Method Statement For Fabrication (Piping Supports Structure) Rev.C

PROJECT NAME: REPLACE HIC AFFECTED VESSELS - NORTH GAWAR FACILITIES CUSTOMER: SAUDI ARAMCO
PROJECT LOCATION: NORTH GAWAR FACILITIES - SAUDI ARABIA BI-10-10215 CONTRACT NO: 6600048365
DOCUMENT TITLE: METHOD STATEMENT FOR TIE-IN CONNECTION
DOC. NO: NCC-NGPD-CON-MOS- REV. NO: A DATE: Sheet 1 of 17
“Method Statement for TIE-IN CONNECTION”
Contract No. 6600048365
Issued
for Naveen Suvarna Naveen Suvarna Mothukuri Raghuram Turki Al Oufi
C
Review
Approved By
Rev. Date Descript Prepared By Checked By Approved By
SUMMARY OF REVISIONContractor Representative (Saudi Aramco
ion (Construction (Construction
Project Engineer)
Manager) Manager)
Rev. Date Page Description of Revision
A
All Issued for Review
Disclaimer: This document has been prepared by National Contracting Company Ltd (NCC) for Saudi Aramco Company and contains proprietary information and may only be released to third parties
with prior approval. c) Copyright National Contracting Company Ltd (NCC); all rights reserved. Page 1 of 17
TABLE OF CONTENTS
1. PURPOSE.................................................................................................................................................................. 5
2. SCOPE OF WORK.................................................................................................................................................... 5
3. REFERENCES DOCUMENTS................................................................................................................................... 5
4. RESPONSIBITIES..................................................................................................................................................... 6
4.1. PROJECT MANAGER........................................................................................................................................... 6
4.2. CONSTRUCTION MANAGER............................................................................................................................... 6
4.3. HSE OFFICER....................................................................................................................................................... 6
4.4. MECHANICAL SUPERVISOR............................................................................................................................... 6
4.5. PIPING/WELDING QC INSPECTOR.................................................................................................................... 6
5. ISOMETRIC DRAWING MARKING........................................................................................................................... 7
5.1. JOINT MARKING................................................................................................................................................... 7
5.2. SPOOL MARKING................................................................................................................................................. 7
5.3. HEAT NUMBER..................................................................................................................................................... 8
6. MATERIAL CONTROL.............................................................................................................................................. 8
7.1 MATERIAL HANDLINNG............................................................................................................................................ 8
7.2 STORAGE AND PRESERVATION............................................................................................................................. 9
7. FABRICATION WORKS.......................................................................................................................................... 10
7.1. PLANT & MACHINERY REQUIREMENT............................................................................................................ 10
7.2. ACTIVITIES INVOLVED...................................................................................................................................... 10
7.3. MARKING, CUTTING AND GRINDING............................................................................................................... 10
7.4. FIT-UP.................................................................................................................................................................. 11
7.5. WELDING............................................................................................................................................................ 12
7.6. WELD CONTROL SYSTEM................................................................................................................................ 12
7.7. STACKING OF THE SPOOLS............................................................................................................................. 13
7.8. MODIFICATION................................................................................................................................................... 14
7.9. STAINLESS STEEL PIPE FABRICATION.......................................................................................................... 14
8. HEALTH & SAFETY REQUIREMENT..................................................................................................................... 15
9. ATTACHMENTS...................................................................................................................................................... 16
1. PURPOSE
The Purpose of the Procedure is to conduct Line Shut down, Grinding Cutting& Tie-In
activities of the existing line pipe in a safe manner to prevent accidental loss or damage
to property and personal injury as well as to ensure that the facility will be returned to a
safe operating condition.
2. SCOPE OF WORK
This method statement covers the specific instructions and methods to perform line shut down ,
Grinding cutting , testing and tie-in/isolate the line from existing line.
3. REFERENCES DOCUMENTS
i) Isometric Piping Detail
ii) Material Take Off
iii) Safety Instruction Sheet(New Line)
iv) Safety Instruction Sheet(Existing Line)
v) Piping Hydro Test diagram
vi) Saudi Aramco Construction Safety Manual
vii) Saudi Aramco GI

