OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 1 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

JOB METHOD STATEMENT FOR INSTALLATION OF PIPING NITROGEN PURGING SYSTEM

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 2 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

TABLE OF CONTENTS

1.0 PURPOSE
2.0 SCOPE

3.0 REFERENCE

4.0 ERECTION WORKRESPONSIBILITIES

5.0 LINE CHECK AND PUNCH LISTJOB SEQUENCE AND STEP BY STEP

6.0 PREPARATION, INSPECTION AND SAFETY DOCUMENTATION

7.0 PRE-FABRICATION AND ON SITE PIPING INSTALLATION

8.0 PRESSURE TESTING

9.0 PRESSURE TESTING AND NON DESTRUCTIVE TESTING

10.0 TOUCH UP PAINTING

11.0 LINE CHECK AND PUNCH LIST

12.0 DOCUMENTATION

13.0 HANDOVER

14.0 TOUCH-UP AND FINAL PAINTING

HANDOVER

15.0 RECEIPT AND STORAGE OF MATERIAL

16.0 MATERIAL TRACEABILITY

17.0 HEALTH, SAFETY AND ENVIRONMENTGENERAL SAFETY REQUIREMENTS

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 3 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

Open
 OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 4 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

1.0 PURPOSE
This method statement is prepared for the execution of nitrogen purging system piping
erection work at 30UMY01 pipe rack structure in Pengerang Cogeneration Plant (PCP)..
This method statement shall be carried out in accordance with the requirement of the
project specifications, code and standards as per contract.

2.0 SCOPE
This method statement covers erection of piping work for Unit 30UMY01installation of piping
for nitrogen purging system including preparations work, lifting of pipe spools and pipe
supports, fit-up and welding work, non-destructive testing, radiography test, line check and
pressure test. This document also covers general HSE requirements while working inside live
plant areas.

3.0 REFERENCE
All works shall be carried out in accordance with the procedures, specification and standards
as defined in the contract requisition parts A & B including but not limited to the following:-

a) a) ASME B31.1 Power Piping

b) Exhibit 1- Scope of Work for Master Service Agreement for Turnaround and Daily
Maintenance for Main Mechanical Works

c) PCP ITB Section 5 Part 11 – Project Technical Requirements and Specifications for Piping

d) PCP ITB Section 5 Part 17 – Project Technical Requirements and Specification for
Materials, Inspection and Corrosion

e) PTS 12.30.02 Piping General Requirements

f) PTS 15.12.04 Welding of Pipelines and Related Facilities (Amendments/Supplements to

API STD 1104)

g) PTS 12.30.05 Shop and field fabrication of piping

h) ASME SEC IX Welding & Bracing Qualifications

i) ASME SEC V Non Destructive Examination (N.D.E)

j) 3080-8440-00-SP-004 Shop & Field Fabrication of Pipework

k) PTS 31.38.01.11 Piping – General Requirements

a) b) PTS 30.10.60.18 Welding of metals

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 5 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

c) PTS 31.38.01.31 Shop and field fabrication of piping

d) PTS 31.40.40.38 Hydro test pressure testing for new pipelines
e) 3080-8440-00-SP-003 PMI of Alloy Materials
f) 3080-8440-00-SP-004 Shop & Field Fabrication of Pipework
g) PTS 61.10.08.11 Field Inspection Prior To Commissioning of Mechanical Equipment
h) ASME B31.3 Process Piping
ASME SEC IX Welding & Bracing Qualifications
j) ASME SEC V Non Destructive Examination (N.D.E)1.0 RESPONSIBILITIES
STS is responsible for the following:

4.1 For providing all construction equipment, materials, tools and labor to perform
works describe herein and in accordance with the specification and design
document.
4.2 Obtaining and renewing required permit to work prior to beginning of work at site.

4.3 Ensure all lifting equipment and vehicles used for carrying out of this work have valid
certifications, and not used beyond safe limits imposed by manufacturer and
applicable safety standards. Ensure all rigging gears are used in safe manner.

4.4 Ensure that welding of piping components and supports are carried out with the
approved WPS and PQR, material traceability is checked as required and ensure
welders and workers trained and qualified for the work.

4.5 Supervisor to ensure personnel involved in the activity are fully aware of their scope
of work, and its criticality through daily toolbox meeting.

4.6 Supervisor to ensure proper housekeeping during and after completion of daily work
activity at work place.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 6 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

5.0 JOB SEQUENCE AND STEP BY STEP

 The pipe installation work process shall be carried out according to Job Hazards Analysis
(JHA) Pipe Installation, and divided into two elevations:

- Job at site below pipe rack elevation 23.3 meters.

