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EPC CONTRACTOR:

PROJECT MANAGEMENT CONSULTANT:

China Petroleum Engineering


& Construction (Group) Corporation
Abu Dhabi Branch
P.O. Box 127345

ILF Consulting Engineers


P.O.Box 73250
Abu Dhabi, UAE

PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

EPC Contractor Doc.


No.:
DOCUMENT No.:

30-99-90-1619

Rev.0

Project No: E30153

PAGE:

of

21

DATE:

03/08/2008

ABU DHABI CRUDE OIL PIPELINE PROJECT

(ADCOP)
METHOD STATEMENT FOR PIPELIENE WELDING
30-99-90-1619

REVISION RECORD

REV

DATE

ORIGINATOR

REVIEWED

APPROVED

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

DESCRIPTION

Project No: E30153


Page 2 of 21
Rev.0

DATE : 08/09/2008

10/08/2008

Dong Yingjun

Ye Xiaopeng

Zhang zhanhui

Issue for Review

08/09/2008

Dong Yingjun

Sibi Peter

Zhang Min

Issue for Construction

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 3 of 21
Rev.0

DATE : 08/09/2008

CONTENTS

PAGE

1.0 INTRODUCTION............................................................................................................................................ 5
2.0 PURPOSE OF THIS DOCUMENT................................................................................................................ 5
3.0 DEFINITIONS AND ABBREVIATIONS......................................................................................................... 5
3.1 Definitions........................................................................................................................................5
3.2 Abbreviations....................................................................................................................................5
4.0 REFERENCES............................................................................................................................................... 6
4.1 Project Specificaion and Procedures .................................................................................................6
4.2 Other References.............................................................................................................................6
5.0 COMPLIANCE STATEMENT........................................................................................................................ 6
6.0 GENERAL...................................................................................................................................................... 7
6.1 APPROVAL / AUTHORISATION........................................................................................................7
6.2 DISTRIBUTION AND CONTROL .......................................................................................................7
7.0 ROLE AND RESPONSIBILITIES.................................................................................................................. 7
8.0 PROCEDURE................................................................................................................................................. 9
8.1 HSE Requirements...........................................................................................................................9
9.0 EQUIPMENTS.............................................................................................................................................. 10
10.0 PROCEDURE QUALIFICATION............................................................................................................... 10
11.0 WELDER QUALIFICATION....................................................................................................................... 11
12.0 METHODOLOGY FOR MAINLINE WELDING......................................................................................... 11
13.0 WELDING RETURN CIRCUIT.................................................................................................................. 12
13.1 Welding........................................................................................................................................12
13.2 Preheating....................................................................................................................................13
13.3 Root Run Process .........................................................................................................................13
13.4 Starting.........................................................................................................................................13
13.5 Closing.........................................................................................................................................13
13.6 Cleaning.......................................................................................................................................13
13.7 Removal of Clamp ........................................................................................................................13
13.8 Hot Pass.......................................................................................................................................14
13.9 Fill and Cap ..................................................................................................................................14
13.10 Cleaning and Restarting ..............................................................................................................14
13.11 Capping and Inspection ...............................................................................................................14
13.12 Subsequent Pipe Alignment ........................................................................................................14
13.13 Weather Protection .....................................................................................................................14
DOCUMENT TITLE

METHOD STATEMENT FOR PIPELINE WELDING

PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.

30-99-90-1619

Project No: E30153


Page 4 of 21
Rev. 0 DATE : 03/08/2008

13.14 Visual Examination .....................................................................................................................14


14.0 FOR TIE-IN WELDING.............................................................................................................................. 15
14.1 METHODOLOGY..........................................................................................................................15
14.2 Repair Welding.............................................................................................................................16
14.3 Visual Inspection and NDT ............................................................................................................17
14.4 Weld Numbering System ...............................................................................................................17
15.0 ELECTRODE CONTROL.......................................................................................................................... 18
16.0 DOCUMENTATION.................................................................................................................................... 19
17.0 EQUIPMENT LIST..................................................................................................................................... 19
18.0 QUALITY ASSURANCE & QUALITY CONTROL....................................................................................19
19.0 ATTACHMENTS......................................................................................................................................... 20
NO.

