Mitsui E&S Engineering Co., LTD.: 1 11 DEC 2020 TP EFD REV Date Prepared by Checked by Approved by Description

FABRICATION AND ERECTION CS/SS PIPE
WORK PROCEDURE
SECONDARY WWTP – CJP PROJECT
1 11 DEC 2020 TP EFD

REV DATE PREPARED BY CHECKED BY APPROVED BY DESCRIPTION
MITSUI E&S ENGINEERING CO., LTD.
PROJECT MECHANICAL WORK FOR SECONDARY COAL CONTRACT NO :

WASTE WATER TREATMENT PLANT L-30037-00
Document Status FOR REVIEW AND APPROVAL
Document Title:
FABRICATION AND ERECTION CS/SS PIPING WORK PROCEDURE
Project Document No: PT.JEL/WWTP/CJP/M20 REV: 1

Contract Doc No: PT.JEL/WWTP/CJP/M20 REV: 1
INDEX OF CONTENTS
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WORK PROCEDURE
Table of Contents
1. GENERAL
2. RESPONSIBILITY
3. GENERAL REQUIREMENT
4. PIPE FABRICATION
5. ASSEMBLING
6. LIFITING AND ERECTION
7. INSPECTION, EXAMINATION AND TESTING
8. PRESSURE TEST (HYDRO/PNEUMATIC TESTING)
9. SAFETY PRECAUTION
10. HOUSE KEEPING
11. DOCUMENT REFERENCES
12. MANPOWER REQUIRED
13. SAFETY PLAN
14. ATTACHMENT
ATTACHMENT:
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WORK PROCEDURE
ATTACHMENT – 1 : ORGANIZATION CHART
ATTACHMENT – 2 : RISK ASSESSMENT
ATTACHMENT – 3 : INSPECTION AND TEST PLAN
ATTACHMENT – 4 : FORM INSPECTION
ATTACHMENT – 5 : PHOTO OF EQUIPMENT, TOOLS, AND MATERIALS
ATTACHMENT – 6 : LAYOUT DRAWING
1. GENERAL
1.1 Purpose
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To provide guidelines to be utilized in establishing reasonable assurance that all utility & process
piping is fabricated, welded, installed and tested in accordance with Central Java Coal Fired Power
Plant 2x1000 MW and the applicable codes and standards governing these functions.
This procedure further describes how utility & process piping related activities will be controlled, the
inspection procedure, reporting structure, resources allocated, personnel responsibilities and
authority defined for key project team members and their interfaces between PT. JEL and
Contractors.
1.2 Scope of Work

This method statement covers following CS/SS Piping work step:
- Fabrication work in fabrication workshop
- Transportation from fabrication workshop to lay down and or directly to filed
- Site preparation around pipe rack/equipment
- Setting scaffolding around fit up & welding work and support installation
- Setting scaffolding for access on pipe rack and access way
- NDE after completed of welding work
- Confined space work
- Pressure Test (Hydrotest, Pneumatic Test, Service Test, Visual Test)
1.3 Code and Standard
The related codes and standards to supplement this specification as follow:

1.3.1 ASME B31.3 Process Piping
1.3.2 ASME B31.1 Power Piping (Black & Veatch Design)
1.3.3 ASME / ANSI B16.5 Pipe flanges and flanged fittings
1.3.4 ASME Section V Non-Destructive Examination
1.3.5 ASME Section IX Welding and Brazing Qualifications
1.3.6 ASME B16.11 Forged Fittings Socket Welding and Threaded
1.3.7 ASME B16.47 Large Diameter Steel Flanges (NPS 26 through NPS 60)
1.3.8 ASME B16.20 Metallic Gasket for Pipe Flange
1.3.9 ASME B16.21 Non-Metallic Gasket for Pipe Flange
2. RESPONSIBILITY
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a. PT.JEL Site Manager has overall responsibility for ensuring that all activities are performed in
accordance with this procedure.
b. PT.JEL Construction Manager is responsible for necessary evaluation, planning and preparation to
enable the work to proceed smoothly.
c. PT.JEL Mechanical Engineer shall be responsible to ensure that the planning, site preparation,
evaluation and construction is carried out in a manner that supports safe working.
d. PT.JEL Mechanical Supervisor is responsible for implementation and controlling the field works
and ensures that the work is effectively and safely carried out.
e. PT.JEL Safety Engineer is responsible for ensuring that all activities are carried out in a safe
manner and in compliance with the established safety procedure.
f. PT.JEL QA/QC Engineer/ Supervisor shall be responsible to monitor and inspect the erection
ensuring it is being done in compliance with this procedure, ITP (Inspection and Test Plan.
Tolerance List, drawing, project specification and other references standard documents and
procedures.
g. PT.JEL Welding Inspector responsibility classified under three main categories: Before Welding,
During Welding, After welding. Before Welding he is responsible for Check the availability of the
latest codes /specifications to be used for construction and familiarization of the same, review
welder qualification, test reports/qualify the welders, check the joint preparation and record the size
and dimensions, check the batch test certificated of the consumables to be used if electrode filler
wire gas & baking of electrodes if required. During welding he is responsible is to check the welding
parameters like amperage voltage travel speed etc., check weather the correct welder is welding
the material in correct position, monitor Welding conditions for root run / hot pass and all
subsequent run, and inter-run cleaning, safety requirements. After welding he is responsible Carry
out visual inspection of the welded joint (Including dimensional aspect), Identify repairs from
assessment of visual or NDT reports, Check and monitor NDT requirement (Method, qualification
of operator, execution), Pressure Test procedure.
h. PT.JEL Foreman is responsible for the direct control of workman and ensures that all works are
performed in accordance with the Supervisor’s instruction. He shall maintain close coordination
between the Supervisor and workmen.
i. PT.JEL Pipe Fitter is responsible to understanding the responsibility and safety of fit up pipe and
erection activities, perform checks and inspection before starting works, Preparing the workplace in
order to secure the working process.
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j. PT.JEL Welder is responsible to Understanding the responsibility and safety of welding work,
perform checks and inspection before starting works, preparing the workplace in order to secure
the working process, giving the good quality of welding
k. PT.JEL Material Control is responsible to Understanding the specification of piping and support
materials, perform checks and inspection material, Arrangement Loading and unloading materials,
arrangement material storage as per procedure.
3. GENERAL REQUIREMENT
3.1 Qualifications
3.1.1 All working personnel shall attend the Client’s safety induction training & other related
safety training course.
3.1.2 Tool box meeting shall be performed on each and every working activity
3.1.3 Tool box shall be carried out by Supervisor or Foreman at site
3.1.4 Person who engaged for welding including support welding work shall have passed the
qualification test stipulated in engineering specification and must be certified by DISNAKER
3.1.5 Welding procedure specification and the Procedure qualification record as per engineering
specification shall be obtained for welding work
3.2 Materials
3.2.1 Piping material shall be in accordance with Design engineering Project specification
3.2.2 It is applicable to use other alternate material which have been approved by Contractor
3.2.3 based on the engineering specification
4. PIPE FABRICATION
4.1 General
4.1.1 Fabrication shall be executed in accordance with the drawing document and related
engineering specification
4.1.2 Stainless steel pre fabrication work including material storing shall be well separated from
other steel pre fabrication works. Tools and equipment to be used shall be suitable for
stainless steel and shall not be used on other material
4.1.3 The bolt holes flanges shall be located symmetrically from a vertical center line in a
horizontal
pipe center line unless otherwise indicated in the drawing
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4.1.4 Marking of piping materials shall be in accordance with material control procedure
All piping materials, fittings, pre-assemblies, pipe spools, etc., delivered to site shall be
clearly identified, checks shall be made of materials supplied to ensure that manufacturer’s identity
markings are stamped or printed on fittings, bolts, etc.
Piping materials shall be identified by means of stencils, stamps or color coding to verify that they
conform to specification. Protective measures shall be implemented to prevent damage and
deformation during transportation and handling of piping material.
Examples of such measures are:
 Cover screw threads to prevent ingress of dirt, moisture and extraneous substances.
 Protect machined surfaces such as valve and flange faces, from damage and deformation.
 Seal the ends of prefabricated spool pieces and valves to prevent ingress of dirt, moisture and
extraneous substances.
4.2 SHOP & FIELD FABRICATION

