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METHOD

STATEMENT

INSTALLATION OF GENERATOR FUME PIPE

MALL OF QATAR MEP SERVICE ARRANGEMENTS SHAFT NO. 19

INTRODUCTION

This method statement describes in detail the procedures for the installation of the generator fume pipe at site. This addresses all the activities involved, which also adheres to the safety and quality standards implemented at the work area.

CONTENTS:

  • 1.0 SCOPE AND PURPOSE OF METHOD STATEMENT

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  • 2.0 OBJECTIVE

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  • 3.0 DESCRIPTION OF ACTIVITIES

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  • 4.0 PROTECTIVE COATING APPLICATION

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  • 5.0 LIST OF TOOL(S) & EQUIPMENT

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  • 6.0 HEALTH, SAFETY AND ENVIRONMENTAL MEASURES

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  • 1.0 SCOPE AND PURPOSE OF METHOD STATEMENT

This document summarizes the method of installation of the generator fume pipe, together with all its components at site. This procedure serves as a guideline for assessing all activities involved.

  • 2.0 OBJECTIVE

This method statement focuses on providing oversight and assistance during the installation activities. It states the specific process involved with respect to the safety and quality control policies currently observed and implemented.

  • 3.0 DESCRIPTION OF ACTIVITIES

    • 3.1 GENERAL PREPARATION

      • 3.1.1 All electrical tools shall be endorsed for inspection to the respective Electrical team of the work site to check the validity and compatibility of each tools to the current power supply requirement.

      • 3.1.2 Safety permits applicable to the work activity shall be prepared and submitted for approval prior to commencement of any activity.

      • 3.1.3 Plumb check shall be performed on the solid concrete wall / beam where the pipe supports shall be installed. Levelness of the surface must be obtained prior to installation of the pipe supports which will hold the fume pipe. A nylon cord shall be fastened on a certain point on both ends. This shall be the reference for the levelness of the wall surface where the saddle support will be fixed.

  • 3.2 INSTALLATION OF SUPPORTS FOR THE VERTICAL PIPE LINE

    • 3.2.1 After the levelness check and all the necessary adjustments have been identified, installation of the saddle support shall commence. The activity sequence for each level shall be:

      • 3.2.1.1 The area where the pipe supports are to be installed shall be marked for drilling.

      • 3.2.1.2 The minimum depth of the hole must be at least 100mm.

      • 3.2.1.3 After all the holes have been drilled, the expansion bolts shall be positioned on each of its respective locations.

      • 3.2.1.4 Once the bolts are placed, the saddle support shall be put. Any necessary spacing specified shall be considered and applied.

      • 3.2.1.5 After all adjustments are done, bolt tightening shall follow. Each bolt shall be tightened to secure the saddle supports on its position.

  • 3.3 WELDING ACTIVITY ON THE VERTICAL PIPE LINE

    • 3.3.1 After all the saddle supports are fixed on their respective location, the 10” MS Generator fume pipe shall be positioned one by one. The tower crane shall lay the pipe into the opening, guided by the rigger while the helpers shall assist on the proper positioning of the pipe inside. The first helper shall serve as a guide above on the upper end of the pipe, while the welder and the second helper shall be on the receiving end of the pipe.

    • 3.3.2 Once the pipe is positioned on the desired manner, tack welds shall be placed on certain points where the pipe touches the saddle support to stabilize and restrict any unwanted movement during the welding process. Once the pipe is secured, the line hook of the crane shall be relieved. The next pipe shall be laid inside, and the previous actions

  • shall be applied again. Prior for tacking the pipe joints, the root pass opening of 2.5mm shall be observed. This procedure shall be repeated on every pipe on every level.

    • 3.3.3 Upon completion of positioning, full welding process shall commence. Weld process to be used shall be SMAW, and welding consumable to be used is E-7018 (Low hydrogen electrode).

    • 3.3.4 A single pass fillet weld (6mm) shall be welded around the contact point of the clamp of the saddle support and the pipe. After all the welds on supports are completed, welding of the pipe joints shall proceed. The procedure are as follows:

      • 3.3.4.1 A single bead root pass shall be executed around the joint

      • 3.3.4.2 After accomplishing the root pass, the next set of weld consists of at least 2 layers shall follow.

      • 3.3.4.3 Once done, the third layer which is the full cap, shall be done.

  • 3.3.5 Cleaning of the welds by hand tool and electrical tool cleaning shall be applied after all the welds are completed. These shall cover the removal of the weld spatters, spurs and other unwanted surface matters.

  • 3.3.6 The 90˚ elbow, which shall be connected onto the horizontal pipe line, shall be installed at the bottom end. The weld procedure mentioned above shall be applied.