Description

30-99-90-1619-QP-01

Inspection and Test Plan

30-99-90-1619-QCL-01

Welding Parameters Record Sheet

30-99-90-1619-QCL-02
30-99-90-1619-QCL-03
30-99-90-1619-QCL-04
30-99-90-1619-QCL-05
30-99-90-1619-QCL-06
30-99-90-1619-QCL-07
30-99-90-1619-QCL-08
30-99-90-1619-QCL-09
30-99-90-1619-QCL-10
30-99-90-1619-QCL-11
30-99-90-1619-QCL-12

Welding Equipment Calibration Record


Pipe Book Form
TO
Welder Performance Report
Welder Qualification Test Certificate
Welder Qualification Card
Qualification Range
WPS Visual Inspection Report
Daily Weld Repair List
Tie in Welding Inspection Report
NDT Request
Radiographic Inspection Report

Pages

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Date/Rev.

6
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Project No: E30153


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Rev.0

DATE : 08/09/2008

1.0 INTRODUCTION
The United Arab Emirates (UAE)

authorities have assigned International Petroleum


Investment Company (IPIC) to execute the Abu Dhabi Crude Oil Pipeline (ADCOP) Project,
which will facilitate the transferring of crude oil from Habshan production facilities to the
Fujairah Main Oil Terminal (MOT) on the eastern seaboard of the UAE. The proposed pipeline
is of approximately 371 km in length. The pipeline is designed for transferring of 0.5~1.5
MMBBLD of crude oil.
China Petroleum Engineering & Construction Corporation (CPECC) has been assigned as
EPC construction for the entire ADCOP project by IPIC with ILF as Project Management
Consultant.
2.0 PURPOSE OF THIS DOCUMENT
The purpose of this method statement is to describe the methodology involved in pipeline
welding activities and to detail out the steps to be taken to meet the requirements as specified
by the Project Specifications.
3.0 DEFINITIONS AND ABBREVIATIONS
3.1 Definitions
CLIENT/ OWNER International Petroleum Investment Company (IPIC)
CPECC/CONTRACTOR means China Petroleum Engineering & Construction Corporation
TPI means, the party which carries out the inspection of the purchased products, all the
requirement of calibration, Construction process inspection.
PMC means,ILF Consulting Engineers
Shall / must / is to be A mandatory requirement
should A non-mandatory requirement
WORKS Means all plans to be provided and work to be done by the Contractor under the
contract.
P-WPS Proposed Welding Procedure Specification before any mechanical test, which is only to all
the necessary information about welding to CLIENT or COMPANY
WPS Welding Procedure used for the welding activities on site, which is qualified by mechanical
test.
PQR the process record and report of qualifying the P-WPS.
NDT Non-Destructive Test, which include the radiography, MT, PT.
3.2 Abbreviations
ADCO
ADCOP

Abu Dhabi Company for Onshore Oil Operations


Abu Dhabi Crude Oil Pipeline

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 6 of 21
Rev.0

DATE : 08/09/2008

API
FEED
IPS
MOT
MPS
MMBPD
PMC
PQP
PPE
QHSE
QA
QC

American Petroleum Institute


Front End Engineering and Design
Intermediate Pump Station
Main Oil Terminal in Fujairah
Main Pump Station
Million barrel per day
Project Management Consultant
Project Quality Plan
Personal Protective Equipment
Quality, Health, Safety & Environment
Quality Assurance
Quality Control

4.0 REFERENCES
4.1 Project Specifications and Procedures
Particular reference is made to the following project specifications:
30-78-12-0606 Specifications and Procedures
30-99-90-1642 Mainline Welding Procedure
30-99-90-1643 Pipe Weld and Cut-Out Procedure
30-99-90-1644 Pipeline Weld NDT Procedure
30-99-90-1650 Tie-in Procedure
4.2 Other References
30-99-90-1611 Project Quality Plan
30-99-90-1672 Project HSE Plan
5.0 COMPLIANCE STATEMENT
This document is in full compliance with the contract except for the following points.
Description of deviation

Reference (Deviation Note)

