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Fabrication of Piping: 01 Rev. Comments
Fabrication of Piping: 01 Rev. Comments
Revision 01
FABRICATION OF PIPING Page 1 of 13
METHOD STATEMENT
FOR
FABRICATION OF PIPING
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FABRICATION OF PIPING Page 2 of 13
INDEX
1. PURPOSE
2. SCOPE
3. REFERENCES
4. DEFINITIONS
5. RESPONSIBILITIES
6. PROCEDURE
8. SAFETY INSTRUCTIONS
9. ATTACHMENTS
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1. PURPOSE
The purpose of this generic method statement is to define the procedure for
fabrication of above ground piping under the MAKORI GPF project specification.
2. SCOPE
3. REFERENCES
Piping Specification
Approved WPS.
Other related Specifications.
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4. DEFINITIONS
CL Client
PM Project Manager
SM Site Manager
CM Construction Manager
DE Discipline Engineer
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
PM I Positive Material Identification.
NCR Non Conformance Report.
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.
DE will ensure that all the works are performed safely as per latest Approved For
Construction (IFC) drawings & specifications.
The relevant DE and Supervisor will ensure that all the piping work is conducted
in accordance with this method statement and project specifications
The QCI will ensure that all work is executed according to PQP and that
requirements of quality dossier are full filled.
The piping raw material received from client shall be offloaded in designated lay 3
down yard.
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During offloading, pipes shall not be dropped off the transport. A crane and
suitable certified slings shall be used. Nylon slings will be used to handle SS and 3
coated piping & fittings.
The pipes shall be placed on concrete blocks with wooden packing in between.
They shall be adequately supported to minimize sagging.
The piping end covers shall be kept in place to prevent foreign particle entry into
the pipes.
All material shall come with color-coding as per size, material & schedule.
6.2 PAINTING
The piping isometrics shall be marked into number of spools to facilitate the
fabrication & erection work.
Each joint on the isometric will be given a unique number preparing a welding
map for traceability. Separate numbering system will be followed for butt welds,
fillet welds, threaded joints etc.
The details of piping isometric breakdown into spools and joints will be recorded
for reference.
Material will be shifted from lay down area to work shop as per relevant piping
isometric drawings
Carbon steel, low temperature carbon steel, NACE and stainless steel pipe
fabrication work will be done in separate areas. Tools & equipment compatible
with the material in fabrication shall be used.
The piping material is to be used in appropriate and economical way. All cuttings
should be collected separately as per material code and place in order to make
best use of these.
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The pipes shall be cut as per dimensions mentioned in the isometric and all pipe
length shall be marked with the relevant spool No, as given in the isometric.
Material traceability shall be maintained as per relevant agreed QIP.
Based on spool break down of piping isometrics, pipe lengths shall be cut 150mm
extra length for pipe will be provided in spools for field adjustment. The pipe ends
for 2 inch & above shall be beveled as per approved WPS for the piping class.
The cutting and beveling of pipes shall be done by mechanical means cold cutting
beveling machine/ lathe machine, flame cutting or plasma/ arc cutting, cutting
shall be acceptable provided that the edges are smooth.
When torch cutting or arc cutting are used for alloy steel or stainless steel, after
grinding to sound metal a dye penetrate examination shall be performed to
eliminate the possibility of surface cracks.
The fit up of pipe ends, fittings & weld neck flanges shall be done to obtain
uniform root opening. The criterion given in related WPS shall be followed.
The joint should be free of grease, oil, scales, rust or other foreign material.
The primer paint coat on pipe & fitting ends shall be removed prior to bevel end
preparation.
The pipes shall be tack welded by a qualified welder. If the pipes are of different
thickness, the larger thickness will be tapered in compliance with standard to
match the smaller thickness.
The adjacent section of longitudinally welded pipes that are to be joined by butt-
welds shall have longitudinal weld seams positioned such that they are at least
30 apart from horizontal center line. The fabricator will also not locate longitudinal
weld seams on top or bottom of the pipe so that branch connections are not
located on the seam.
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isometric. It is preferable that the pad shape is circular, however, the pad size
may be altered provided equivalent cross sectioned area is maintained as per
ASME requirement. The pad shall have a 1/8” NPT vent hole, drilled & tapped to
NPT prior to installation of reinforcement pad.
The Flanges indicated on isometric to be supplied loose shall be tack welded with
the pipe. Full welding shall be made after site checking.
The pipe for welded sockets joint shall be ground to remove burrs due to cutting.
A gap between end of pipe & bottom of socket will be maintained as per Project
Specifications.
In case of threaded pipes (for utilities piping only) screw threads shall be
concentric with axis of pipes with no burrs or stripping. The threading dies shall be
sharp & properly designated for the piping material.
The pipe work 3 inch & larger shall be fabricated in flanged spools as per design.
The size of spools shall conform to dimensions of hot dip galvanizing bath. The
same shall be galvanized from both inside and outside.
The threaded joints of galvanized pipes shall not be seal welded. Tape/ sealant
will be used as per project specification.
6.5 WELDING.
All welding work will be according to approved WPS and B31.3 and only qualified
welders shall be employed.
