DESCON ENGINEERING LIMITED MS//MECH/16

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METHOD STATEMENT FOR Page 1 of 17
CROSS COUNTRY PIPELINE INTALLATION

METHOD STATEMENT
FOR
CROSS COUNTRY PIPELINE INTALLATION

0 Initial Issue April 23, 2002 A.Hameed Q.Mannan DSZ

Rev. Comments Date Prepared by Checked by Approved by Client

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INDEX

1. PURPOSE

2. SCOPE

3. REFERENCES

4. DEFINITIONS

5. RESPONSIBILITIES

6. PROCEDURE

7. TOOLS AND EQUIPMENTS

8. SAFETY INSTRUCTIONS

9. ATTACHMENTS

1. PURPOSE
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The purpose of this generic method statement is to define the procedure for installation of
cross country pipeline.

2. SCOPE

Scope of this method statement covers the following activities.

 Material handling

 Survey

 Route and Demarcation

 Right of way

 Trenching

 Stringing

 Welding

 Inspection

 Holiday test

 Trench Inspection and Sand padding

 Lowering in

 Field Bending

 Crossings

 Cleaning

 Hydro testing

 De watering and drying

 Nitrogen purging and inerting

 Restoration of right of way

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3. REFERENCES

3.1 PROJECT DRAWINGS

 Applicable Project Piping Isometrics.

 Project Piping Layout drawings.

 Others.

3.2 PROJECT SPECIFICATION

 Site Material Management

 Painting & Protective Coating for Field Joints

 Coating & Wrapping for Field Joints

 Approved WPS.

 Other related Specifications.

3.3 PROJECT QUALITY PLAN (PQP)

 Project Quality plan.

3.4 CODES AND STANDARDS

 Project Drawings

 Project Specifications

4. DEFINITIONS
CL Client
PM Project Manager
SM Site Manager
CM Construction Manager
DE Discipline Engineer
ROW Right Of Way
ITP Inspection and Test Plan
QC Quality Control
QCI Quality Control Inspector
PQP Project Quality Plan
PPE Personal Protection Equipment
HSE PLAN Health Safety & Environment Plan.
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5. RESPONSIBILITIES
 It is overall responsibility of PM/SM to organize resources to perform construction
activities as per project specification, in compliance with quality, schedule & safety
requirements.

 It is the responsibility of CM that construction activities are executed according to

the relevant project specifications, in compliance with quality, schedule & safety
requirements.

 DE will ensure that all the works are performed safely as per latest Approved For
Construction (AFC) drawings & specifications.

 The relevant DE and Supervisor will ensure that all the piping work is conducted
in accordance with this method statement and project specification.

 The QC Inspector will ensure that all work is executed according to PQP and that
requirements of quality dossier are full filled.

 Safety and Construction supervision will be carried out under responsibility of

Client.

6. PROCEDURES / METHODOLOGY.

6.1 RECEIPT, HANDLING & STORAGE

 The piping material/piping components received from client shall be offloaded in

the lay down yard.

 A suitable crane and Nylon slings shall be used for off loading of piping.

 The Nylon slings will be used for handling of the pipes to avoid / minimizes the
external coating damaged.

 During loading or unloading pipes shall not be dropped onto or off the transporting
vehicle.

 The material received shall be checked for quantity and quality items.

 The pipes shall be placed above ground by using sandbag packing.

 The pipe ends shall be covered to prevent foreign matter entry.

 The piping materials shall be segregated as per size to facilitate the location and
ease of handling.
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6.2 PIPELINE ROUTE AND DEMARCATION:

 Using survey drawings, alignment sheets for the Pipeline route, a survey of the route shall
be carried out to establish pipeline corridor, working grades, levels and install survey
markers / monuments. The survey markers shall be established as per the project
drawings or at every 200m along the route on ground. The survey shall be used to know
the crossings, underground or close by services or any other possible hold ups, that must
be kept in mind during the job planning stage.

 It is understood that Client shall obtain necessary right of way from the concerned
Agencies / Authorities and there shall be no reason of dispute with the landowners, which
can become cause of any delay. However, Descon shall keep a liaison with these
Agencies / Authorities for smooth working on the project.

 Four to five survey teams shall be deployed for carrying out the survey. It is planned to
submit for Clients’ approval a ROW survey carried out in first 10 days enabling the ROW
crew to start work.

6.3 RIGHT OF WAY (ROW)

 It is understood that client has already obtained approval for Right of Way. The area shall
be handed over by client to carryout uninterrupted work to match project schedule.

 Make the width of ROW from the survey stones and start cutting and leveling of ROW as
per sectional drawings.