Approval date

- None -

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 7 of 21
Rev.0

DATE : 08/09/2008

6.0 GENERAL
6.1 Approval/Authorization
This document shall be issued, verified and approved by project members as described
in the Project Procedure 30-99-90-1619 REV.A
6.2 Distribution and Control
This document shall be distributed in a controlled manner by the Document Control Centre
according to the respective document control procedure PP 104 Engineering Document
Management.
7.0 ROLE AND RESPONSIBILITIES
Construction Manager
The Construction Manager (s) in conjunction with Interface Coordinators, Permit Cocoordinators and Public Relation Officer are responsible for the implementation of the
work in accordance with safety regulations and also shall be responsible for ensuring all
required permits and approvals are in place prior to commencement of the Construction
works.
HSE Manager
The Site HSE manager monitors the work to ensure compliance with safety regulations
at site. He is responsible for preparation and implementation of all safety procedures
and practices for all activities as well as imparting training for supervisory, workmen for
execution of the works in a safe manner.
QC Manager
Site Quality control manager will be responsible for implementation of project quality
procedure and inspection of work as per Inspection and Test Plans.
Interface Coordinator
Interface coordinator will coordinate with ILF, CPECC, Highway contractors, other subcontractors and owners of all other utilities and facilities interfacing with new pipeline.
Arrange for meetings as required.
Survey Engineer
Survey Engineer shall be responsible for ensuring all construction survey activities to be
carried out in strict accordance with the approved procedures and safety requirements.
a) The Permit Co-coordinator (s) shall be responsible to coordinate all permits and
approval requirements before commencement and after completion of works at site,
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 8 of 21
Rev.0

DATE : 08/09/2008

which shall be handled as expeditiously as possible.


b) The Permit Co-coordinator (s) shall also be responsible for ensuring full details of
permits and approval issued are known to appropriate personnel, including any
restrictions or impediments to progress list within.
c) The Permit Co-coordinator (s) shall have the further responsibility of compiling and
maintaining a Permit and Approval Register which lists full details of each permit
and approval, including expiry date.
Welding Inspector
a)
b)
c)
d)
e)
f)
g)

Ensure compliance of quality requirement as per the ITP.


Ensure no welders shall work on any phase of the pipeline unless he has been
tested and approved.
Welding parameters shall be monitored during production welding and repair
welding.
Responsible for overall control of welding at site and for the implementation of
approved procedure.
Updated WPS register and qualified and approved welders list shall be available
with the welding inspector.
Generate daily welding inspection reports and NDT request shall be given for
visually accepted butt joints.
Explain to welding foreman and all other persons involved in welding of the detailed
operations to be done during various phases of activity.

Welding foreman
a) Shall be the team leader of welding crew and shall report to the pipeline
superintendent.
b) Welding foreman shall conduct the daily tool box talk.
c) From fit up stage to weld completion his close supervision is mandatory and he
shall control the job activities to achieve target production.
e) He shall ensure end caps are in place of the pipe string before leaving the site.
Pipeline superintendent.
a) Shall report to the construction manager and be responsible for supervision of the
job at site.
b) Shall be responsible for co-ordination with CPECC/ILF regarding activities at
site.
c) Shall have overall responsibility to ensure all necessary work permits, safety and
quality at site for the working group as well as the public and environment.
8.0 PROCEDURE
8.1

HSE Requirements
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 9 of 21
Rev.0

DATE : 08/09/2008

a) All personnel shall have attended HSE induction / awareness training programs
conducted in-house. This shall be documented adequately. Register shall be
maintained with Site HSE Manager.
b) NOC / Work permits shall be obtained from the concerned authorities prior to start
of the activity.
c) Work permits will be obtained from the concerned authorities. All permits passes
shall be issued prior to start of any excavation work.
d) Tool box talk shall be conducted before starting the work and all Hazards and safety
measures shall be discussed.
e) Warning tapes of red/white stripes shall be used to cordon off the area of operation
to prevent entry of unauthorized persons and vehicles
f)

Barricades shall be put up on either side of the area of operation at least 10 meters
away. The barricades shall have blinking lights on them to catch the attention of
driver as well as the users of the road to be crossed.

g) A clearly visible warning board stating "diversion" with arrow mark indicating the
direction of the diversion shall be placed at the point of diversion on both sides of
the area of operation.
h) Limits of the by-pass roads shall be clearly indicated by installing warning tapes,
distance boards, Traffic speed boards on either side of the by pass road.
i)

Necessary banks men or traffic regulators shall be deployed on both side of the area
of operation to control the traffic during the operation through the by-pass route /
tracks till the entire operation is completed and at least temporary restoration is done
on the crossing areas.

j)

It shall be ensured that only authorized personnel, for the operations and
inspections, shall be allowed to enter into the area of operation during the
excavation of the road and installation of the pipe.

k) If the operation is during night, the entire area of operation should be illuminated
well so that the workers and the supervisory personnel are safe within the area and
area is clearly visible for the possible users of the road. The diversion signs and the
by pass road shall be well illuminated.
l)

Not withstanding the above, any other measure, as demanded by the site conditions
and the climatic conditions at the time of operation shall be adopted to ensure safety
of the public property and the environment.