- CRITICAL: Job at site above pipe rack elevation 23.3 meters.

 Below is the job sequence:

5.1 All preparations as per Section 6.0 shall be completed prior to start work.
5.2 Upon approval of WPS and WPQ by Client, STS may start with shop fabrication (e.g.
material receiving, pipe support and pre-fab). at STS workshop, located in Teluk
Ramunia.
5.3 Prior to start work at site, STS shall apply Permit to Work (PTW) from Area Owner for
scaffolding, lifting and pipe installation.
(material receiving, pipe support , etc)5.4 STS shall mobilizing materials and
equipment to site.
5.5 Piping erection at 30UMY01 area will be divided into two category based on
elevations, as per JHA Pipe Installation.
5.6 Installation work BELOW pipe rack elevation 23.3 meter:
5.6.1 Job below EL 23.3m: Pipe installation using chain block, lever block and sling
belt/wire.
5.6.2 Job below EL 23.3m: Pipe cutting using oxy-acetylene shall be carried out at
laydown area at ground level.
5.6.3 Job below EL 23.3m: Pipe and pipe support installation work which involves
grinding, fit up, welding, and flange connection.
5.7 Critical installation work ABOVE pipe rack elevation 23.3 meter. The following work
shall only be carried out once the piping system is ready to be connected to the vent
stack. All steps below shall be carried out within the same day.
5.7.1 Re-position the lightning arrester rod at the vent stack (to turn the position
of lightning rod from north to east side of vent stack). (to confirm effect of
change to lightning arrester coverage).
5.7.2 Unbolt flame arrester and lift off the component from the vent stack.
5.7.3 Connect the flame arrester to the reducing tee section. This job shall be
carried out at ground level.
5.7.4 Lift the flame arrester together with the pre-fab piping section to the vent
tip. Ensure check valve attached to the piping to be lifted, has been blinded.
5.7.5 Install the flange connection of reducing tee section to the vent tip.
5.8 Remove the blind at check valve and connect the piping at the check valve to the
piping at below elevation.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 7 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

5.9 For any field welding (pipe or pipe supports) ABOVE 23.3 meter that require NDT
testing, only Dye Penetrant Inspection (DPI) or Magnetic Particle Inspection (MPI) is
allowed.
5.10

1.1 Check valve must be blinded downstream.

Perform inspection and testing as well as painting for the piping system as per section 8.0
and Section 9.0. (requirement pressure test and radiography test with SRAIM).
5.11 Ensure good housekeeping practice throughout the work and after completion of
work prior to PTW surrender.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 8 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

6.0 PREPARATION PRIOR TO START WORK

The following items shall be carried out before commencement of works:

6.1 Submission of WPS, PQR, WPQ for review and approval by SRAIM..
6.2 STS to Ccheck weight calculation of pipe spools and components such as flame
arrester and pipe supports to ensure weight shall not exceed the lifting capacity of
crane.

6.3 Submission of Lifting Plan for approval by CMT UF and HSE PCP offor critical lifting
activity (lifting above live equipment).

6.4 STS to Ssubmitmission of crane operator’s certificate and crane inspection record
prior to any lifting works (PTW application).

6.5 STS to submit Inspection Test Plan (ITP) for review by SRAIM..

6.6 Prior to site installation, scaffolding shall be erected and inspected by STS as per JMS
for Scaffolding work.

6.7 STS to Eensure all workers have successfully gone through PCP HSE induction training
and related trainings such as Working at Height

6.8 STS to identify material laydown area, genset location, crane location and shelter for
workers, and request approval from Area Owner..

6.9 RA from PCP, RAR from TSD, WL from STS.

7.0 PRE-FABRICATION AND ON SITE PIPING INSTALLATION

7.1 Piping installation will start once preparations as per Section 6.0.

7.2 The pipe spools be transported to site for erection once permit to work is obtained.

7.3 The pipe spools shall be air-blown prior to erection when the open end caps were
broken.

7.4 The pipe spools shall be erected as per isometric and layout drawings. Position,
verticality and alignments shall be checked during erection.

7.5 Piping erection shall start from bottom to top level of pipe rack, and then connected
to the vent stack. The piping installation work shall be divided into two categories:

7.5.1 Job below pipe rack elevation 23.3 meter.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 9 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

7.5.2 Job above pipe rack elevation 23.3 meter.

7.6 Pipe supports shall be installed progressively with pipe erection.

7.7 Valves and other in-line equipment shall be installed as erection progress.

7.8 Particular attention shall be paid during installation of spools to cold vent stack to
prevent stressing the equipment nozzles.