 Any trees or existing structures obstructing the right of way shall be removed after
approval from client.

 Sand dooms shall be scraped out to make level and inclination of pipeline laying.

 An exclusive team shall be made responsible for maintenance of ROW & to keep it
worthy of traffic.

 Generally natural ground shall be used as ROW after removal of boulders, grubbing and
grading.

 After satisfactory leveling and easy movement of machinery draw centerline for pipeline
trench.

6.4 TRENCHING:

 The center line of pipeline shall be marked as per relevant drawings.

 Particular care shall be taken to locate any buried installation, working.

 Hydraulic excavators, rock breakers and / or dozer with pull shall be deployed to excavate
the trench. Controlled blasting shall also be used wherever required.
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 Where the trench is know to cross other pipeline or under ground system / services, the
excavation at that point shall be done by manual. The trench at these points shall be
excavated so that the pipeline crosses under the encountered obstacle. Care shall be taken
so as not to damage the crossed pipeline or under ground system.

 The dimensions of trench shall be generally maintained as per approved drawings. It shall
be made wide to avoid any damage to pipe coating especially at the bends.

 The soil will be placed a minimum 0.4m from the edge of the ditch.

 The trench walls and bottom shall be made free of any sharp edges and elements that may
cause damage to pipe coating.

 Sufficient lead to piping shall be provided to avoid any obstruction to their flow of works.

 The excavated materials suitable for back filling shall be placed along side the trench at a
sufficient distance, 1m away to avoid any unnecessary load on trench walls and it does not
obstruct pipeline stringing and welding works.

 Before welding activity is started, 3KM lead for trenching shall be achieved. Trenching
work shall be executed using excavators. Major Equipment Deployment Schedule depicts
the equipment deployed on this activity.

6.5 ROCK BLASTING

 In the area of rock excavation controlled blasting shall be done. Necessary approvals
from client shall be obtained prior to the blasting work.

 Only well trained & experienced people shall be allowed to use explosive for blasting
works. The area to be blasted surveyed and pneumatic drills shall be used to make holes in
ground for loading explosives.

 The holes shall be made in such a fashion to have minimum unnecessary blasting of hard
soil.

 The explosive shall be charged just before the start of blasting works.

 The area to be blasted shall be covered with an appropriate blanket (chain or used tyres or
equivalent) to arrest flying pieces.

 Also please refer safety precautions for handling explosive given in Section 12.0

6.6 HAULING & STRINGING OF MATERIAL

 Stringing may proceed after the ROW clearing and grading is complete and will be in
accordance with the specifications.

 Place wooden skids / dirt berms approximate 02 meter away and along the side of the
trench.

 After achieving one-KM trench, stringing activity shall be started using the equipment as
shown in the Major Equipment Deployment Schedule.
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 The pipes shall be strung along side excavated trench and marked for identification.

 The trailer bed and their side supports shall have a suitable protective material to avoid
chances of scratches, scars or brusis to the pipe coating.

 The pipe will be off loaded in accordance with the stringing schedule. This is to ensure
that, pipes of the correct wall thickness are placed in correct sequence of use.

 Where necessary the lines of string pipes will be interrupted to allow passage of vehicles
and animals.

6.7 WPS & WQT

 The WPS shall be prepared in accordance with API Standard 1104 latest edition for field
welding of pipeline / as per the project specifications and shall be submitted for client’s
approval. The tests shall be conducted for the final acceptance of welding procedure,
welding consumables, welding current and other parameters. The incharge quality control
shall maintain a record of all WPS.

 Upon the acceptability of the WPS, welders’ qualification tests shall be performed. This
process shall be on going for some period on the project till a desired number of welders
are selected. Each welder shall be issued an identification tag having following
information:

A) Own Photograph
B) Welder’s name
C) Company name
D) Qualification symbol

 The identification tag shall be displayed during the welding process. The welder number
shall be progressive and shall not be repeated.

 A weld repair procedure shall also be established.

6.8 CLEANING & INSPECTION OF PIPES AND BEVELS

 The pipe ends shall be factories beveled to satisfy API 1104. The ends shall be checked
for their geometry, mechanically cleaned, reset on the sandbags / wooden skids and shall
be made ready for welding crew. Cleaning shall be performed on the inside and outside of
the pipe and at least up to ten cm from the edge. In case any end is damaged beyond the
permissible limits set in the Project Specification/Applicable Code it shall be brought to
the notice of the Job Inspector and a suitable remedial action shall be taken.

 The line shall be swabbed and cleaning means. Subsequently the pipe ends shall be
covered using polyethylene sheet and tape or any other economical means.