9.0EQUIPMENTS
The following instruments and equipments have been identified for the execution of
activities:

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 10 of 21
Rev.0

DATE : 08/09/2008

9.1

Instruments

9.2

Radio Detector PL4000


Gas Detectors

Machineries

Excavator

PC400 or equivalent.

Side boom/ Crane

C594/60T

Dozer

D9 + Ripper or Komatsu D85

Rock breaker

PC 400

Asphalt cutter

Grader

CAT 140G

Dump Truck

6x4

Front-end loader

CAT 950F

Water Tanker

6x4

Roller / Plate Compactor

10T BOMAG / 2T TANDEM

Holiday Tester

0 To 25 KV

Hand Tools

Adequate nos. of equipment (of suitable type / capacity) in good working condition
will be deployed.
10.0 PROCEDURE QUALIFICATION
a)

Procedure Qualification shall be carried out as per the requirement of 30-78-12-0606


Rev.0.

b)
c)
d)

e)
f)
g)
h)

Welding parameters shall be observed and recorded by calibrated instruments


during procedure qualification.
Mechanical test to be conducted as per the requirement of API 1104 in addition to
the requirement of project specification 30-78-12-0606 Rev.0
WPS/PQR as per API 1104 format shall be prepared and submitted to ILF / TPI for
acceptance by filling the parameters measured and the results of NDT and
destructive tests. Following supporting documents shall be attached with PQR.
As run weld parameter recording sheet
Weld visual inspection reports.
Other NDT Reports
Mechanical test reports

11.0 WELDER QUALIFICATION


a)

Approved welding procedure specification shall be in place before the start of


welder qualification tests. Welders shall be made aware of the WPS requirements

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 11 of 21
Rev.0

DATE : 08/09/2008

b)
c)

prior to commencement of any qualifications


Front end welders (for root and hot pass) shall be qualified for all pass and deployed
for both front end and back end welding as required.
Back end welders (filler and cap) intended to be deployed on fill and cap passes can
be qualified on test coupons where other all pass qualified welders has deposited
the root pass.

11.1 The welding inspector shall:


a)
b)
c)

Check and ensure that all parameters as per WPS are followed during welding.
Monitor and record the actual parameters random by using a clamp meter.
Visually inspect all stages of each qualification and present the test coupons for
Companys approval.

The following records shall be compiled and submitted for Client approval:
a)
b)
c)
d)

As run parameters record sheet


Radiography reports
Welder's qualification certificate
Welder's identity card.

Welders shall be issued with qualification cards identifying the WPS numbers that he
can be allowed to weld; Essential variables for the welder qualification shall be as per
API 1104.
11.2 Welders qualified on tie-in welding can be used for fill and cap on mainline welds.
Each welder shall be assigned a unique ID number. The numbers once assigned to a
particular welder shall not be reused for any other welder under any circumstances.
12.0 METHODOLOGY FOR MAINLINE WELDING
12.1 Cleaning of Pipe, Beveling Inspection & Clearing
a)