0002_100 : Work permit system.
0006_004 : Near miss reporting process.
0007_028 : Crane Lifts-Types and procedures
0007_029 : Rigging hardware requirements.
viii) SAEP-310 – Piping & Pipe Line Repair
ix) SAES-L-150 – Pressure Testing Of Plant Piping & Pipelines
x) SAES-A-004 – General Requirements For Pressure Testing.
xi) SAEP-327 – Management of Waste Water From Cleaning, Flushing and

dewatering Pipe Lines & Vessels.
xii) SAEP-1143-Radiographic Examination.
4. RESPONSIBITIES
The following subcontractor's personnel shall be involved and responsible for the
incorporated in this method of statement.
4.1. PROJECT MANAGER
The overall responsibility of PM is to organize the resource to perform construction activity

as per project specification in compliance with Quality, Schedule and HSE requirement.
4.2. CONSTRUCTION MANAGER
The construction manager is responsible for that construction activities are executed
according to the relevant project specification, in compliance with Quality, Schedule and
HSE requirement.
4.3. HSE OFFICER
The Safety Officer has to monitor the implementation and adherence to this procedure and
report violations and / or noncompliance issues to project management for immediate
corrective action.
4.4. MECHANICAL SUPERVISOR
Shall arrange all tie-in Material and equipment must be available at site during shut down,
Shall be responsible for Tie-in Planning, Fabrication, Testing, Cleaning and Tie-in
Execution.
4.5. PIPING/WELDING QC INSPECTOR
Shall confirm that all joints are Welded, NDT Cleared and Inspected, responsible
for verifying the calibration reports of all cable equipment are available and
accepted for the work to be performed, Shall confirm that supports/Pads welded
and piping is secured on supports or temporary supports, shall witness Tie-in Fit-
up and welding, shall ensure that the procedure is followed for Tie-in, Shall be
responsible to Raise RFI for Fit-up and Welding, Shall responsible to ensure that
all reports, Checklist are signed from Company after completion of Tie-in.
5. SHUT DOWN PROCEDURE
• Contractor will make a request letter in advance to SAPMT prior to conduct any shutdown
activities at site
• SAPMT will send notification letter in advance to operations Department prior to conduct
any shutdown activities at site
• Once the request for shutdown is approved by the operations, SAPMT will send a
confirmation letter to contractor
• Contractor will prepare all the necessary tools manpower and equipment prior to conduct
the cold cutting/ Grinding Cutting, Fabrication, Welding, Hydrotest and Tie-in activities.
• Operation is responsible to reduce the flow of the existing pipe line.
• Shutting down of the existing line is the sole responsibility of Operations Personnel.
Construction Personnel should not under any circumstances be involved in any
operational activities.
• Contractor shall schedule the work activities for the shut down and execute the work to
minimize the shutdown period.
6. COLD CUTTING PROCEDURE
• Make sure that all safety measures are in place and all equipments and tools to be used
are available specifically cold cutting machine, welding machine , Grinding machine etc.
• Determine,isolate and install blind flanges at the isolation points of the existing line before
Cold cutting/grinding Machine etc.
Lockout Tag out procedures shall be followed .
Indicate the lines that shall be isolated and blinded and make sure the blinds must meet
the line specification(Size and Rating) .
• The cutting locations must be clearly indicated at the site and approved by area Inspector
prior and of any cutting procedure.
• Prior to cold cutting/Grinding, wind direction shall be established. Ensure that the crew is
situated upwind of the cutting location. The cutting machines shall have sufficient spare
wheels/blades. The air compressor shall be in good working condition and spare machine
is available.
7. TIE-IN PROCEDURE
7.1. PLANNING
• The CONTRACTOR will have the related COMPANY Engineering Standards,