 The crew shall have its own dedicated crane and necessary tools to continue the job
independently to provide lead to the welding crew.

 Pipe diameter and thickness will be verified at each pipe end and any deviation shall be
brought to the notice of field inspector for corrective action if needed.
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6.9 MAIN LINE WELDING

 Following codes and standards shall be used for welding and welding related
requirements:

API 1104 latest edition.

ANSI B31.4 latest edition.
ASME code-Section IX

 The pipe shall be visually checked from inside for any foreign material. In case it carries
any foreign material it shall be swabbed again before engaging the two ends by external
line up clamp.

 Bevel ends shall be checked for their cleanliness

 The two sections shall be aligned together using nylon belts and line-up clamp. On
achieving the proper gap as given in WPS the root bead will be run by a pair of qualified
welders as per parameters established during the execution of the WPS.

 The lifting tackle shall be disengaged as soon as the root bead is complete and the pipes
are placed on supports. Care must be taken to protect the coating on the pipes.

 Another pair of welders shall carry out hot pass and hot fill pass while the third pair of
welders shall complete filling / capping. Thorough cleaning of the root pass shall be done
before start of the subsequent passes by using power brush and / or disc grinder. The hot
pass shall be applied quickly before the stinger bead gets cool. Minimum and maximum
interpass temperature shall be checked during welding. Particular attention to welding
current and travel speed shall be given to achieve a good weld.

 No arc strike shall be permitted outside the bevel area. Any accidental arc strike shall be
ground out and then subject to MPI or DPT test in accordance with ASME SE-138 / 165
respectively.

 Any weld not completed on the day due to any reason shall be well supported and
protected against dew and dust.

 Each weld shall have a unique number. Welder shall write their identification number with
crayon on each weld. A record shall be maintained to control the quality of the welders
and also to work on the modification / repair of any joint.

6.10 WELDING INSPECTION & RADIOGRAPHY

 The weld acceptance standard of API 1104 shall apply to the visual and non-destructive
inspections.

 The welding inspectors shall have visual check of the weld joints to ensure procedure and
specification compliance.
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 Welds shall be radiographed as per approved Project Quality Plan (PQP). A record of
each radiographed joint shall be maintained with reference to weld numbers, welders’
number and the radiography results.

 Safety and protective measures shall be taken during radiography operations as laid down
in the Project Safety Manual.

6.11 INSTALLATION OF HEAT SHRINK SLEEVE

 The weld shall be cleaned and the sleeve shall be installed as per the sleeve
manufacturer’s recommendations and project specifications. Holiday test shall be carried
out after the installation is complete.

6.12 HOLIDAY TEST & REPAIR COATING

 As soon as the welding operation is completed on a stretch, Holiday test shall be carried
out using calibrated test equipment of proper capacity and range as per ITP. The repair
work on the holidays shall be carried out as per approved procedure provided by the Coat
and Wrap / Pipe manufacturer.

6.13 TRENCH INSPECTION & SAND PADDING

 Before lower in the pipe the trench shall be inspected for its dimensions, centerline and
soil condition along its walls and at its bottom as per ITP. The bottom of the trench shall
not have elements, which can cause damage to the pipe and its coating. In case the soil
condition is such that such fragments cannot be avoided then sand padding shall be
provided to protect the pipe.

6.14 LOWER-IN & TIE-IN

 Lowering-in shall be accordance with the project specification.

 Standing water shall be pumped out from the trench wherever possible prior to
lowering the pipe into the ditch.

 A rigging study, to lower a line with 30 to 40 joints welded shall be prepared.

 Lowering operation shall be done using the side booms of proper capacity and nylon belts.

 During lowering operation Holiday test shall be performed on skid marks and if needed
repair work shall be carried out as per repair procedure.

 Care shall be taken to ensure that the pipe is in the center of the trench and that the coating
or joint wraps are not damage.

6.15 TIE-INS

 All Tie-ins shall be undertaken by a dedicated crew (s) fully equipped for this operation.

 Tie-in shall be carried out where sections of pipeline laid in the trench join and at road,
canal, railway crossings and other major crossings.
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 For tie-ins the pipe shall be cut so as to permit a good alignment of two strings and a good
weld. The lap of pipe strings at tie-ins shall be at least 1~2 meters. The weld seams of the
adjoining pipes shall offset by 30% of the diameter or 76mm which ever is greater. If this
is not possible then a spool piece of not less than 1.2 meters in length shall be inserted.
The minimum pup length shall be one (1) meter. The tie-ins shall be made at the minimum
temperature of the day but not less than 10C 0.