4.2.1 General
Quality Department shall review the contractor’s welding procedures. Where the contractor
has no applicable procedure, quality department shall use a standard qualified procedure from the
welding manual or require that the contractor develops and registers a new procedure. All
procedures shall be registered with appropriate authorities and shall meet requirements of the
project design, codes and Standard authorities.
All piping shall be installed in accordance with the applicable engineering drawings, P&ID’s,
Piping Layout, Isometric drawings and specifications. Attention shall be given to the removal of
corrosion preventatives, temporary shipping supports, pipe hangers/spring support shipping stops,
etc.
Checks shall be made to verify the proper application of cold spring requirements, the
settings for spring supports and hangers. Pipe supports shall be installed, tested and inspected in
conformance with approved specifications for pipe supports.
4.2.2 Stainless steel pipe

Stainless steel pipes shall be prepared for welding by grinding or machining and all burrs shall be
removed.
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In order to prevent contamination, JEL Welding Supervisor shall ensure that all tools, grinders, etc.,
used on stainless steel are NEVER used on carbon steel. Similarly, tools used on carbon steel
shall NEVER be used on stainless steel. The usual arrangement of pipe shops shall ensure that
stainless and carbon steel use separate facilities.
Equipment used to prepare welded joints such as wire brushes and steel wool, shall be
manufactured from stainless steel. When grinding wheels are used is required, only those that
have been used exclusively on stainless steel shall be permitted. Color coding may be used for
identification.
Material 3.5 mm and under may be welded using a square butt or may be beveled as required for a
particular welding process. Metal thicker than 3.5 mm shall have a single “V” beveled joint.
Welding procedure specifications shall be submitted to Contractor QA-QC Coordinator for approval
before commencing work.
Butt welded joints shall have 100% penetration.

The inside of all welds shall be smooth and free of depressions. Smooth projections (maximum
1/16”) are permitted however (as this gives better assurance of 100% penetration).
All welds shall be marked with the welder’s number who performed the work.
The inert gas shielded arc welding process with shielding gas protection on the underside of the
weld, “back purge” shall be used for welding stainless steel. The root welding equipment shall be
GTAW.
The SMAW welding process, using a coated rod may be used for welding filler passes in stainless
steel.
Tack welds shall be made small enough to allow them to be absorbed into the following beads, (or
removed as the root weld progresses) and they shall have all slag and oxide removed in advance
of making the finished weld. Ideally, they should be ground to a feather edge to blend in with the
root weld.
All materials shall be dry and completely protected from the wind and weather during a welding
operation.
Supports shall not be welded on pipes. Lugs on fixed points can, however be welded on the pipe
but should be of the same material as the pipe.
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If carbon steel must be welded to stainless steel pipe less than 3 mm thick it shall be seated on a
stainless reinforcing pad equal in thickness and material to that of the pipe. Flanges and collars
shall be true and square within the limits specified.
4.2.3 Carbon steel pipe

All welds shall be marked with the welder’s number. Butt welds in carbon and low alloy steel piping
shall usually have the root pass welded by the Gas Tungsten Arc Welding process (GTAW). Water
pipes and drains may have root welds made by Shielded Metal Arc Welding (SMAW). This may
vary depending on the PQR qualified.
All materials should be dry and protected from the weather during a welding operation. Welding
joints shall have a root opening of 2-3 mm after tack welding.
Pipe lines to be cold sprung shall be anchored at both terminals and cold spring joints shall be
dimensionally checked before the ends are pulled together and welded.
Flanges shall be true and square within the limits specified, by Contractor Piping Department. Slip-
on flanges shall be welded both inside and out. The flange face shall be protected from weld
spatter while making the internal weld. Flange bolt holes shall straddle the flange center-line.
Valves with welded connections shall not be welded to each to other directly. They shall be
separated a piece of pipe between them.
Raised face flanges shall have either a spiral or concentric standard finish on the raised face.
Instrument orifice plate flange connections shall have all weld spatter removed and have the inside
of the welds ground smooth.
Instrument orifice weld neck flanges shall have the inside diameter of the flange taper bored to suit
the ID of the matching pipe.
4.3 Cutting
4.3.1 Cutting line shall be marked on pipe. Based on Cutting List information, Where the material
marking will become invisible after cutting, additional material marking shall be provided
4.3.2 Before cutting need to verify by QA/QC, In the case of gas cutting, cutting surface shall be
ground off to remove any edge and roughness and be made flush & smooth so as not to
harm
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welding quality. In the case of automatic or semi-automatic gas cutter, the cut edge may be
beveled without such grinding off
4.3.3 In the case of gas cutting, cutting slag stocked inside pipe shall be completely removed,
especially for boring of pipe for weld branch
4.3.4 Abrasive disc used for cutting of austenitic stainless steel or other high Cr-Ni Steel shall
not
be used for carbon steel, or vice versa
4.3.5 Plasma jet cutting may be applied for stainless steel, etc.
4.4 Beveling
4.4.1 End preparation for Butt weld shall be in accordance with table 4.3.1 or any other which
meets
the WPS
1) Welding Bevels for Butt welds
2) Shape of beveling other than mentioned in table 4.4.1 shall be in accordance with the WPS
(welding procedure specification)
4.5 Alignment and Trimming

