Marjan Increment Program

Tanajib Gas Plant (TGP) Industrial Support Facilities

MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

   

 
   
 

METHOD STATEMENT
FOR
WELDING WORKS
(PRECAST ELEMENTS)  

Page 1 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

Revision History & Signatories:

2nd submission
01 16-Nov-20 for review &
approval

1st submission
00 31-Oct-20 for review &
approval

Engr. Mohd Al Zioud Engr. Randy Villaruel Engr. Bilal Obeidat

Rev. Revision
Revision Date
No. Description Prepared by: Reviewed by: Approved by:
Construction Manager Project QA Manager Project Manager

Revision History Marks: (If any)

 

Page 2 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

Table of Contents
1.  OBJECTIVE .............................................................................................................................................................. 4 
2.  PURPOSE AND SCOPE OF WORK .............................................................................................................................. 4 
3.  REFERENCES AND STANDARDS ................................................................................................................................ 4 
4.  RESPONSIBILITIES ................................................................................................................................................... 4 
4.1.  PROJECT MANAGER .......................................................................................................................................................... 4 
4.2.  PROJECT QA MANAGER ..................................................................................................................................................... 5 
4.3.  SITE QC MANAGER ........................................................................................................................................................... 5 
4.4.  CONSTRUCTION MANAGER ................................................................................................................................................. 5 
4.5.  SITE ENGINEER: ................................................................................................................................................................ 6 
4.6.  WELDERS: ....................................................................................................................................................................... 6 
4.7.  QC INSPECTOR: ................................................................................................................................................................ 6 
4.8.  SAFETY INSPECTOR: ........................................................................................................................................................... 6 

5.  MATERIALS ............................................................................................................................................................. 7 
5.1.  RTA‐ISF‐M‐GA‐778 – APPROVAL OF WELDING ROD FOR PRECAST CONCRETE STRUCTURES ......................................................... 7 
5.2.  RTA‐ISF‐M‐GA‐624 – APPROVAL OF WELDED STEEL PLATES  ................................................................................................. 7 

6.  PROCEDURE AND METHODOLOGY .......................................................................................................................... 7 
6.1.  WELDING CONSUMABLES CONTROL PROCEDURE ....................................................................................................... 7 
6.2.  PREPARATION OF MATERIALS ...................................................................................................................................... 7 
6.3.  TACK WELD................................................................................................................................................................... 7 
6.4.  CLEANING ..................................................................................................................................................................... 8 

7.  REPAIR OF DEFECTS ................................................................................................................................................ 8 
8.  TESTING .................................................................................................................................................................. 8 
9.  QUALITY INSPECTION .............................................................................................................................................. 8 
10.  PRECAUTIONS AND SAFETY INSTRUCTIONS ............................................................................................................. 9 
11.  PROTECTION OF FINISHED WORK .......................................................................................................................... 10 
12.  TOOLS AND EQUIPMENT ....................................................................................................................................... 10 
12.1.  TOOLS & EQUIPMENT SHALL COMPRISE, BUT NOT LIMITED TO: ................................................................................................. 10 

13.  ATTACHMENTS ..................................................................................................................................................... 11 
13.1.  JOB SAFETY ANALYSIS (JSA) .............................................................................................................................................. 12 
13.2.  SATIP‐M‐001‐01 ......................................................................................................................................................... 17 
13.3.  RTA‐ISF‐M‐GA‐778  .................................................................................................................................................... 19 
13.4.  RTA‐ISF‐M‐GA‐324  .................................................................................................................................................... 25 

Page 3 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 
 

1. OBJECTIVE

1.1. The objective of this Method Statement is to describe about materials,, application
procedure, safety measures and tools & equipment etc. for ARA welding works of pre-cast
panel with the requirements of the specifications, standards and construction procedures.

