint inspection TECHNIP and Lahoud shall be performed prior to backfill, a punch list shall be established and backfilling will only be authorized upon clearance of all punch items Sand bedding and backfilling will be carried out as per specification. Sand bedding surrounds and backfilling works will be conducted in a manner that will prevent damage and abrasion to the coating Service testing activities will be carried out. This activity will be subject to a deviation request.