 Bell Holes shall be made in the trench to perform the weld. The bell hole shall be of
following minimum dimensions

Depth 60 cm below the lower part of the pipe

Length 70 cm in excess of the outside diameter of the pipe

Width 90 cm between the outside of the pipe and the bell hole wall on either side of the
pipe.

6.16 FIELD PIPE BENDING

 Field pipe bending shall be done accordance with the project specification.

 Bend will be made along the longitudinal axis of the pipe, so that the weld is not
subject to elongation or stress.

 All field bends shall be free from buckling or flattening, particular care will be taken
to minimize the ovality.

 Any pipe showing defects shall be rejected and replaced.

 Field pipe bending shall be done by using hydraulic pipe bending machine. The machine
shall bend pipe with a bending radius more than or equal to 40 time nominal diameter of
pipe. Bend geometry shall be prepared for each bend suiting to its location.

6.17 BEDDING

 The trench shall be back filled after client’s approval. A proper documentation shall be
prepared for the back filling operation.
 The trench shall be back filled initially up to 20cm as the approval is received.

 After reaching the level of surrounding ground, the ground shall lightly compacted and
later the remaining excavated material shall be crowned enough up to height above as
per specifications over the trench and shall be compacted lightly.

 Where the trenches have been dug through driveways, roads, dikes, etc. the
compaction shall be done using mechanical means by adding small layers of materials.

 Project specifications shall be followed in carrying out the back filling.

6.18 CROSSINGS
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Following points shall be considered for crossings.

 Project specification & drawing shall be followed. If specified casing pipe shall be laid
and the carrier pipe passed through it.

 The activity shall be planned in a way to ensure minimum disturbance to the facility and
to create as little as possible hindrance/inconvenience to the general public. Where the
activity has to continue over the night warning signs shall be displayed to avoid risk of
any accident.

 The detours shall be adequate to meet the requirement of the traffic.

6.19 CLEANING

 It is proposed that cleaning & testing of pipeline may be done in sections after agreement
with client.

 Temporary Pig Launcher & Receiver shall be welded to either end of the pipeline section
under test.

 Pipeline cleaning pigs equipped with polymer discs & wire brushes shall be used for
cleaning. During the cleaning process the following information shall be noted.

 Cleaning pig run number

 Time launched

 Time received

 Average pigging pressure

 Amount of debris connected

 Once the debris collected in front of the pig shows decreasing trend & subsequent
cleaning pigging process does not bring much debris, the clearing process shall be
considered complete.

6.20 GAUGING

 The gauging of pipeline shall be carried out by propelling a Gauging pig in the line using
compressed air

 The Gauging pig shall be fitted with polymer discs & an aluminum gauge plate. The
diameter of plate shall be 95% of minimum ID of the pipeline section.

 The pig shall be passed through the pipeline at controlled speed with compressed air.

 A gauging acceptance report shall be prepared by checking the Gauge Plate after a run.

6.21 HYDROTESTING
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6.21.1 FLOODING:
 The flooding of pipeline shall be carried out by propelling two pigs in the line
using water

 If required the flooding water will have corrosion inhibitor added to it.

 Prior to launching of first pig around 10 cum water shall be pumped into the line
to wash away any foreign materials.

 Similarly before launching the second pig around another 10 cum of water shall
be pumped in the pipeline.

 The two pigs shall be pumped forward using water at a speed around 1.8m / sec.

 Once the first pig is received at the other end pumping shall continue until the
second pig is also received ensuring that the line is completely full.

 The water pumping shall be stopped after maintaining a positive pressure in the
pipeline.

6.21.2 PRESSUREIZATION
 Temperature stabilization shall begin upon completion of flooding works.

 Thermocouples shall be attached on external surface of the pipeline after removal

of coating.

 Thermocouples to measure soil temperature shall also be buried close to pipeline.

 Temperature reading for pipeline & soil shall be taken at regular intervals.
Temperature stabilization shall be considered achieved when the difference
between the two is not above 1oC.

 The line shall be pressurized to test pressure at a pre-agreed rate. During this
process the following readings shall be taken:

1. Fill water flow rate

2. Pipeline pressure recording

3. Pipeline temperature recording

4. Temperature of fill water

 A plot for pressure Vs volume shall be made & compared with a theoretical plot.
In case of a deviation beyond a specified limit (approx. 0.2% of line volume) the
pressurization will be stopped to investigate cause.

 Two consecutive pressures lowering of approx. 0.5 bar & measuring amount of
water drained shall check the volume of air in pipeline. This volume shall be
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compared with theoretical volume. The ratio between the two should not exceed
by a valve given in specifications.

 Upon achieving 100% test pressure the pump shall be disconnected form the
pipeline and temperature & pressure charts removed for safe keeping.