The welding work piece will be shielded against high winds and rain. The wind
speed exceeding 10 m/sec and 3 m/sec for SMAW & GTAW respectively.
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The weld surface shall be cleaned with wire brush or grinding prior to welding
operations to give a surface free from rust, scale or mill coating.
Between each layer of welding any cracks, pores or welding spatters shall be
removed by grinding the surface before application of next layer.
The appearance of finished welds shall conform to ASME B31.3 code & WPS and
shall exclude any under cuts, spatters, and cracks.
All branch connections shall be joined to headers with full penetration welding.
The bore side shall be ground smooth, free from cracks.
The distance between centrelines of adjacent grith butt welds and staggering of
longitudinally welded pipe for making butt weld shall be according to project
specification.
Welding shall be performed to ensure complete fusion of the weld deposit and the
base metal in order to obtain homogeneous bound over the entire cross section
area of the weld.
Welding current and polarities shall comply with the approved WPS. And or
instruction given by the manufactures of the filler metal.
6.6.1 GENERAL
Before starting any heat treatment process, it will be checked that welding has
been completed.
The preheating temperature shall be maintained throughout the welding cycle and
it should be done over sufficient width on either side of welds.
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Thermocouples and their location on the job to be heat reated shall be checked.
Stress relieving shall be performed as per project specification when specified for
relieving residual stresses caused by welding, cold working etc.
Stress relieving shall be performed when specified to obtain softer, more ductile
material than is obtained by stress relieving. Normalising is the usual commercial
annealing operation for low carbon steels. It shall be formed as follows:
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After heat treatment hardness of weld will be checked as per specification (if
required) and hardness test report shall be prepared.
6.6.3 PRECAUTIONS
6.7 INSPECTION
The fabricated pipe spool shall be checked against project drawings to verify its
compliance.
The dimensions, angle and direction of spool and allowances for field welding
shall be according to the IFC isometrics & project specification. (ASME B.31.3
(chapter “V”)
NDE shall be performed as per ASME section “V” after PWHT if specified on
isometric drawings or project specifications.
The acceptance criteria for visual inspection shall be done according to the ASME
B.31.3. (Chapter VI).
Visible small transverse cracks & star cracks of limited thickness shall be removed
by grinding & repaired by welding. However circumferential cracks shall result in
weld rejection. The defective material will be cut out & rewelding preformed.
NDE tests shall be performed & recorded as per Piping Class, relevant Code and
Project (Welding) Specifications.
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All welding records for each joint shall be maintained throughout the fabrication
work.
CS, SS and Low temperature carbon steel material tracibility shall be maintained
through out the fabrication work such that location & heat numbers of all welded
pressure retaining pipe component is maintained. The heat number will be
transferred by permanent marker to all pieces cut from main pipe.
6.8 IDENTIFICATION
Each fabricated spool shall be clearly marked with a number. This number shall
include line number & spool number as shown on the piping isometric. (For piping
up to diameter 6 inch) it will be hard marked on to a steel plate 2x 3x 1/16 inch
which shall be securely wired to the pipe. (However for piping greater than 6 inch
diameter the number will mark on inside of the pipe using a permanent marker.)
6.9 STORAGE
All spools shall have their identification/piece number clearly designated on each
spool.
The spool will be cleaned in an inclined position by tapping so that all foreign
materials are removed.
The spool shall be placed on wooden baton to avoid direct contact with soil.
The open ends shall be covered by polyethene sheets or end caps. In case of
flanged spools the same shall be covered by securely tied wooden blanks to avoid
foreign material entering the pipes.
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FABRICATION OF PIPING Page 12 of 13
The fabricated support shall be painted after surface preparation as per project
specifications.
Pipe support welding on piping requiring PWHT shall be done prior to the heat
treatment.
7.1 EXECUTION
Hand Tools
Cutting, Beveling & Grinding Machines
Cranes (Mobile)
Cranes (Tower) if required
Lathe Machine
Hack Saw
Trailer
Stress Relieving Equipment
Welding Machine
7.2 SAFETY
Safety helmet
Safety Goggles
Gloves
Safety Shoes
Welders Helmet
Ear Plugs/Muffs (if required)
Dust mask (If required)
7.3 TESTING
Radiography
Ultrasonic Testing
Mage Particle Testing
Dye Penatrant
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8. SAFETY INSTRUCTIONS
During execution of the job all measure shall be adopted to ensure safe working.
DE will ensure that, PTW system shall be implemented as per client requirements
in CPF and GPF areas.
DESCON 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 E&P (DESCON) as per routine while execution
supervisor should inspect it prior to use.
During transportation of pipes and other fittings, the material shall 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 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 should be strictly followed to keep the job site neat and
clean.
HSE shall provide due support to the execution team in the fulfillment of HSE
requirements.
9. ATTACHMENTS.
Nil.
THIS DOCUMENT IS THE INTELLECTUAL PROPERTY OF DESCON ENGINEERING LIMITED. ANY UNAUTHORIZED USE, INCLUDING THE MODIFICATION AND
REPRODUCTION OF THE CONTENT IS STRICTLY PROHIBITED. © COPYRIGHTS ORDINANCE 2002-2008, ALL RIGHTS RESERVED