2. PURPOSE AND SCOPE OF WORK

2.1. This procedure is applicable for welding activities during precast concrete elements
installation works.

3. REFERENCES AND STANDARDS

3.1. SAES-W-011 Welding Requirements for On- Plot Piping

3.2. Project Specification
3.3. Project drawings issued for construction
3.4. Contractor Site Safety Plan
3.5. AWS D1.1 Structural Welding Code
3.6. SATIP-M-001-01 – Structural Steel, Steel Support and Miscellaneous Steel Support

4. RESPONSIBILITIES

4.1. Project Manager

4.1.1. The Project Manager is responsible for overall planning, control and Execution of the
project in a cost-effective manner and shall ensure compliance with the Contract
technical specification, program, financial and commercial policies and practices,
quality requirements including the development, coordination and authorization of the
site specific management plans.
4.1.2. This position has an authority in determination of all quality related matters affecting
the project. The Project Manager also has direct coordination to the Project QA
Manager to resolve quality issues should this be necessary. The Project Manager shall
respond in writing as necessary in case of any received Quality concerns by the Project
QA Manager or the Corporate PMO Manager / Management Representative in relation
to the Project Quality Requirements.

Page 4 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

4.2. Project QA Manager

4.2.1. The QA Manager shall act as the Management Representative for all Quality
Management areas. He will focus on objective and methods of implementation of
quality management system. Check the effective implementation and evaluate
systematically its fitness for the company needs. He shall assure that all Quality
Documents are available and communicated to all relevant personnel. This position
ensures that all activities are in accordance with the Approved Quality Documents,
such as this PQP and other related procedures applicable to the project, to meet the
Company requirements. The Project QA Manager shall manage to meet the Company
expectations and requirements through management system audits, management
reviews, customer feedback, performance monitoring and continual improvement to
achieve customer satisfaction.
4.2.2. Project QA Manager shall Report to RTCC Corporate PMO Manager. He will internally
communicate with RTCC PMO Manager / Project Manager / Construction Manager /
Quality Dept. Project Coordinator and Site Quality Team. He will also communicate
externally with SAPMT, SAVID, SAPID Subcontractor, Supplier Representatives and all
external interested parties related to the project. Records might be retained by any
involved personnel in the project, which might be subject assessment and evaluation
in all project areas and processes.

4.3. Site QC Manager

4.3.1. Site QC Manager is responsible to implement and control the requirements of the
Project Quality System. This position ensures that all approved and related quality
documents are implemented at site.
4.3.2. The Site QC Manager shall ensure that all appropriate testing and inspections are
conducted, to assure the conformance of the product as per the contract, He shall
report to the Project QA Manager.

4.4. Construction Manager

4.4.1. The Construction Manager is responsible to the Project Manager for overall planning,
control and execution of the project in a cost-effective manner and shall ensure
compliance with legislation, contract technical specification, programs, quality, safety
and environmental requirements to meet the Company’s expectations and
satisfactions.
4.4.2. This position has an authority in determination of all quality, safety & environmental
related matters affecting the Site. In addition, this position collaborates with the
Project QA Manager and Site QC Manager to maintain quality of work and resolve
quality issues should it is necessary.

Page 5 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

4.5. Site Engineer:

4.5.1. Site Engineer shall monitor all the construction activities including welding procedure
for Pre cast panel work in accordance with project specifications, rectification drawings
by following the safe conditions under the contractor’s site safety plan.

4.6. Welders:

4.6.1. Qualified welders shall be mobilized to the site with complete right tools being used
and have complete drawing and procedure. Permits must be securing before start any
of any work.

4.7. QC Inspector:

4.7.1. QC Inspector shall make sure the following items and carry out all field inspections:
4.7.1.1. He will ensure the material shall conform to project specification.
4.7.1.2. Work should be carried out as per the approved drawing.
4.7.1.3. He will make sure that all the panels and others related works are adequately
executed.
4.7.1.4. He will coordinate with the Client representative for the required inspections as
per approved ITP.
4.7.1.5. He will monitor the quality of works and in conformance with the rectification
drawing as per approved checklist.
4.7.1.6. He will keep records of all inspections and testing related to the activity.

4.8. Safety Inspector:

4.8.1. He will make sure that all construction activities would be carried out under approved
CSSP.
4.8.2. He will make sure that all workers have proper PPEs.
4.8.3. He will make sure that proper certifications and inspections of equipment are updated
prior to start the work.
4.8.4. He will inspect and confirm all steps for physical installation and completion of pre-cast
panels defined under CSSP.
4.8.5. He will make sure the provision of safety arrangements for work area and will carry
out the required inspections.
4.8.6. He will make sure the provision of flagman/banksman to assist the operator and warn
people for movement of equipment.