Specifications and Engineering Instructions required in completing the Tie-in Work. The
Tie-in work planning will be completed in accordance with a shutdown schedule agreed
with COMPANY and will indicate the date one month ahead of Tie-In Installation.
Coordination meeting will be held as required at site in order to establish and update the
detailed Tie-in schedule among all individual parties, COMPANY, PMC, COMPANY
Operation, PID, CONTRACTOR Confirm that equipment, lines, valves, spectacles blinds
and drains shown in the test package will give the required isolation to conduct the
Works.
7.2. SPOOL MARKING
• Each material item and fabricated spool will be identified and delivered to the Tie-in
location as “bagged and tagged” with individual Tie-in number. Material removed from
the existing facility for this task should be disposed in safe location with the approval
from Company operations and inspection personnel. The wastewater from cleaning and
flushing should be disposed in accordance with SAEP-327.
7.3. PREPARATION
• Prior to fabrication, actual dimensions at Tie-in location will be measured for back-check
of the pipe design drawing. At each Tie-in point, a metal tag will be wired to the pipe line
and in addition a color-coded paint mark will be applied as per the witness of company
operations and Inspector personnel.
7.4. FABRICATION
• Fabrication works will be done in accordance with relevant standards and requirements of
SAES-L-110, SAES-L-350, SAES-W-011, SAEP-351, 01-SAMSS-010 and
04-SAMSS-048.
7.5. TIE-IN WORK EXECUTION
• In general, the Tie-in Work execution will proceed in accordance with Tie-in Check list
and Tie-in schedule, after acquiring the approval of company on this package and all
relevant procedures required for the job.
7.6. WELDING TIE-IN
• Tie-in point to be cut, welded or to be drilled for any connection shall be “Ultrasonic Test-
UT” Tested to be determine the Tie-in point thickness. If the “UT” thickness reading is not
acceptable, CONTRACTOR should report to COMPANY and discuss about re-location.
• Contractor shall prepare and ensure that the Tie-in material readily available near the
Tie-in point inspected and ready to install prior to line or plant shutdown.
• Line Isolation shall be properly performed to ensure there is no any service fluid remains
on existing header pipe prior to Tie-in activity.
• Isolate and close all branch isolation valves.
• Locate existing line lowest point and fully open the drain valve.
• Upon the successful completion of line isolation and draining, Work permit for Tie-in
preparation shall be obtained, To be followed by permit to cut the existing line.
• Company operations shall clear the line from Steam and water to turn over to Contractor
prior to Tie-in activity.
• Gas testing is required to ensure that no flammable gas contents on pipeline.
• Obtain valid hot work permit for pipe cutting and end preparation, such as grinding.
• Cut the existing line using cold cutting method.
• Perform welding according to the welding approved procedure.
7.7. TESTING/INSPECTION
• Tie-in work and Tie-in documentation shall be in accordance with Saudi Aramco Typical
Inspection plan(SATIP-L-350-02) including the applicable SAIC shall be followed,
implemented and maintained accordingly.
8. TIE-IN REINSTATEMENT
• Lay on safe location all the removed pipe sections to avoid hazard for the movement of
equipment’s and manpower.
• Remove all temporary installations and equipment’s from the new and existing facility.
Clean the area from all left over during the Tie-in activity. Ensure that the newly installed
piping is safe to operate prior to putting back the line on stream.
• Company operations will determine the sequence of putting the facility back in service.
9. GENERAL REQUIREMENTS
• The Procedure will be made available on site for reference and proper compliance
accordingly by all concerned.
• All valves to the body and seat tested prior to installation per the scope of work
requirements, and all the documents of the testing shall be made available to
SAPID/Operation upon request.
• Field preparations, Cold cutting, tie-in welding, NDT shall follow safety requirements in
accordance with applicable Saudi Aramco Standards and Procedure.
10. WORK PERMIT SYSTEM
• Must obtain a work permit from Operations Supervisors for the area before commencing
any work in a restricted area.
• The work permit is a written permission to proceed with the work in accordance with the
plans and the restrictions written in the permit. Without a proper work permit, Work will not
be allowed in the area.
11. PERSONNEL QUALIFICATION & TRAINING
• Contractor personnel executing Cold cutting, fabrication and welding & NDT, Hydro Test
and Tie-in activities shall be aware of the importance of adhering to proper work practices
and shall have proper training and skills to conduct this job.
• All personnel should familiarize himself with the procedure before work starts.
• It is necessary to familiarize themselves with the disaster Control plan for the area in
which the job is located.
12. LIST OF EQUIPMENTS REQUIRED
 Pressure Gauge
 Relief valves
 Hydro test Manifold
 Welding Machine
 Cold Cutting Machine
 Air Compressor
 Grinding Machine
 Hydro test Pump
 Brass Hammer
 Crane
 Pick Up Vehicle
 Fire extinguisher
 Other Hand Tools.
13. TIE IN INDEX
Existing Service Line Location Type of

New line Number
Line No.
Shutdown connection

New line Number
Line No.
Shutdown connection

New line Number
Line No.
Shutdown connection

New line Number
Line No.
Shutdown connection
14. HEALTH & SAFETY REQUIREMENT
• Take appropriate work permit from the safety Department.