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4.5.1 Root gap for butt weld shall be in accordance with the WPS
4.5.2 In the case of butt welding pipe and / or fitting having unequal wall thickness, of which the
difference is more than 3 mm in outer surface and / or 1.5 mm in inner surface, the end of
the thicker pipe shall be trimmed by grinding as per the fig 3.4.2(a),(b) and (c) shown below
The gradient of this trimming shall be less than 30° between worked and un worked part
shown bellow:
Note: In the case that “special end detail “in specified in the piping specification for the pipe and or
fitting of which the normal wall thickness is 30 mm and over, the end preparation shall be in
accordance with such provision
4.5.3 Branch connection which about the outside surface of the run pipe shall be contoured for
groove welds which meet the WPS requirements. Branch connection which are inserted
through a run opening shall be inserted at least as of the inside surface of the run pipe at all
point.
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Note: Drill used to first make hole branch connection
4.5.4 When a pipe having a longitudinal weld, seam is used in a horizontal line, the pipe shall be
laid so that the longitudinal weld seam is not on bottom or top of the pipe. Allocation and
relation among circumferential, longitudinal and other (branch, support, etc) weld are shown
in the figure below
1) Circumferential Joint
2) Branch Pipe and weld line on run pipe
Remarks:
1. L and L1 show distance between both toes of the bead
2. L shall be three times the pipe thickness or over
3. L1 shall be five times the pipe thickness or over
3) Support /shoe and weld seam of main pipe
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4.6 General Requirement for Welding

4.6.1 Requirement and criteria for welding shall be as follows, unless otherwise specified in the
Drawing:
1) Welding shall be performed in accordance with WPS. All welders shall pass the
qualification test and valid certificate in accordance with WPS being applied
2) Complete back shielding with argon gas shall be required during the welding of root of
Stainless steel in accordance with WPS
3) Welding shall not be carried out in adverse weather condition where there is impingement
of rain or snow, sleet storm or excessive wind at the working area, unless appropriate and
adequate protection is provided
4) The bevel shall be fully cleaned so that there is no rust, oil, paint, sand, moisture, etc.
remaining care shall
be taken that the
stainless steel does
not come into contact
with any form of zinc-
based material.
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Where bevel is not to be welded immediately it shall be protected to prevent

contamination
5) Spatter, slag, etc., on the weld or in the heat affected zone shall be thoroughly removed to
the metal surface
6) Arc strike on base metal shall be avoided at all times. Arc strike shall be grinding flush
and liquid penetrant test. Any defect shall be ground out and weld repaired
7) Material of wire brush shall be properly selected for working carbon steel and stainless
steel respectively. They shall always be kept separate and never used on anything other
than designation
8) Weld internal protrusion at the weld neck joint of an orifice flange shall be removed flush
and smooth with a grinder. Any concavity in the root, shall be weld repaired and ground
flush and smooth
9) Socket welding shall be performed at least 2 layers weld and end point of weld at each
layer shall not be aligned
4.5.2 Notes on Stainless Steel Welding

1. Maintain short arc during welding to avoid loss of alloying material during transfer across
the
arc
2. Tack at regular intervals, at about half the pitch used for mild steel
3. Use stringer passed rather than wide weaves
4. Thoroughly remove slag between passes
5. To minimize distortion, apply back step or block sequence when welding
6. When welding double V joints, Balance the welding on each side to minimize distortion
7. Never use very wheels of buffs for grinding or polishing stainless steel if they have
previously
been used for mild steel
8. Do not use excessive welding current because of the high electrical resistance and low
thermal conductivity, lower current is used than mild steel
4.6 Welding Rods

4.6.1 Welding rod to be used at shop and site shall be in accordance with WPS.
4.6.2 Brand name of welding rod to be used at shop and site shall be approved by
Contractor before work starts.
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4.7 Welding
4.7.1 Tack welding shall be carried out as follow:
1) Both root and bridge tack welding method may be applied
2) Avoid wrong fit-up which would cause residual stress
3) Keep the correct root gap by using spacer according to WPS
4) Welding condition of tack welding shall be in accordance with WPS
5) Provide sufficient external pipe clamps or internal spiders for setting up
6) Ensure the contact surface of the clamps of spider are made of the same base metal or an
inert compound.
7) Bridge tack shall never be hammered off. Bridge tacks shall be removed by grinding or gas
cutting. Gas cutting shall only be performed at the upper part of the weld toe and flush
surface of base metal by grinding, any defect shall be ground out and weld repaired.
8) Tack welding or temporary welding of jigs, etc.
Root tack weld Bridge tack weld
4.7.2 Butt joint welding of pipes shall be performed as follow:

1) Welding shall be performed in accordance with WPS
2) Circumferential butt welding shall be performed without the use of a backing ring unless
specified in WPS.
3) Before welding of the root, both ends of the root tack weld bead shall be prepared with a
grinder as shown in the following illustration in order to make complete fusion
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4.7.3 Branch connections shall be made by using the fittings as specified