 The pressure will be maintained for 24 hours. During this period the following
readings shall noted.

A) Pipeline pressure

B) Pipeline temperature

C) Soil temperature

D) Ambient temperature

 At the end of 24 hour hold period the pressure change valve as a function of
temperature shall be added to the pressure valve reading noted the adjusted
pressure valve, shall be compared with initial valve. The test shall be considered
acceptable if the difference is within specified limits (usually 1bar)

 Upon acceptance of pressure test the line shall be depressurized carefully.

6.21.3 BULK DEWATERING AND

 The pipeline de watering will be done form the lowest point.

 The drained water shall be disposed at a pre-agreed location.

 Pipeline pigs shall be propelled in the line using compressed air.

 Upon complete bulk de watering drying process shall start.

 The drying will be achieved by propelling several trains of foam pigs.

 After the foam pigging dry air will be blown through the pipeline to achieve
desired valve of dew point.

6.22 NITROGEN PURGING AND INERTING

 A nitrogen tanker with an evaporator shall be used as source.

 Nitrogen gas shall be introduced from one end and air purged out form the other end by
controlled opening of a small valve.

 Purging shall continue until 02 pipeline volumes have been purged.

 On completion of purging the valve shall be closed and Nitrogen pressure to be maintained
in the line.

6.23 CATHODIC PROTECTION SYSTEM

 The qualified staff following the AFC drawings and project specification provided shall
carry out the installation of CP System by client.
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 A team from civil work shall be assigned to carry out all civil works associated with this
installation in a sequence determined by the CP installation team.

 Testing of CP System shall be done to ensure achieving the desired resistivity using the
proper testing instruments having valid calibrated certificates.

6.24 RESTORATION OF THE RIGHT OF WAY

 Restoration and clean up of the ROW will be in accordance with the project
specification

 All waste materials, wooden supports and foreign materials shall be removed and
shifted to a dump and or the appropriate storage location.

 Any excess earth shall be spread along the ROW by scraping and or harrowing to
the satisfaction of the client representative.

 Access roads, tracks, banks, water courses, fences etc, which have been partially
demolished during the work, shall be restored their original shape and condition.

 Special attention will be taken during restoration of the area of the road, canal and
railway crossing.

 Pipeline route and aerial markers shall be positioned as stated in the project
specification and drawings.

7. TOOLS & EQUIPMENTS

7.1 EXECUTION

 Hand Tools
 Cutting, Beveling & Grinding Machines
 Welding Machine
 Welding Machine (Diesel)
 Cranes
 Trailer
 Tractor with Trolley
 Pipe Layer (Side Boom)
 Excavator with Jack Hammer
 Loader
 Dozer
 Motor Grader
 Dump Truck
 Compressor
 Power Generator
 Blasting machine
 Painting spray machine
 Pipe Bending Machine
 Sewage Tanker
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 Water Bouser
 Diesel Tanker

7.2 TESTING

 Holiday Detector
 DPT Unit
 RT Of Welds
 Pressure and Temperature Recorder
 Hygrometer
 Dry Film Micrometer
 Salt Detector
 Adhesive Test
 Profile Meter
 Reference Electrode (Half Cell)
 Digital Multimeter
 Insulation Resistance Tester (Meger)

7.3 SAFETY

 Safety helmet
 Safety Shoes
 Safety Goggles
 Gloves
 Welders Helmet
 Dust mask (if required)
 Fire Extinguishers
 Blasting hood.
 Long sleeve (if required)
 Cover all.

8. SAFETY INSTRUCTIONS

During execution of the job all measure shall be adopted to ensure safe working.
 Client site management system (latest revision) will be implemented.

 All personnel involved will use necessary PPE as required.

 The workers will be made aware of safety requirements related to this activity
through daily, weekly and monthly toolbox and safety talks.

 Safety notice board will be installed.

 All equipment will be inspected by HSE (DESCON) prior to use.

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 During transportation of pipes and other fittings, the material shell be properly
supported and tied on the Trailer.

 Ensure that pipes are properly wedged or blocked to avoid rolling.

 Correct rigging procedure should be observed.

 Access and good housekeeping should be maintained in all fabrication and

erection areas.

 Fire extinguisher should be available in all working areas.

 Proper storage, handling and use of gas cylinders will be observed.

 All cylinders shall be kept in trolleys and in an upright position.

 Welding sets should be checked and maintained regularly for wear and tear.

 Waste Management Procedure shall be strictly followed to keep the job site neat and
clean.

9. ATTACHMENTS
 Project Quality Plan.
 HSE Plan.