Each length of pipe shall be thoroughly examined internally and externally to make
sure it is free from visual defects, corrosion, dirt or foreign matter.
b) Each pipe length shall be adequately swabbed to remove foreign matter and pulled
through proper to ensure it is free from dirt before lineup. While using pull through
proper care should be expressed to avoid damage of coating before welding,
c) All rust and foreign matter shall be removed from the beveled ends by poweroperated tools. This shall be affected inside and outside and for a minimum distance
of 25mm from the edge of the weld bevel.
d) On pipes, which have been cut back, a zone extending 25mm back from the new
bevel, shall be ultrasonically tested to the requirement of the line pipe specifications to
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 12 of 21
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ensure freedom from laminations. The new bevel shall be 100% visual / MPI tested.
A report shall be written for all testing and records.
12.2 Alignment, Fit up
a) Pipes shall be checked for correct thickness, dia. and spec. with respect to the
approved alignment sheets.
b) Before Welding, the pipes shall be checked to confirm that the inside is clean and
free of any objects. The supports shall be strong enough to support the line pipes.
Sand bags are suggested as supports.
12.3 The root gap shall be checked accurately and shall be as per qualified WPS.
a) Longitudinally or spirally welded pipes ,a minimum distance of 10 inches (254 mm)
between each longitudinal and spiral weld shall be maintained in lining-up pipes and
these weld seams shall be located in the top half of the pipe (120) Particular
relaxation in case of welding pipe to bend or bend to bend shall be subject to
approval.
b) For pipe of same nominal wall thickness the off set shall not exceed 3 mm. The
offset may be checked from outside by dial gauge.
12.4 Alignment and fit-up shall be checked before welding.
Before starting of welding works Welding engineer shall submit batch Certificates of the
electrodes for review by ILF/TPI. Only approved batch of electrodes /filler wires shall be
used at site.
13.0 WELDING RETURN CIRCUIT
Earthling clamp shall be used and the power connection on line pipe cant make arc
strike.
13.1 Welding
Welding shall be done as per the approved welding procedure specifications (WPS).
Only qualified welders shall be engaged and each welder shall bear an identity card
during welding operation. Weld box shall be used to meet the requirement of
identifications.
13.2 Preheating
Pipe shall be heated using the method as per WPS required Preheat temperature shall
be maintained prior to commencement of root run and subsequent runs. The burners
shall be equally spaced, so as to ensure uniform heating all around the joint. The
temperature shall be checked by calibrated temperature crayons and digital pyrometers.
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 13 of 21
Rev.0

DATE : 08/09/2008

13.3 Root Run Process


a) The root gap shall be accurately checked and shall be as per approved WPS. The
use of internal clamp is mandatory and shall not be released before 100%
completion of the root pass and hot pass.
b) The root pass of butt joints shall be executed properly so as to achieve full
penetration with complete fusion of the root edges. Welding shall not be interrupted
during a pass and shall be completed as early as possible.
c) Any kind of movement of components, shocks, vibrations, bumping and stresses are
prohibited while welding is in progress. Peering shall not be permitted. Once the
deposit of the first pass has been started, it must be completed as rapidly as
possible to reduce interruption to the minimum. The welding speed shall be
approximately same as that established in the qualified welding procedure.
13.4 Starting
Start the welding must according to the approved WPS after qualification and the
earthing shall be connected strong enough. When the welding arc is started the
electrode arc can not be ignited at the surface of line pipes.
13.5 Closing
The welder who start the work and the welders following shall meet each other at
the end of the weld joint.
13.6 Cleaning
Removing the flux craters, welding irregularities slag etc. by Grinding.
13.7 Removal of Clamp
Clamp shall be disengaged and taken out of the second pipe. For line pipe welding only
after the root and hot pass is finished.
13.8 Hot Pass
Welding progression shall be same as root pass second pass shall start within the time
qualified during procedure qualification.
13.9 Fill and Cap
a) Soon after cleaning the hot pass, filling and capping starts within the time qualified
during procedure qualification. Two weld beads shall not be started from the same
location, if required; welding may be suspended after the completion of the third pass
or 50% of pipe wall thickness, whichever is greater so as to allow the joint to cool
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


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DATE : 08/09/2008

down.
b) Arc strikes outside the bevel surface shall not be permitted. If any such arc strikes
are caused accidentally, such areas shall be repaired as per the method approved by
ILF. The skids used in during welding shall be removed only, after completion of full
welding.
13.10 Cleaning and Restarting
Every pass shall be cleaned by power-brush, grinding machine and chisel, starting and
finishing point shall be staggered for every pass.
13.11 Capping and Inspection
Capping shall be max 1.6 mm over the surface of the pipe. Spatters shall be removed
and cleaning shall be done by power brush and any remedial grinding necessary, shall
be performed limited to dressing.
13.12 Subsequent Pipe Alignment
Further, joints shall be welded in the same manner as explained above.
13.13 Weather Protection
Wind shelter shall be provided to cover the welders and joint during welding, if
necessary to protect against rain/drizzling/wind.
13.14 Visual Examination
a) All finished welds shall be visually inspected for excessive reinforcement, concavity
of welds, shrinkage, cracks, undercuts, dimensions of weld surface porosity and
other surface defects. If any such defects are noticed they shall be rectified.
b) Night Caps to be welded after completion of main line section as per ILF
specification.
14.0 FOR TIE-IN WELDING
14.1 METHODOLOGY
a) Field welding of pipelines TIE-IN joints shall be done by method as approved WPS
after qualification.
b) Qualified welding procedures shall be used for welding of TIE-IN joints after due
approval from ILF/IPIC.
c) Only ILF/IPIC approved brands of welding consumables as specified for each run in
the WPS shall be used.
d) A TIE-IN pit of suitable length, depth and width shall be cut to enable to work freely
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 15 of 21
Rev.0