However, where the branch is to be welded directly to the main run in accordance with Piping
Arrangement Drawing, welding shall be performed, unless otherwise specified, shown in following
in fig:
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Notes:
1) Throat thickness “tc” shall be of 0.7 Tb (minimum 6.4 mm).
2) The symbols used in these figures are as follows:
Th: nominal thickness of run pipe
Tb: nominal thickness of branch pipe
Tr: nominal thickness of reinforcement pad
3) At first, weld part 1 and prepare the weld surface with a grinder, then weld the part 2.
4) Where reinforcement is necessary, it is indicated in the Piping Arrangement Drawing and
Notes for Piping Drawings.
4.7.4 Fillet welding of pipe to slip-on and socket weld flanges shall be performed as shown in
following Fig:
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Notes
1) T: thickness of pipe
t : thickness of flange hub
2) If 1.4 T is larger than t, t shall be taken.
4.7.5 Socket welding of pipe components other than flanges shall be performed as shown in
following Fig
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4.8 Bending
4.8.1 The extent and classification of pipe bending shall be in accordance with Table 4.8.1
unless otherwise specified.
Tabel 4.8.1
4.8.2 Radius of curvature shall be 4 to 6 times of outside diameter of pipes, unless otherwise
specified.
4.9 Marking
4.9.1 All piping component for which welding has been completed shall bear the painted
marking with the identification symbol of the welder as confirmation
4.9.2 Spool piece no shall be clearly marked on fabrication components
4.10 Storing
4.10.1 Inside of fabricated components shall be cleaned by air blowing then opening of
fabricated components shall be covered with suitable materials so as not to enter the
foreign materials such as sand, stone etc.
4.10.2 Gasket surface of flange, thread, and welding bevel shall be protected from any damage
due to cleaning work and handling of storing.
4.10.3 Zinc contamination to stainless and high Ni-Cr steel shall be avoided. Countermeasures
shall be taken to the materials such as protection from Zinc adheation by paint spray
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work, separation from Zinc contact when the material is laid on the galvanized grating
floor, etc.
4.10.4 Fabricated components painted (with primer) shall be well protected during lifting to
avoid scratching or damaging of paint. Suitable lifting devices (such as lifting sling belts)
shall be used to protect the paint from damaging.
4.10.5 Storing of fabricated components painted shall not be laid touching directly to the ground
or soil. Laying using wooden pallets or timber underneath is one of the best methods for
paint protection of fabricated components. Covering protection may require for rainy
seasons if components are too kept for a while at the open storing area.
4.10.6 Damage paint due to welding, PWHT, or scratches shall be repaired by suitable type of
paint after cleaning. Exposed weld joints shall be wrapped with masking tapes after
cleaning to avoid extensive corrosion. Ends shall be covered with plastic end caps or
plugs also.
5. ASSEMBLING
5.1 General
5.1.1 Before assembling of piping, actual tolerance causing from foundation, steel structure,
and equipment installation work shall be considered for the piping assembling work.
5.1.2 Excessive stress shall not be allowed to the nozzles of rotating machine when the
flange of fabricated component is connected, such work shall be carried out in the
presence of person in charge of the mechanical work. And openings such as flanged
joints of a pump, compressor, etc. shall be kept covered with thin metal plate or other
solid blinds with a handle to prevent dust and/or foreign material from entering into the
machine.
5.1.3 If hot work to be performed in the vicinity of instrument control or power cable duct, an
adequate protective cover shall be provided in advance so as not to damage the
cables.
5.1.4 When work is carried out in the vicinity of piping made of, or lined with special materials
such as plastics, rubber, glass, etc., care shall be taken so as not to damage them.
5.1.5 Valves shall be assembled in clean condition, they shall not be opened during piping
erection except that welding and heat treatment of a welded valve joint shall be carried
out with valve opened.
5.1.6 If cutting, making of holes to the assembled piping and such kind of work is carried out
at assembled place due to the reason of modification, improvement, etc., cut piece and
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foreign materials shall be removed from inside of piping and it shall be confirmed that
the inside of piping is cleaned.
5.1.7 Valves having flow direction shall be installed to conform the flow direction in
accordance with piping drawings. Care shall be taken to the valves in case valve flow
direction is reversed against the flow direction of pipe line.
5.1.8 It is prohibited to use small size piping, pumps, instrument etc. as scaffolding or
working stage.
5.1.9 The following requirement shall be observed for piping support.
1) Pipe supports shall be fabricated and installed in accordance with Pipe Hanging
Details
2) As a rule, the location of pipe-supports shall be in accordance with the Piping
Arrangement
3) Drawing and Hook-up Drawing.
4) The pre-setting pieces of the pipe hanger shall be removed after completion of
pressure test of the pipe line. However, pipe lines which will be insulated, it shall be
removed after completion of the insulation work.
5) A shoe support shall be attached to the pipe in accordance with the drawings. It is
not permitted to tack-weld a shoe support to the pipe rack, where the shoe support is
not to be permanently fixed to the pipe rack.
6) When supports are installed on building or such kind of structure, permission of
installation shall be given by Contractor before installation.
5.2 Flanged Joint

5.2.1 Any damage to the gasket seating surface which would prevent gasket seating shall
be repaired, or the flange shall be replaced.
5.2.2 Flanged joints shall be bolted up, after checking the alignment of the flange centers
and the parallelness of flange faces, to ensure that the contact faces bear uniformly
on the gasket.
5.2.3 Particular care shall be exercised to ensure that all bolt, nut and gasket are correctly
installed in accordance with the requirements of Construction Specification
5.2.4 All flanged joints shall be fitted up so that the gasket contact bear uniformly on the
gasket, and then made up with uniform bolt stress.
5.2.5 Steel to cast iron flange joints shall be assembled with care to prevent damage of the
cast iron flange.
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5.3 Threaded Joint

5.3.1 The standard to be applied to all threads shall be ANSI/ASME B1.20.1 Pipe Threads
(NPT).
5.3.2 Lubricant shall be removed completely from the thread and inside of pipe after threading.
5.3.3 In a threaded joint between pipe and flange, the length of thread on the pipe shall be
such that the end of the pipe is short of the gasket surface on the flange by 1.5 to 3.0
mm when screwed-in.
5.3.4 Thread shall be jointed with full coupling between straight pipes, and piping shall have
union joints in consideration with repairing at pressure test.
5.3.5 Threaded joints shall be sealed with tape or threading compound, unless there is
restriction from process requirement.
5.3.6 Seal welding of threaded parts, if specified, shall be performed after the part is screwed-
in completely
5.3.7 without using paste or oil and fully cleaned, degreased and dried out. Reinforcement of
the seal weld bead shall cover completely the remaining thread and must be at least 2-
layers weld using a suitable size of electrode.
5.4 Mechanical Joint

5.4.1 Mechanical Joint other than flanged joint and threaded joint shall be in accordance with
manufacturer’s instruction or drawing.
5.4.2 Care shall be taken to avoid distorting the sheet when incorporating such joint into
piping assemblies by welding.
5.5 Tubing Joint

5.5.1 The sealing surface of the flare shall be examined for imperfections before assembly and
any flare having imperfections shall be rejected for flared tubing joints.
5.5.2 Flare less and Compression Tubing Joint shall be performed so that the compression nut
becomes finger tight.
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6. LIFTING AND ERECTION

6.1 Preparation Prior to Spool Erection
1) Site Survey
2) Centerline Marking
3) Mobilization Tools and Equipment
4) Tools & Equipment Inspection
5) Make sure erection drawing is the last revision drawings issued
6.2 Lifting and Stringing Pipe Spool

The following steps need require to performing a spool lifting and stringing to pipe rack
6.2.1 Requirements Data of Lifting Equipment
All rigging operations require an experience rigging superior and foreman, lifting work is
complexity work, require a full focus on the method statement of lifting.
6.2.1.1 The dimension, weights, center of gravity, and configuration of the pieces to be
consider before tie-up and lifting.
6.2.1.2 Inventory of available lifting equipment (percentage of availability of lifting
apparatus, capacity and strength of wire/sling)
6.2.1.3 Planning lifting path or location to be doing rigging spools.
6.2.1.4 Crane operation radius and the maximum vertical angle to be consider is free
movement of the boom.
6.2.1.5 Perform checklist of the crane and tool-box talk daily of lifting activities.
6.2.2 Base/Foundation of Lifting Equipment
6.2.2.1 Soil or base or foundation of Pipe rack under the lifting spool pipe and piping
support shall have adequate bearing capacity to support any payload due to
lifted spool pipe and piping support and lifting spool pipe and piping support
shelf load. These requirements shall support with the technical calculation which
is provide by CONTRACTOR / Subcontractor and approved by COMPANY.
6.2.2.2 When lifting activity to be located to pipe rack or embankment shall be

positioned to prevent of the underlying spool pipe and piping support and
subsequent collapse of the area that supports the lifting equipment.
CONTRACTOR/Subcontractor shall investigate the stability of the proposed
crane support area and has taken sufficient precautions to prevent failure.
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6.2.2.3 When doing a critical lifting, there are some criteria that should be doing. The
criteria critical lifting is:
- Loads exceeding 75% of the rated capacity of any one crane