7.9 Fit up of piping for parts to be welded shall be fixed using jigs, clamps and bridges or
direct tack weld, so that the required dimension, tolerance and alignment can be
attained.

7.10 All tack welding shall be carried out by qualified welder.

7.11 Materials of tack weld shall be compatible to the base material (same P number).

7.12 The joint number shall be written on the pipe or fitting near for clear identification.

7.13 Prior to welding, groove face and its adjacent area shall be cleaned and free from oil,
dust and other foreign materials/debris.

7.14 Welding shall be carried out as per approved Welding Procedure Specifications
(WPS).

7.15 Welder number for root and capping welding shall be marked on the pipe adjacent
to the welding joints.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 10 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

8.0 INSPECTION AND TESTING (NON DESTRUCTIVE TEST AND PRESSURE TEST)
8.1 Inspection and testing shall be carried out according to Inspection Test Plan (ITP).

8.2 Contractor shall submit Notice of Inspection (NOI) to SRAIM UF one day before the
day of inspection.

8.3 The piping system shall be subjected to non-destructive examination as for Group 1
as per PCP Project Specification ITB Section 5 Part 11 as below:

8.3.1 100% visual examination on butt welded connection.

8.3.2 10% volumetric examination (RT/UT) on butt welded connection.

8.3.3 10% surface examination (DPI/MPI) on butt welded connection.

8.4 Hydrotest shall be carried out as below:

8.4.1 Hydrotest section A shall be carried out at site.

8.4.2 Hydrotest for Section B shall be carried out during prefabrication at

workshop.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 11 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

8.5 Line check shall be carried out before pressure test for a piping test package.
8.6 Release note / form to be sign-off by all parties involved before releasing pressure
testing group.

8.7 The piping system shall be pressure tested in accordance with project specifications
and procedures.

8.8 Test package shall be prepared and test limits shall be spaded according to the
package.

8.9 Test package shall indicate at a minimum but not limited to test pressure, medium
and holding time.

8.10 After spading, the test circuit shall be pressurized, held for inspection and
depressurized.

8.11 If testing medium is water, it shall be drained off after depressurizing.

8.12 After draining, the test circuit shall be air blown.

8.13 Test blinds and spades shall then be removed.

8.14 Hydrotest certificate to be signed off immediately after Hydrotest.

8.15 Test Pack to be re-instated after test.

8.16 Re-instatement punch list to be carried out.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 12 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

9.0 COATING AND PAINTING

9.1 Coating shall be carried out as per Coating System 1A, as specified in PCP Project
Specification ITB Section 5 Part 17.
9.2 The weld seams and damaged spots shall be touched-up in accordance to approved
specification.
9.2 The piping shall then be final painted fully in Light Green MUNSELL 10GY 7/6 or BS
14 E 51 based on color coding as specified in PCP Project Specification PCP-SAG-CVS-
ERP-U-10002-Color Code (Lettering) of Pipes.

4.0 ERECTION WORK

4.1 The pipe spools shall be transported out to site for erection.

4.2 The pipe spools shall be air-blown prior to erection when the open end caps were
broken.

4.3 The pipe spools shall be erected as per isometric and plan drawings.

4.4 Position, verticality, alignments and etc. shall be checked during erection.

Weld joints shall be prepared, tacked and welded in accordance with approved procedures.
Pipe supports shall be installed progressively with pipe erection.
Particular attention shall be paid during installation of spools to cold vent stack to prevent stressing
the equipment nozzles.
Valves and other in-line equipment shall be installed as erection progress.

10.0 LINE CHECK AND PUNCH LIST

10.1 The completed piping or line shall be checked by Contractor for completeness
against latest revision of piping isometric and P&ID drawings.

10.2

10.3 A punch list shall be issued to detail the remaining / rectification works to be done.

10.4

10.5 The line shall be re-checked upon completion of the punch items.

10.6

10.7 The process shall be repeated until full confirmation of all punch items is completed
satisfactorily.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 13 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

10.8

10.9 The line shall be checked with the client and a punch list shall be issued again if
rectification work is required.

10.10 The process shall be repeated as before until full confirmation of all rectification
work is completed satisfactorily.
10.11 All in line instruments to be removed prior to Hydro test.

10.12 Release note / form to be sign-off by all parties involved before releasing pressure
testing group.

5.0 DOCUMENTATION

All QC documentation shall be compiled in line with Project Quality Requirements and
approved Inspection and Test Plan.

5.1 While going through the line checking / punching, documents shall be compiled to
confirm that all drawings are of the latest revision and tally with P&IDs.
5.2 Documentation shall be checked for completeness of required non-destructive testing
in accordance to the pipe class.