Page 6 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

4.8.7. He makes sure the presence of work permit and list of involved personal at site.
4.8.8. He shall ensure placement of all signals, signs and barricades until work completion.
4.8.9. He will produce the Job Risk Assessment prior to work commencement and will
identify the hazards (if any) before start of all construction activities.

5. MATERIALS

5.1. RTA-ISF-M-GA-778 – Approval of Welding Rod for Precast Concrete structures

5.2. RTA-ISF-M-GA-624 _ Approval of Steel Plates

6. PROCEDURE AND METHODOLOGY

6.1. WELDING CONSUMABLES CONTROL PROCEDURE

6.1.1. Portable Electrode Oven shall be issued to each welder for keeping electrodes at
moisture-free condition while at work.
6.1.2. Any combustible material should be removed from the vicinity of welding operations;
where removal is not possible the material should be protected.
6.1.3. Particular care must be exercised in damp weather to avoid contact with the welding
electrode or holder.
6.1.4. Electrode stubs should be rejected into a metal container or other non-combustible
receptacle.
6.1.5. In case of non-availability of Portable Electrode Oven, vacuum packed electrodes shall
be used.

6.2. PREPARATION OF MATERIALS

6.2.1. Surfaces and edges to be welded shall be smooth, uniform, and clean.
6.2.2. Surfaces of the parent-metal shall be free from scale, slag, rust, moisture, oil, grease
or other harmful materials that will prevent achievement of good welds. Before
welding every material shall be checked and inspected in detail for any defects.
Remove cut edges of plates, grind back 1.5 mm.

6.3. TACK WELD

6.3.1. Prior to performing main welds, tack welds shall be done by shielded metal arc
welding, under the same conditions as for actual welds.

Page 7 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

6.3.2. All parts shall be adequately supported to provide the best possible alignment and
minimize stresses on tack welds and root passes.
6.3.3. Every defective tack weld shall be cut out before completion of finished welds.
6.3.4. Care shall be taken while removing tack welds. Temporary fittings will be used for
assembly ensuring the base metal is not damaged.

6.4. CLEANING

6.4.1. All slag and flux shall be ground or brush cleaned from each bead before depositing
the next successive layer. The edges of the parts to be welded shall be free of rust,
paint, sand, tar, oil and grease.
6.4.2. If they are wet, they must be dried before proceeding with the weld.

7. REPAIR OF DEFECTS

7.1. Blow holes, irregularities of deposit, undercut sharp corners of other unacceptable defects
shall be removed by grinding or chipping before depositing the next successive layer of
welding.
7.2. Before proceeding Repair of cracks QC Inspector to notify Saudi Aramco assigned Inspector
for approval. Cracks that are related to base metal or welding consumable shall evaluate by
CSD any repair attempts as per SAES-W-011.
7.3. Cracks shall be removed by grinding, chipping and to be re weld.
7.4. Defects such as porosity, slag, lack of penetration, irregularities of deposit shall be removed
by chipping, grinding and to be re weld.

8. TESTING

8.1. All completed welds shall have 100% visual inspection performed per AWS D1.1 Table 6.1
8.2. Non-Destructive Test (by Approved 3rd Party NDT Technician)
8.3. Dye Penetration Test Testing shall be carried out after grinding the root and if there is doubt
about certain location.

9. QUALITY INSPECTION

9.1. Welding works will be carried out as per Approved Welding Procedure Specification (WPS)
9.2. Approved Inspection Test Plan (ITP) SATIP-M-001-01 – Structural Steel shall be utilized.
9.3. After completing of Welding for pre-cast panel will be checked with respect to shop drawing
and the approved sample.

Page 8 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

9.4. Approved drawings shall be used for all steps of the work.
9.5. Approved Inspection Checklist SAIC-M-2012 shall be utilized.