- Personnel lifting
- Loads that will require suspension directly above rigging personnel
- Lifts that result in loads leaving direct view of the crane operator
- Loads that are extremely valuable, irreplaceable, or unrepairable
- Loads that could potentially become damaging to other equipment or utilities
- Loads that are potentially unstable in flight
6.2.2.4 The procedure for critical lifting for the PIC shall ensure that a step-by-step
procedure is prepared for critical lifts. Although individual procedures are
prepared for one-time critical lifts, general procedures may be employed to
accomplish routine recurrent critical lifts, for example, a general procedure may
be used to lift an item or series of similar items that are frequently lifted or
repeatedly handled in the same manner. A critical lift procedure should contain
the following, as applicable:
- Identify the items to be moved.
- Special precautions, if any (such as outrigger or track cribbing for mobile
cranes).
- Weight of the item and total weight of the load (For mobile cranes, see the
manufacturer’s instructions regarding components and attachments that
must be considered as part of the load).
- Centre of gravity location.
- A list of each piece of equipment (e.g., crane, hoist, fork truck), accessory,
and rigging component (e.g., slings, shackles, spreader bars, yokes) to be
used for the lift. (This list shall identify each piece of equipment by type and
rated capacity).
- Designated checkpoints and hold points and estimated instrument readings,
as relevant, so that job progress can be checked against the plan.
- Lift point identification.
- Load vectors.
- Sling angles.
- Accessories used.
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- Other factors affecting the equipment capacity.

- Rated capacity of equipment in the configuration(s) in which it will be used.
(For mobile cranes, many factors affect rated capacity, including boom
length, boom angle and work area).
- A sign-off sheet to verify that equipment and tackle inspections or tests are
current.
- When spool lift from ground to pipe rack or steel structure, all lifting plan
should be clear and equipment for lifting must be complete for inspection
from HSE. When transfer load happens from crane to pipe rack steel
structure, at pipe rack or steel structure must be install chain block on pipe
rack or steel structure for transfer load if crane cannot reach the area of
spool. When the transfer load happens, the spool must be connected to
chain block but sling belt on spool from crane don’t be released until the
chain block can handle lifting the weight of spool.
6.2.2.5 Substitution of inadequate bearing capacity of soil Foundation or Base of Pipe

rack surface, any fill, matting, metal plate, and slabs is permitted with
COMPANY approval.
6.2.2.6 Lifting pipe under 6-inch pipe, the appointment could be done by hauling one
more pipe by using Double Wrap Chocker Hitch. The Double Wrap Chocker
Hitch a formed by wrapping the sling completely around the load and hooking it
into the vertical part of the sling. This hitch is in full 360° contact with the load
and tends to draw it tightly together. It can be used either singly on short, easily
balanced loads or in pairs on longer loads.
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6.2.2.7 Material Lifting Categories

1) Spool piece.
2) Pipe Support.
3) Testing Equipment.
4) Box of Tools and Others.
6.3 General Safety During Crane Operations

Basic lifting method required to execute spool rigging works:
6.3.1.1 Permits
Obtain PTW is signed and tool box briefing before start works.
6.3.1.2 Use Correct Lifting Gear
Use only tested and certified lifting gear and equipment. Visually inspect all
lifting gear and equipment before use as per safety color codes.
6.3.1.3 Safe Working Loads
Never exceed the safe working load and exceed working radius boom.
6.3.1.4 Location of the Working Areas
The area must have sufficient clearances for the load including the swinging of
the lifted items should not hit any equipment or machinery.
6.3.1.5 Weather Limitations
Windy velocity shall be considered not to do any lifting as per HSE instruction.
Rainy shall stop all the lifting activities.
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6.3.1.6 Prior Lifting

Prior lifting the pipe spools, ensure a right angle, center of gravity, balancing of
the spools and other rigging method has be consideration and study. To suit
method of rigging and actual location of the spools to be install.
7. INSPECTION, EXAMINATION AND TESTING

7.1 Extent of Inspection, Examination and Testing
Prior, during and after completion of the works, the following examination and tests shall be
performed:
7.1.1 In-Process Inspection
1) Prior to commencement of work
Examination and testing Acceptance Criteria

a. Material Check To satisfy the requirement
b. Welding Procedure To satisfy the requirement

Specification
c. Welder Performance Welder’s performance qualification certificate
Qualification authorized by Contractor
d. Electrode and welding Material certificate (material name, brand).
Consumable To satisfy applicable codes and standards.
2) Prior to Welding

a. End preparation Shape and dimension To satisfy the requirement
engineering specification
Cleanliness To be free from paint, oil, rust,
scale, or other foreign material
b. Tack weld Root opening (Gap) To be within the tolerance specified
in WPS
Alignment (Mismatch) Misalignment is not more than 1.5
mm for internal surface and 3.0 mm
for outer surface
c. Electrode Drying temperature To be in accordance with
manufacturer standard
Drying time -ditto-
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3) During fabrication and assembling
Examination and testing Acceptance Criterion

Dimension (1) See fig 6.1.1
(1) : Flattening ratio and reduction of thickness acceptance criteria, which shall be decided in
accordance with practical conditions, shall not be applied for steam trace piping.
Fig 6.1.1 Application of Pipe Fabrication Tolerances
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4) After Welding
Examination and testing Acceptance criteria

Visual Crack None
examination of Under cut Lesser 1.0 mm or 0.25 t. but for low
weld Girth weld and branch temperature service materials and cyclic load,
connection undercut is not permitted.
Overlap (cold lap) Less than 1.0 mm
Throat thickness of fillet Over 0.9 t (Half/Full Coupling)
metal Over 1.0 t (SO/SW Flange)
t : thinner pipe thickness
Weld reinforcement or Wall thickness (mm) Max
internal protrusion (root 6.4 or under 1.6
Penetration) Over 6.4 up to 12.7 3.2
Over 12.7 up to 25.4 4.0
Over 25.4 4.8
Weld scars from jigs and Visual check and no defect liquid penetrant
arc strike examination as be part (b) for high
temperature and low temperature service
Lack of fusion Nil
- Girth weld and branch
connection
Incomplete penetration None
- Girth weld and branch
connection
Surface porosity None
Non- Radiographic examination As per par 341.3.2.A of ASME B31.3 and
Destructive (RT) article 2 of ASME Sect 5
Examination Liquid Penetrant As per par 341.3.2.A of ASME B31.3 and
Examination (PT) article 6 of ASME Sect 5
5) After completion of works

a. Visual Check No extra distortion
b. Pressure test According to engineering specification and
no leak shall be acceptable
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7.2 Non-Destructive Examination