DATE : 08/09/2008

inside the trench. Proper care shall be taken so as not to allow pit to collapse or pit
wall caving in. Necessary supports shall be used wherever required.
e) In connecting pipes, special items, fittings on joints of differing material thickness as
supplied transition piece with 1:4 taper shall be used and the welds shall be
subjected to Radiographic and Ultrasonic examination.
f) Cut pipe ends shall be examined wherever for laminations by Ultrasonic over
distance of 25 mm minimum. Defective pipe length shall be cut back until laminated
section is removed and re-beveled For pipe which have been cut, Pipe no., Heat no.,
Coating yard no., Balance length has to be transferred on to remaining pipe length.
g) Alignment of the TIE-IN joint shall be done using external clamp capable of removing
offset and misalignment shall be minimized.
h) Seam orientation of welded pipe shall be selected to ensure that the longitudinal
welds shall be staggered in the top 120 of the pipeline or 254 mm. which ever is the
less and shall be positioned in the upper half of the pipe. In case the seams come
closer than as defined above, a pup piece of minimum 2.0 m shall be used. For pipes
of same wall thickness.
i) TIE-IN shall be done in such a way as to leave minimum stress in the pipe. If any pup
end is required for TIE-IN, the minimum length shall not be less than 750 mm.
j) TIE-IN joint welding including necessary cutting, beveling, grinding and line up etc
shall be carried out as per this procedure and approved WPS.
k) The new field bevels shall be examined visually before offering for MPI and ultrasonic
testing. All reports of TIE-IN along with NDT reports shall be prepare. Cleaning,
Priming, coating and other activities shall be performed as per approved procedures.
l) The root gap shall be accurately checked and shall conform to the qualified welding
procedure. All spaces between bars or at least 50% of first pass shall be welded
before the clamp is released and pipe remaining adequately supported on each side
of the joint.
m) Segments thus welded shall be equally spaced around the circumference of the pipe.
Slag etc. shall be cleaned off and the ends of the pass shall be prepared by grinding,
so as to ensure continuity of the weld bead.
n) Qualified welders shall carry out welding. While welding is in progress, care shall be
taken to avoid any kind of movement of the components / pipe, shocks vibration and
stresses to prevent occurrence of weld cracks.
o) Electrode starting and finishing points shall be staggered from pass to pass.
p) Arc strikes outside the bevel on the pipe surface shall not be permitted. Accidental
arc strikes shall be repaired as method approved by CLIENT.
q) All finished welds shall be visually inspected for parallel and axial alignment of the
work, welds, surface porosity and other surface defects.
r) Parts being welded and the welds shall be protected by windshields made of metallic
frame covered by Canvas, whenever necessary, to protect from rain and strong
winds.
s) The completed welds shall be covered with asbestos cloth covered by GI sheets,
whenever necessary, to protect from bad weather conditions.
t) For TIE-IN of adjacent sections of pipeline already pressure tested also called golden
joints and for final joints, a single length pup or off cuts, which have been
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 16 of 21
Rev.0

DATE : 08/09/2008

hydrostatically pre-tested shall be used.