10. PRECAUTIONS AND SAFETY INSTRUCTIONS

10.1. No welding activity will take place under boom radius during crane operation.
10.2. Hot work permit shall be obtained prior to start any welding job.
10.3. Welders must wear protective clothing and eye protection when welding or chipping slag
from welds.
10.4. A fire extinguisher should be kept in close proximity to welding operations.
10.5. Any combustible material should be removed from the vicinity of welding operations;
10.6. Where removal is not possible the material should be protected.
10.7. The area around the welding operation should be cordoned off to protect other people
from welding sparks or spatter.
10.8. Welders should not interfere or tamper with welding equipment.
10.9. The mains supply to the welding machine should be transformed down to a safe working
voltage (usually between 80 and 110 volts).
10.10. The actual welding circuit should be isolated from the mains.
10.11. Trailing leads should be as short as possible, armoured and visible to avoid trip hazards or
damage.
10.12. All equipment should be properly earthed.
10.13. All connections should be made with proper fittings or equipment.
10.14. Connections to the work to be welded should be made with clamps or lugs.
10.15. When not in use, all welding equipment should be disconnected from the main supply or
isolated and protected if left unattended for any length of time.
10.16. The welding equipment must be well maintained and in good condition.
10.17. When welding the welder must always use standard protection equipment for welder. If
welding is done on galvanized steel or steel with toxic paint then a mask that protects
against toxic fumes must be used.
10.18. Welding on close containers, tanks and pipes are not allowed.
10.19. The gas cylinders used by the flame cutting must be supplied with intact pressure Gauges.

Page 9 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

10.20. The fire hazard must be observed by welding and flame cutting. If the welding or cutting
take place near flammable materials then the welder must have a helper looking for fire
while the welding or cutting is on-going.
10.21. Welders must have Aramco Certification.
10.22. Welding equipment must have Aramco approved 3rd party.
10.23. All combustible & flammable materials shall be removed or protected with fire blanket.

11. PROTECTION OF FINISHED WORK

11.1. All finished work shall be protected under contract requirements.

11.2. Surface preparation and Coating procedure will be submit separately for SAPID review and
Approval

12. TOOLS AND EQUIPMENT

12.1. Tools & equipment shall comprise, but not limited to:

12.1.1. Calibrated Welding Machine

- Description: Welding machine
- Manufacturer: Kemppi
- Model: Minarc 150
- Capacity: 150 Amperes
12.1.2. Calibrated Portable Electrode Oven
- Description: Electrode Oven
- Manufacturer: Metweld
- Model Number: EQ-20SID
- Range / Capacity: 30 to 150 deg Celsius
12.1.3. Welding Cables
12.1.4. Welding Hammer
12.1.5. Grinder
12.1.6. Welding Jacket
12.1.7. Welding Mask (Helmet Type)
12.1.8. Welding Gloves

Page 10 of 51
 Marjan Increment Program
Tanajib Gas Plant (TGP) Industrial Support Facilities
MS FOR WELDING WORKS (PRECAST ELEMENTS) 
BI/J.O. No.: BI‐10‐09003‐0006 / MTGP13  Period: 16 November 2020 
Document No.  :  RTA‐ISF‐M‐GA‐1004  Revision No. : 1 

12.1.9. Fire Extinguisher

12.1.10. Fire Blanket

13. ATTACHMENTS

13.1. Job Safety Analysis (JSA)

13.2. SATIP-M-001-01
13.3. RTA-ISF-M-GA-778
13.4. RTA-ISF-M-GA-624

Page 11 of 51
Page 12 of 51
Page 13 of 51
Page 14 of 51
Page 15 of 51
Page 16 of 51
Page 17 of 51
Page 18 of 51
Page 19 of 51
Page 20 of 51
Page 21 of 51
Page 22 of 51
Page 23 of 51
Page 24 of 51
Page 25 of 51
Page 26 of 51
Page 27 of 51
Page 28 of 51
Page 29 of 51
Page 30 of 51
Page 31 of 51
Page 32 of 51
Page 33 of 51
Page 34 of 51
Page 35 of 51
Page 36 of 51
Page 37 of 51
Page 38 of 51
Page 39 of 51
Page 40 of 51
Page 41 of 51
Page 42 of 51
Page 43 of 51
Page 44 of 51
Page 45 of 51
Page 46 of 51
Page 47 of 51
Page 48 of 51
Page 49 of 51
Page 50 of 51
Page 51 of 51