7.2.1 The weld joints of piping shall be examined to the extent specified in Table with
the following random examination procedure:
1) The examination made at random shall consist of examining not less than one
production weld joint selected from each production weld joint lot made by the
same welder or welding operator defined as follows.
The above each production weld joint lot means;
(a) each 20 production weld joints or less for 5 % random examination,
(b) each 10 production weld joints or less for 10 % random examination and
(b) each 5 production weld joints or less for 20 % random examination,
respectively.
2) The examination shall be applied to the entire length of weld of the selected
joint, except as provided in (4) hereof.
3) The weld joints between dissimilar materials shall be examined by the method
used for the material requiring the more stringent examination.
4) Not less than one shot (with a 150 mm weld length) on one in each 50 girth
butt weld joints by each welder or welding operator for Category D Fluid
Service as designated in the Specific Job
Requirements attached hereto, shall be examined by the spot radiography (Table
7.2.1)
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7.2.2 When a random or spot examination of weld joints reveals a defect, the
progressive examination for the same lot defined in Par. 7.2.1 shall be
carried out as per the following procedure.
1) Two additional weld joints of the same lot, by the same welder shall be
given the same type of examination; and
2) If the weld joints examined as required by (1) are acceptable, all items
represented by this additional examination shall be accepted; but
3) If any of the items examined as required by (1) reveals a defect, two
further weld joints of the same lot by the same welder shall be examined
for each defective item found by that examination; and
4) If all the items examined as required by (3) are acceptable, all items
represented by this additional examination shall be accepted; but
5) If any of the items examined as required by (3) reveals a defect, all items
represented by the random examinations shall be fully examined and
repaired or replaced as necessary to meet the requirement of this
specification.
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6) The defective item(s) revealed during progressive examination, shall be

repaired or replaced and reexamined at above each step as specified in
Par. 6.1.2.
7.2.3 The requirement for radiographic examination shall be as follows:
1) For P-No.3, 4 and 5, radiographic examination shall be carried out after

completion of any heat treatment. For P-No. other than the above, the
examination for the weld joints for which PWHT is required shall be carried
out before PWHT unless otherwise specified.
2) Prior to the radiographic examination, the scattering radioactivity around
the area shall be measured and the controlled area of the radioactivity shall
establish, providing sufficient countermeasures to prevent hazard of
radioactivity.
3) Radiographic examination by using Co 60 or Ir 192 will be instructed in
accordance with government regulations.
4) Number of films to be taken for one peripheral joint at radiographic
examination shall be as follows:
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7.2.4 Requirement for liquid penetrant examination shall be as follows:

1) Liquid penetrant examination shall be carried out at cover pass for
branch weld, socket weld and attachment weld.
2) Procedure for random examination shall be in accordance with
Par. 7.2.1 and 7.2.2 of this specification.
8. PRESSURE TEST (HYDRO / PNEUMATIC TESTING)

8.1 General
1. System requiring hydrostatic pressure test as specified in the line list shall be flushed and
tested for continuity by filling with clean, fresh, non-corrosive water free of un dissolved
solids.
2. All test equipment and temporary materials shall be compatible with the pressure rating
and material of the system under test. The welding of temporary fitting for test purposes
shall be carried out to the same standards as for the piping under test.
3. No testing shall be performed during of rain unless the entire piping system under test is
protected from the weather.
4.Isolation of piping and equipment during testing shall be accomplishing by the use of
designated block valve, permanent blind flanges, or spectacle blind where block valves
are used, the specifications for the valve shall be reviewed to ensure that the valve will
not be damaged by over-pressure. All blind flanges and spectacle blind used for pressure
testing shall be fully pressure rated and meet agreed standards.
5. Prior to initial operation, installed piping shall be pressure tested to assure tightness of all
joints (welded, threaded or flanged) under witness of OWNER Inspector.
6. Before filling the test fluid, the entire line to be pressure tested shall be examined in the
manner described in Para. 6.2 and all faults shall be repaired. On all repairs or additions
made after the pressure test, the effected piping shall be retested.
7. Until after completion of field pressure testing, field piping joints (including flanged,
threaded or welded) shall be left unpainted and/or uninsulated, except for underground
piping.
8. Piping which connects to the lines installed by others shall be isolated from those lines by
valves or test blanks during pressure testing and flushing.
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8.2 Pressure Piping Examination

Examination requirements prior to test punch listing:
 Pipe material specification correct
 Flange, ratings, schedule and material specification correct
 Fittings, tees, return bends, reducers, coupling, weldolets etc. are correct schedule and
material specifications
 Valves identification – manufacture’s name etc. correct
 Valves installed correctly, flow direction, accesses, rising stems free from obstructions.
Clearance for removal adequate
 Lubrication fittings, drains, etc., installed as required
 Bolts and stud’s length and material correct, studs at least flush with heads, min thread
exposure beyond nut should be 2 threads
 Gaskets are correct type, material size, etc.
 All welding accepted
 All attachment welds satisfactory
 All NDE and PWHT complete, records filed
 Required guide anchors and shoes installed correctly
 Line supports to be checked against drawings
 Spring hangers – correct type
 All deficiencies recorded on punch list
 All sensitive instruments removed for pressure test
 Temporary spools substituted for valves where allowable body pressure is exceeded by test
pressure
All piping with a test pressure specified on the line classification lists shall be pressure tested after
erection at site at the specified test pressures. The detail of pressure test refers to the following
Engineering documents:
a. B-GNC-M-MS-6011 Line List
b. B-GNC-M-MS-6050 Marked-up P&ID for Pressure Leak Test
Hydrostatic test : Piping shall be tested with water at 1.5 times the design pressure,
(in
conjunction with ASME B31.3 Chapter VI, Section 345.4) and ASME
B31.1
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Pneumatic (Air) Test : Piping shall be tested with air pressure at 120% of the
design pressure
Service Test : Piping shall be tested at operating pressure using the appropriate
medium for normal operation.
Visual Test : Visually checked by Inspector, this is Not pressurizing for System
Except as specifically detailed in the project drawings, all piping within the scope of this Procedure
shall be hydrostatically tested.
8.2.1 Hydrostatic Testing Procedure

JEL shall request Contractor to carry out a joint walk–down inspection when it has been
confirmed by the JEL QA/QC Coordinator that all NDE has been verified complete and the Test
Pack piping is physically 100 % complete and ready (including test blinding) for Pressure Test.
JEL Construction Supervisor accompanied by the Contractor Piping Supervisor / QC Inspector

shall fully inspect the piping system to the limits of testing, identifying any outstanding items
and indicating the completion category i.e. punch “A”, or punch “B”, where:
 Category “A” : Items, which require to be completed or corrected
before any kind of test takes place on that item
 Category “B” : Items that can be completed or corrected after the
release of the item inspected but before Mechanical Completion
Note: All Category “A” Items and the Piping Pre -Test Checklist shall be completed and
signed by JEL & Contractor before testing can proceed.
8.2.1.1 Pressure Piping Examination

Examination requirements prior to test punch listing:
• Pipe material specification correct
• Flange, ratings, schedule and material specification correct
• Fittings, tees, return bends, reducers, coupling, weldolets etc are correct
schedule and material specifications
• Valves identification – manufacture’s name etc. correct
• Valves installed correctly, flow direction, accesses, rising stems free from
obstructions. Clearance for removal adequate
• Lubrication fittings, drains, etc, installed as required
• Bolts and stud length and material correct, studs at least flush with heads,
min thread exposure beyond nut should be 2 threads
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• Gaskets are correct type, material size, etc.