    • 3.4 INSTALLATION OF SUPPORTS – HORIZONTAL PIPE LINE

      • 3.4.1 Exact location of hanging supports shall be marked prior for drilling.

      • 3.4.2 After drilling, each pipe support shall be positioned in a uniform manner and fastened by expansions bolts.

    • 3.5 FIXING OF HORIZONTAL PIPE LINE

      • 3.5.1 The first spool shall be lifted in a safe manner, in compliance with the safety standard implemented at site. This shall be positioned in line with the elbow connected on the vertical pipe line. Upon achieving the desired position, it will be tack welded on certain points. It shall also be fixed on position by fastening the assigned hanging pipe support into it.

      • 3.5.2 Once the spool is in position, lifting the second spool shall be initiated. The previous steps shall be applied afterwards and implemented for the rest of the spools are in positioned.

      • 3.5.3 Upon completion of the positioning of the spools, full welding shall of the joint shall commence. The welding method shall be of the same procedure as the one applied on the welding of the vertical pipe line.

        • 3.5.4 Cleanliness of the surface shall be observed and the cleaning

    method applied on the vertical pipe line shall also be followed.

    • 4.0 PROTECTIVE COATING APPLICATION

      • 4.1 Surface preparation shall be observed on every area where application of protective coat is necessary. It shall be in accordance with SSPC-SP2 Hand tool cleaning which states that hand tool cleaning is a method of preparing steel surfaces by the use of non-power hand tools. Hand tool cleaning removes all loose mill scale, loose rust, loose paint, and other loose detrimental foreign matter. On weld joints, SSPC-SP11 Power tool cleaning shall be applied.

      • 4.2 Upon completion of the necessary surface preparation, application of the protective coating shall commence. A single layer of Red oxide paint shall be applied on the prepared surface by roller. On concealed or narrow areas, paint shall be applied by brush. Each surface must achieve an acceptable uniform appearance.

    • 5.0 LIST OF TOOLS AND EQUIPMENTS

      • 5.1 SMAW welding machine

      • 5.2 Angle grinder

      • 5.3 Single-phase extension wires

      • 5.4 3-phase extension wire (if the welding machine is 3-phase)

      • 5.5 Fire extinguisher

      • 5.6 Safety hazard tape

      • 5.7 PPE’s:

        • 5.7.1 Welding mask

        • 5.7.2 Welding gloves

        • 5.7.3 Welding apron

        • 5.7.4 Fire blankets

        • 5.7.5 Protective clear glasses

        • 5.7.6 Safety shoes

        • 5.7.7 Safety helmet

        • 5.7.8 Safety vest

        • 5.7.9 Safety harness

  • 6.0 HEALTH, SAFETY AND ENVIRONMENTAL MEASURES

    • 6.1 WORK EXECUTION SAFETY

      • 6.1.1 Everyone shall undergo a safety induction / orientation conducted by HSE Department. The site person-in-charge shall ensure that every member of the work team are duly inducted and fully aware of the safety rules and regulation currently implemented at the work site.

      • 6.1.2 All safety work permits shall be prepared and completed before start-up of any activity at site.

      • 6.1.3 Prior for start-up, risk assessment shall be performed to ensure safety awareness of the work team. Duties and responsibilities of each team member shall be discussed with consideration to the work hazards in their respective areas.

    • 6.1.4 Installation of safety barricades around the perimeter of the work area shall be initiated prior to commencement of any activity, providing a safe work space to other nearby activity and site personnel passing by.

    • 6.1.5 Extension wires and panel boards shall be plugged only on the designated power supply outlets. Sudden power interruption or any associated situations shall be immediately reported to the concerned HSE Department. Interference shall be avoided to prevent any accident.

    • 6.1.6 Safety tools and equipment, such as warning signage, fire blankets & fire extinguishers, shall be arranged within the vicinity of the work place, on a location easily accessible in case of emergency. Personal protective equipment (PPE) applicable to the work activity shall also be worn by each team member prior to any work-related activities.

    • 6.1.7 In case of activities on elevated locations, use of lanyards / safety harness shall be observed. Work shall be performed on the recommended access platforms complete with tag or any written approval issued by the HSE Department.

    6.2

    HOUSEKEEPING

    • 6.2.1 Good housekeeping shall be applied after completion of any activity at site. Cleanliness and neatness of the area shall be observed.

    • 6.2.2 Removal of safety warning devices such as perimeter barricades shall be performed after work has been done.

    • 6.2.3 Work tools shall always be kept on areas where it will not be an obstruction or may cause accidents to other workers.

    • 6.2.4 All tools & equipment shall be stored on the designated storage areas. No item shall be left the work area.

    • 6.2.5 Daily cleaning of the work area shall be performed before leaving, and all collected waste shall be discarded only on the specific dump areas.