5.3 All documentation shall be in place prior to pressure testing.

5.4 Contractor shall allocate sufficient personnel to compile properly & handover QC
documentation.

11.0 PRESSURE TESTING

The piping system shall be pressure tested in accordance with project specifications and procedures.
Pressure tests could be of pneumatic, hydro-static, service test, visual inspection depending on the
design conditions but shall be specified by Consultant.
Test package shall be prepared and test limits shall be spaded according to the package.
Test package shall indicate at a minimum but not limited to test pressure, medium and holding time.
After spading, the test circuit shall be pressurized, held for inspection and depressurized.
If testing medium is water, it shall be drained off after depressurizing.
After draining, the test circuit shall be air blown.
Test blinds and spades shall then be removed.
Hydrotest certificate to be signed off immediately after Hydrotest.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 14 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

Test Pack to be re-instated after test.

Re-instatement punch list to be carried out.

8.0 TOUCH-UP AND FINAL PAINTING

8.1 The weld seams and damaged spots shall be touched-up in accordance to approved specification.
The piping shall then be final painted fully in accordance with project requirements.
DOCUMENTATION
All QC documentation shall be compiled in line with Project Quality Requirements and
approved Inspection and Test Plan.

11.1 While going through the line checking / punching, documents shall be compiled to
confirm that all drawings are of the latest revision and tally with P&IDs.
11.2 Documentation shall be checked for completeness of required non-destructive
testing in accordance to the pipe class.

11.3 All documentation shall be in place prior to pressure testing.

11.4 Contractor shall allocate sufficient personnel to compile properly & handover QC
documentation.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 15 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

912.0 HANDOVER
Contractor shall liaise with Consultant Turnover Group to ensure proper completion of all
documentation prior to handover.
12.1 9.1 The completed piping system shall be jointly inspected with the client
representative.

12.2 9.2 Upon completion of the inspection with no non-compliance, the piping shall be
handed over to the client.

13.0
14.0
15.0 RECEIPT AND STORAGE OF MATERIAL

15.1 Upon delivery, material shall be inspected by Material Inspectors with regards to
quantity, quality and damages.

15.2 Inspected material shall be recorded and up-date into the tracking system.

15.3 Pipe spools shall be stored in fenced open yard area.

15.4 Pipe fittings & Valves – big bored pipe fittings shall be stored in open yard where
small bored which prone to loss / missing shall stored in covered stored.

15.5 Valves when stored in open yards shall be protected from weather.

15.6 Gaskets, bolts & nuts shall be stored in covered area.

15.7
15.8 Specials materials such as orifice plates, hangers, etc which not require at the early
stage of the project shall be kept separate from the remaining materials to prevent
from damages.

16.0 MATERIAL TRACEABILITY

16.1 A material controller shall be assigned to the warehousing and working closely with
the Warehouse Representative.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 16 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

16.2 The respective supervisor shall be responsible to raise materials requisition through
material controller.

16.3 Requisition for the required materials shall be approved by relevant section heads.

16.4 Material controller shall check availability of materials and review the material
requisition.

16.5 Warehouse Representative shall verify and approved the issuance of materials.

16.6 Colour coding shall be developed to identify different grades of materials.

16.7 Materials delivery shall be in stages to match with project progress and minimize
storage areas on site.

16.8 Pipe spools to be tagged for easy identification and tracking.

17.0 GENERAL HEALTH, SAFETY & ENVIRONMENTSAFETY REQUIREMENTS

18.0 The work will be carried out in accordance to establish site Health, Safety &
Environment Plan.

19.0 All lifting tackles and equipment is subjected to inspection by client prior to usage at
site.

19.1 Job Safety Analysis for this method statement will be submitted separately.

19.2 All workers shall go through induction training and related training such as working
at height.

19.3 All workers shall wear proper Personal Protective Equipment (PPE) according to the
work carried out. In area of high noise level, workers must wear hearing protection.

19.4 Ensure valid Permit to Work available prior to commencing work. PTW shall be
visible at site during the work.

19.5 Fire extinguisher shall be located at accessible nearby locations.

19.6 Minimize obstruction of access route at the work area. Keep work place clear and
tidy. Maintain good housekeeping at work place at all time.

19.7 Ensure live equipment, electrical cables are protected and does not obstruct access.

Open
OWNER: OWNER : CONTRACTORS: STS EDAC

DOCUMENT NO : JOB METHOD STATEMENT PIPING INSTALLATION FOR REV:001 Page 17 of 17

NITROGEN PURGING SYSTEM
TECHNICAL SERVICES DEPARTMENT PRPC UF

19.8 All personnel must be familiarized with emergency exit route and muster points.

Open