• All welding accepted
• All attachment welds satisfactory
• All NDE and PWHT complete, records filed
• Required guide anchors and shoes installed correctly
• Line supports to be checked against drawings
• Spring hangers – correct type
• All deficiencies recorded on punch list
• All sensitive instruments removed for pressure test
• Temporary spools substituted for valves where allowable body pressure is
exceeded by test pressure
8.2.1.2 Test Record

According with ASME B31.1, The hydrostatic test pressure at any point in the
piping system shall not be less than 1.5 times the design pressure, but shall not
exceed the maximum allowable test pressure of any non-isolated component,
nor shall it exceed the limits of calculated stresses due to occasional loads.
Hydrostatic testing of the pipeline including riser should follow the below
procedures:
a. The pressure should be raised to the test pressure and allowed to stabilize
then held for 10-15 minutes. The rate of pressure increase should not
exceed 100 kPa (15 psi) per minute during all operations.
b. The pressure should be lowered to approximately 25 percent of test
pressure, allowed to stabilize then held for 15 minutes. Rate of pressure
decrease should not exceed 200 kPa (30 psi) per minute during all
operations.
c. The pressure should be raised to an amount approaching the test pressure
and again allowed to stabilize before it is finally raised to the test pressure.
The pressure should not decrease more than 0.2 percent after compensating
for temperature. None of this or the foregoing should be included in the test
duration. The allowable, unaccounted pressure loss of 0.2 percent is based
on a maximum allowable air content of 0.2 percent.
d. Water should be injected or withdrawn from the test section to maintain
pressure within the specified limits. The volume of these injections and/or
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withdrawals should be measured and recorded.

e. Each test of a line or system shall be approved by the Owner Inspector.
f. Records shall be made for each piping installation.
g. Test result of the pressure test shall be prepared as an attached form of the
pressure test record.
8.2.1.3 Test Fluid

1) Hydrostatic test water shall be clean, fresh, non-corrosive water as raw water
source from tapping point or existing owner.
2) The test medium of hydrostatic testing of piping system shall be portable
water at ambient temperature with pH value between 6 and 7
All pressure testing shall be witnessed and approved by Contractor representative at pre
designated testing time. Piping shall be thoroughly flushed before the introduction of the
test water. Precautions shall be taken, by opening vents or by other means to prevent
buildup of excessive pressure in items under test. Particular care shall be applied to plastic
and GRP.
Test pressure readings shall be taken at a low point and high point in the system. Minimum
2 Test Pressure Gauge are installed in test System. The static head shall be subtracted
from the maximum hydro test pressure to give the required reading.
Hydrostatic test pressure shall be maintained on a piping system for a minimum of 10

minutes and a maximum of 2 hours, depending on the line class requirements.
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Immediately after pressure testing, all piping shall be thoroughly drained of water.
Particular care shall be given to the draining of austenitic stainless-steel piping to ensure
that no pockets of water are allowed to remain. Where for any reason it would not be
possible to completely drain piping.
Piping that is repaired or modified after a pressure test shall be re-tested unless in the case
of minor repairs or additions and agreement is obtained from Contractor to waive this
requirement. However:
• Retesting of the system is not required if a repaired flanged spool is individually
hydro tested or radiographed. Closing flanges shall be inspected for leaks
during commissioning.
• Where repaired sections require closing welds, these shall either be retested or
subjected to 100% radiography.
Where an equipment item has been blanked off at a flanged joint to allow pressure testing
of connecting piping, it shall not be necessary to pressure test the joint after the blank is
removed. Such joints shall be visually examined to ensure that gaskets are properly
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installed, bolts tightened etc. Flanged joints that are broken for pressure test purposes shall
have a new gasket installed after pressure testing is completed prior to commissioning.
8.2.1.4 Hydrostatic Test HDPE, PVC, ABS Pipe

Hydrostatic pressure leak test of PE pressure piping systems should be conducted in
accordance with ASTM F 2164 and PPI. The preferred hydrostatic testing liquid is clean
water.
8.2.1.4.1 Test phase, the test procedure consists of initial expansion, and test
phases. For initial expansion phase, the test section is pressurized to test
pressure and monitor within 4 hours and reduce test pressure by 10 psi (0.7
bar) if no drop and monitoring pressure for 1 hour. Do not increase or add
make-up water.
But if during test pressure indicate pressure drop but no leakage the
pressure can reduce base on piping design compare to the pipe
temperature.
8.2.1.4.2 Pass/Fail Phase, if no visible leakage is observed and pressure during the
test phase remains steady (within 5% of the test phase pressure (for the 1-
hour test period, a passing test is indicated.
8.2.1.4.3 Retesting, if retesting is necessary. Depressurize the test section by
reducing pressure or releasing test liquid at a controlled rate. Sudden
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depressurization can cause water hammer. And correct faults of fix leaks
while the test section is under pressure.
8.2.1.4.4 When maximum test pressure is between design pressure and 1.5 x system
design pressure. Allow the test section “relax” for at least eight (8) hours
before re-pressurization.
8.2.1.5 Hydrostatic Test FRP & GRP Pipe

Hydrostatic pressure test basis for FRP & GRP by evaluating strength regression
data derived from testing pipes or fittings and it should be conducted in accordance
with Contract Specification.
8.2.1.5.1 A hydrostatic test of the installed piping system provides a means to check
the integrity of the assembled piping and its interaction with all components
of the system. Often a 10-cycle pressurization test is most desirable to
confirm good soundness. Then the measurements are taken in the last
pressurization. Prior cycles in a cyclic test many uses holds at pressure for
10 minutes or more depend of Visual inspection during test.
8.2.1.5.2 If leaks are discovered, the test section shall be depressurized. The testing
medium shall be completely removed. The discontinuity that cause leak
shall be prepared for re-lamination, the whole section will be test again.
Repair shall be judge successful if no indication of leak is found.
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8.2.2 Pneumatic Testing Procedure

Pneumatic (air) testing is hazardous due to the possible release of stored energy.
Therefore, the test area shall be clearly barricaded to ensure no unauthorized entry. For
WWTP, Pneumatic Test will be applied for Instrument Air Line as service test.
The test arrangement shall be such that the temperature of gas entering the piping
system is not lower than the following bearing in minds that if a gas is let down from
high pressure its temperature will fall:
• Plastic (ABS and PP) : minimum temperature 15 ˚C
• Metallic and PTFE lined carbon steel: minimum temperature 5 ˚C
Prior to testing, it shall be demonstrated that as far as possible, no person would be
exposed to injury should any part of the piping system fail during the test procedure.
Only authorized test personnel should be allowed within the designated test area.
Where the source of pressure is higher than the test pressure, precautions against over-
pressurization shall be taken through the use of reducing valves, pressure gauges and
safety valves of adequate size. A pressure relief device shall be provided, having a set
pressure not higher than the test pressure plus the lesser of 345 kPa (50 psi) or 10% of
the test pressure.
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All pneumatic tests shall include a preliminary check at a pressure not exceeding 1.4
barg (20 psig). This pressure shall be held until all joints have been inspected for leaks
by brushing each joint with soap solutions.
8.2.2.4 Protection N2 Release