u) All quality records generated during the welding of TIE-IN joints shall be reviewed
and approved by ILF
14.2 Repair Welding
a) Welds identified for repair shall be recorded in the Daily repair list and welding
chart. This list shall be updated daily to identify the repairs on the previous day
production and also the status of pending repairs. A copy of this report shall be given
to the Pipeline Superintendent I Welding Inspector.
b) MPI and visual Inspection shall be done on the excavated groove to ensure that the
repair is completely removed.
c) The requirements of repair WPS such as parameters, time lapse between passes,
preheat, inter pass temperature, pass sequence and the electrode weaving
limitations shall be complied with at all time. All weld repairs shall be completed as
per approved WPS.
d) Weld repair shall be analyzed & the root cause of repairs shall be investigated and
remedial action implemented. If the cause is due to the performance of welders,
those welders shall be given an agreed period of re-training by the CONTRACTOR,
after which the welder shall be re-tested. When a re-test is accepted the re-qualified
welder can return to pipeline production welding.
e) Only once repair is allowed in one weld unless prior approval from CPECC/ILF.
When re-repair occurs in the same location the joint shall be cut and removed
including the heat affected zone from both ends and shall be re-welded.
f) All repairs shall be subjected to 100% visual inspection and 100% NDE by the same
technique used for original examination.
g) Only TDC and Engineer approved technician shall be engaged on the job.
14.3 Visual Inspection and NDT
a) All finished welds shall be visually inspected for excessive reinforcement, concavity
of welds, shrinkage, cracks, undercuts, dimensions of weld surface porosity and
other surface defects. If any such defects are noticed they shall be rectified. The
visually accepted joints shall be offered for Radiography.
b) The extent of Non- Destructive Testing for the welding is as tabled below. The
acceptability requirement is as set forth in API-1104 latest edition
Job Type

Mainline welds

NDT
100 % Visual Inspection
100 % RT for manual and 100% automatic UT for
semi/automatic welding or as per specification No:
30.78.12.0605.
30 % UT

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 17 of 21
Rev.0

DATE : 08/09/2008

100 % Visual Inspection


Tie In welds

100 % RT
100 % UT
100 % Visual Inspection

Repair welds

Attachment/ Branch welds

100 % MPI on the repair excavated area.


100 % MPI on the completed weld
100 % Visual Inspection

Field cut bevels


100 % UT if pipe is cut 25 mm from the factory bevel

Arc Strikes

100 % Visual Inspection


100 % MPI on the affected area

14.4 Weld Numbering System


a) The total pipeline section is divided into Kilo-meter points (KP), which shall be shown
on marker posts along the line. Welds shall be numbered continuously in ascending
order starting from the isolating joint towards the flow direction till the end of each KM
and with prefix of K.
b) Example: The weld number shall be starting from isolating joint as K0 M1, K0 M2 ...
Continued up to the start of new KM and start again with weld No.1 with the new KP
(K1 M1, K1 M2 ... continued up to the next KP).
c) Note: K0 is for the section between start point and up to Kilo-meter 1. Similarly K1 is
for the section between Kilo-meter 1 & 2.
d) When two pipe strings are tied in, the tie in joint number shall be suffixed with letter
'T' for tie in.
e) Example: 'K0 T 40
f) If additional pipes/ pups have to be welded between open ends and where the
reserved numbers are not sufficient they shall be numbered by suffixing letter A, B, C
etc to the last joint number.
g) Example: K0 M 40A, K0 M 40B, K0 T 40C - Tie In
h) Repair Joints shall be identified as K0 M1R or T1R as applicable.
i) Re-welds shall be numbered with suffix RW attached to the original weld number.
Example: K0 M 40 RW and K0 M 40 RW1.
j) If a re-weld is required to be made as Tie - In, the joints shall be numbered as
follows. Example: K0 T40 RW and K0 T40 RW1.
k) Transition joints in mainline shall be numbered with suffix "TR- attached to the
original weld number. Example: K0 M40 TR
l) If a weld is repaired of Transition joints shall be numbered as follows.
m) Example: For Mainline joints K0 M40 TR-R, For Tie-in Joints K0 T40 TR- R
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 18 of 21
Rev.0

DATE : 08/09/2008

n)
o)

If cut out / Re-weld requires to be made in Transition joint, the joint shall be
numbered as follows. Example: K0 T40 TR-RW1
Weld Joints made after hydro test shall be numbered as K0 GT 40.