All nozzle manhole shall be opened as soon as they are accessible by
permanent platforms etc. Flange facings shall be verified for damage, cleaned
and protected by rust preventive. If no direct activity is required, the nozzles and
manholes shall be closed.
- Barricade the area with PTW signed.
- Open the valve of N2 sealed slowly till very small hissing sound is heard, and
let it drain slowly.
- Standby manpower who is responsible to do the work
- Sign board (N2 release) is required for notification
- Till all N2 is drained from vessel and no hissing sound is heard that work is
completely done.
Coil and tube ends shall be sealed and bevels protected for field welding. Equipment
under N2 pressure shall be first released from N2 prior to open manholes/nozzles.
Oxygen shall be measured before do activity.
8.3 Extent of Testing

1) Lines and systems which are open to the atmosphere, such as drains, vents, open safety
valve discharges, and atmospheric sewers, do not require pressure testing.
2) The following equipment shall not be subjected to the piping pressure test:
a. Pumps, turbines and compressors, associated lube and seal oil systems which
could be impaired by the pressure of water.
b. Control valves, level controls and switches, pressure relieving devices such
as pressure relief valves, rupture disc.
c. Safety valves, flame arresters, rupture discs and filter elements.
d. Pressure gages, thermometers, flow meters and other instruments.
e. Expansion joints, steam traps.
f. Pressure vessel or any mechanical equipment
g. Restriction orifices or orifice plates
h. Strainers and filter elements.
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i. Self-regulated controllers
j. Diffuser, Transmitter
l. Positive displacement meters
3) In case piping is connected to equipment nozzle by welding and where equipment is not
hydro tested, the piping shall be pressure tested before connection, and after welding of
the
piping and equipment nozzle, the final welded joint shall be 100% radiographic instead
of pressure test.
4) Instrument take-off piping shall be tested up to the first block valve with the piping or
equipment to which it is connected.
9 SAFETY PRECAUTIOS
1) Prior to work activity, ensure that all permits are signed & validated by authorized person.
2) Use only inspected and proper tools & equipment for every work
3) Barricade crane lifting radius and area under welding point
4) Gas checking continuously around welding point area
5) Wear full body harness when working at height
6) Implemented lifting plan signed by Contractor authorized person.
7) If any unsafe condition, stop the work & directly contact superior & safety person
8) During Emergency, personnel have to proceed to the nearest Muster Point
10 HOUSE KEEPING
Each group have responsibility to maintain working area clean from waste and scrap after working
time before leaving working area, if not possible to bring down pipe place after work, do not leave
pipe place on the scaffold platform without tied up and /or secured.
11 DOCUMENT REFERENCES
a. Organization Chart
b. Risk Assessment
c. Inspection and Test Plan
d. Form Inspection
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e. Photo of Equipment, Tools, and Materials

f. Layout Drawing
12. MANPOWER REQUIRED

12.1 Manpower
a. Safety Staff
b. QA /QC Staff
c. Supervisor
d. General workers
12.1.1 Roles and Responsibilities

Safety Coordinator
• He / She shall review Risk Assessment and understand the risk involved.
• He / She shall check the surrounding environment to ensure that the operation
can be executed safely.
• He / She shall conduct a daily safety briefing at the site prior work at site.
• He / She shall ensure proper Personal Protection Equipment is used at all time.
• He / She shall be authorized to give instructions to all employees regarding
safety at work.
QA/QC Staff
•He / She shall inspect and ensure all material are in good condition prior to pipe
fabrications.
•He / She shall upkeep all material record prior and during the installation for the
final project documentation.
•He/she shall responsible for performing ITP Construction of Pipe Fabrications
Supervisor
•He / She shall ensure the installation work is carried as per system design.
•He / She shall be present at the site to supervise the installation work is carried
Out as per this Method of Statement and installation drawing.
•He / She shall coordinate with Site Manager for schedule and resource planning.
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•He / She shall coordinate with Site Manager for site planning.
•He/she shall check mark up drawing for as built drawing purpose from
Engineering.
13. SAFETY PLAN

General Requirements
 PT.JEL's Nominated Personal in Charge (NPC) Nominated: PT.JEL Supervisor or their
assigned personnel will have primary control over all personnel within his group in Pipe
Fabrications.
 The work will be executed in accordance to the requirements under the local
legal requirements, the HSE Plan, Construction HSE Instruction for the Sub-
Contractors and Personal Protective Equipment Procedure.
 All workmen from PT.JEL that are involved in this operation, including supervisors and
operators, etc. would be provided with the required personal safety protection items such as
safety helmets, safety harness, safety boots and safety goggles. As per the site lay down
environment all the crew would be provided by dust masks and ear protectors.
 In morning tool box meeting, prior to the commencement of the operation (Pipe Fabrications
Work Procedure), all the personnel involved in this operation or work shall be briefed about
the erection by the erection supervisor or his assigned person, and its hazards by PT.JEL's
safety personnel before commencement of the work.
 Works carried out shall be in compliance with the HSE Plan, Construction HSE
instruction for the Sub-Contractors and Personal Protective Equipment Procedure
 Prior to the operation, PT.JEL's assigned Safety Personnel shall ensure that all the
relevant safety permits. (e.g.: Lifting permits, Height work permit, Piping work permit,
etc.) are approved.
 The lifting slings, chain blocks and shackles used shall have valid statutory certificates.
 Lifting Supervisor and Signalman from PT.JEL will coordinate with Lifting Supervisor to
ensure safety and smooth operation.
 No unauthorized personnel shall stand under any suspended load.
 The chemical substances, paint materials are kept in separate area under hazards material
sign board, no smoking sign board.
 The hazards materials are kept in proper ventilated places.
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14. ATTACHMENT
REVISION HISTORY
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Revisio
Date Section Page Revision Summary
n
0 23 Nov 2020 Issued for Approval
1 11 Dec 2020 Follow as MES Comment (8-Dec-2020)

PREPARED BY: CHECKED BY: APPROVED BY:
NAME:
POS:
SIGN:
Date:
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Mitsui E&S Engineering Co., LTD.: 1 11 DEC 2020 TP EFD REV Date Prepared by Checked by Approved by Description

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Mitsui E&S Engineering Co., LTD.: 1 11 DEC 2020 TP EFD REV Date Prepared by Checked by Approved by Description

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FABRICATION AND ERECTION CS/SS PIPE

SECONDARY WWTP – CJP PROJECT

1 11 DEC 2020 TP EFD