Note: K = KILO METER, M = MAIN LINE, T = TIE IN. R = REPAIR, TR = TRANSITION,


RW = RE-WELD, GT= GOLDEN TIE IN
15.0 ELECTRODE CONTROL AND STORAGE
a) Electrodes shall be supplied with the manufacturer's batch certificates complying with
the requirements of CLIENT.
b) Electrodes shall be stored in clean and dry conditions in accordance with the
manufacturer's recommendations or in a dry location at a temperature of at least 20 C
and in a manner that shall prevent damage. Consumables shall remain in their original
containers, which contain the information of manufacturer's name, brand name and the
batch number. Different classes of electrodes shall be segregated and stored separately.
Storekeeper shall issue the electrodes on first come first issue basis.
c) Unused electrodes shall be checked by the storekeeper everyday and if the coating
damage is observed the same shall be put into the quarantined containers. Material
controller shall ensure that damaged /quarantined electrodes are not issued to welders
to weld on the project related works.
d) The welding foreman shall be responsible to collect correct electrodes (type and size as
per WPS) and to ensure that the correct issue is made to each welder.
e) Electrodes which are wet, rusty or have damaged flux coating or which have been bent
or unshaped or have lost the identification shall be removed from site.
f) Electrode shall always be kept in the container and it shall be taken only for welding and
handling. Holding of electrodes with bare hands shall be avoided.
16.0 DOCUMENTATION
The following documents shall be prepared:
a. WPS Register WPS I PQR
b. Electrode batch certificate
c.NDT Reports
d. Mechanical Test Reports
e. Welding Parameter Record Sheet
f. Welder Qualification Test Certificate
g. Welder Qualification Card
h. WPS Visual Inspection Report
i. Daily Repair List
j. Tie in Welding Inspection Report
k.Repair Welding Inspection Report
l. Pipe Book
m. NDT Request
On completion of each shift welding foreman and welding inspector shall fill up the reports
in the attached format as applicable and handed over to QA I QC.
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 19 of 21
Rev.0

DATE : 08/09/2008

17.0 EQUIPMENT LIST

Welding Machines

DG sets

Prime Movers

Internal Camp

External clamps

Compressors

Grinding Machines

18.0 QUALITY ASSURANCE & QUALITY CONTROL


a) Quality Assurance shall be maintained by ensuring the systematic implementation of
this procedure and ensure that necessary quality records are generated.
b) The working Crew supervisor shall report to the concerned QA/QC Engineer about
the work completed and the work planned for next day daily basis. (Daily
construction report).The level of inspection of respective construction activities will be
as per the attached Inspection Test Plan (ITP, Attachment 1). Before H points
are achieved the working crew supervisor/QAQC engineer shall notify to the
ILF/IPIC representative, by means of issue request for inspection (RFI) before 24
hours and QA/QC Engineer on site shall schedule for the planned activity and
maintain the RFI record. If the ILF / TPI representative failed to get the place on
time, the consequent work beyond the H point shall not proceed but the working
group shall keep the corresponding record.
c) 24 hours before the witness (W) points are achieved, the working crew
supervisor/QAQC Eng. shall notify the ILF / IPIC representative, by means of issue
request for inspection (RFI) before 24 hours and QA/QC Engineer on site shall
schedule for the planned activity and maintain the RFI record. If the ILF / TPI
representative failed to get the place on time, the consequent work beyond the W
point shall be proceed and the TDC working group shall keep the corresponding
record also it should be highlighted in the daily construction report of TDC. Before
R points are achieved the working crew shall not invite ILF / TPI representative for
such activity, but the necessary records shall be maintained and submitted for
review of ILF/TPI representative by TDC QA/QC Engineer after R points are
achieved.
19.0 ATTACHMENTS
NO.

Description

30-99-90-1619-QP-01

Inspection and Test Plan

30-99-90-1619-QCL-01

Welding Parameters Record Sheet

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Pages

Date/Rev.

6
1
Project No: E30153
Page 20 of 21
Rev.0

DATE : 08/09/2008

30-99-90-1619-QCL-02

Welding Equipment Calibration Record

30-99-90-1619-QCL-03

Pipe Book From

30-99-90-1619-QCL-04

Welder Performance Report

30-99-90-1619-QCL-05

Welder Qualification Test Certificate

30-99-90-1619-QCL-06

Welder Qualification Card

30-99-90-1619-QCL-07

Qualification Range

30-99-90-1619-QCL-08

WPS Visual Inspection Report

30-99-90-1619-QCL-09

Daily Weld Repair List

30-99-90-1619-QCL-10

Tie in Welding Inspection Report

30-99-90-1619-QCL-11

NDT Request

30-99-90-1619-QCL-12

Radiographic Inspection Report

To

1
1
1
1
1
1
1
1
1
1
1

Note: In case of any conflict between the requirements of this procedure and ILF Specification the
later shall govern, until and unless specific intention is meant.

DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING


PROJECT:

ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT No.:

30-99-90-1619

Project No: E30153


Page 21 of 21
Rev.0

DATE : 08/09/2008