• All work force shall be completed their safety induction before commencement of their work.
• 100% PPE shall be implemented (Hard hat, coverall, safety shoes and safety glasses).
• All fabrication shop operatives shall understand the fabrication shop risk assessment as per
site requirements and where required additional task specific PPE shall be used.
• All equipment and tools shall be certified by Armco approved by 3 rd party
• All operators should have valid Saudi license, third party certification and Aramco
certification.
• All vehicle drivers should have valid Saudi license.
• Only third party and Aramco certified riggers shall rig the loads.
• Safety caution/warning sign boards shall be displayed in the required places.
• A Tool Box Talk (TBT) shall be carried out by the Supervisor at the work site.
• A copy of job Safety Analysis (JSA) should be kept on job for reference.
• Maintain the necessary standards of cleanliness and tidiness within the workplace.
• Barricades shall be erected to keep unauthorized personnel away at the proper distance
away from the work area.
• The certified Rigger and Rigging supervisor shall ensure the equipment and rigging gears
are adequately inspected, certified and maintained.
• Provide the trained flag man to control the equipment while marching
• All lifting gears such as slings, belts, shackles shall have third party certificates and free from
corrosion.
• No lifting shall be allowed during high winds more than 32kph (20mph).
• No one work under the suspended load and follow the safety instruction
• Lifting area shall be barricaded properly before commence the work
• Use two tag line used to control the materials
• Pipe fabrication team must in strict compliance of the approved procedure.
• All Oxygen-fuel welding and cutting cylinders shall be fitted with flashback arrestors on the
regulators.
• Welding and open flame activities shall be specially protected from the flammable and
explosive materials
• Fire extinguisher shall be placed in the hot work areas.
• All tools shall be inspected and monthly colour coded to be used at work place.
• Site Safety representative shall be present at the job site at all times while personnel are
working.
• Safety Officers shall be assigned to monitor safety condition of the work area, and are
authorized to stop any activities if the conditions at the site changed such that to continue
working would be unsafe.
• Ensure COVID-19 protocol shall be followed by all the working crew
• Ensure housekeeping to be done every day before and after the job.
• Ensure materials shall not been kept for obstructing the entrance and exit.
• Ensure all the electrical cable and electrical panel must be approved and intact.
• Ensure any damaged /insulated cable not using in the fabrication yard.
• Dead man switch for all electrical tools must issue to the working crew.
• Ensure the safety training analysis and request for their working crew.
15. ATTACHMENTS
1. Job Safety Analysis.

a) NCC-MGPD-HSE-JSA-002 Fabrication work (piping & Pipe support )

Method Statement For Fabrication (Piping Supports Structure) Rev.C

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PROJECT NAME: REPLACE HIC AFFECTED VESSELS - NORTH GAWAR FACILITIES CUSTOMER: SAUDI ARAMCO

“Method Statement for TIE-IN CONNECTION”

Contract No. 6600048365

Rev. Date Page Description of Revision

4.1. PROJECT MANAGER........................................................................................................................................... 6

4.3. HSE OFFICER....................................................................................................................................................... 6

4.4. MECHANICAL SUPERVISOR............................................................................................................................... 6

4.5. PIPING/WELDING QC INSPECTOR.................................................................................................................... 6

5. ISOMETRIC DRAWING MARKING........................................................................................................................... 7

5.1. JOINT MARKING................................................................................................................................................... 7

5.2. SPOOL MARKING................................................................................................................................................. 7

5.3. HEAT NUMBER..................................................................................................................................................... 8

7.1 MATERIAL HANDLINNG............................................................................................................................................ 8

7.2 STORAGE AND PRESERVATION............................................................................................................................. 9

7.1. PLANT & MACHINERY REQUIREMENT............................................................................................................ 10

7.2. ACTIVITIES INVOLVED...................................................................................................................................... 10

7.3. MARKING, CUTTING AND GRINDING............................................................................................................... 10

7.6. WELD CONTROL SYSTEM................................................................................................................................ 12

7.7. STACKING OF THE SPOOLS............................................................................................................................. 13

7.9. STAINLESS STEEL PIPE FABRICATION.......................................................................................................... 14

8. HEALTH & SAFETY REQUIREMENT..................................................................................................................... 15

i) Isometric Piping Detail

ii) Material Take Off

iii) Safety Instruction Sheet(New Line)

iv) Safety Instruction Sheet(Existing Line)

v) Piping Hydro Test diagram

vi) Saudi Aramco Construction Safety Manual

vii) Saudi Aramco GI

viii) SAEP-310 – Piping & Pipe Line Repair

ix) SAES-L-150 – Pressure Testing Of Plant Piping & Pipelines

x) SAES-A-004 – General Requirements For Pressure Testing.

xi) SAEP-327 – Management of Waste Water From Cleaning, Flushing and

xii) SAEP-1143-Radiographic Examination.

4.1. PROJECT MANAGER

The overall responsibility of PM is to organize the resource to perform construction activity

4.3. HSE OFFICER

4.4. MECHANICAL SUPERVISOR

4.5. PIPING/WELDING QC INSPECTOR

5. SHUT DOWN PROCEDURE

6. COLD CUTTING PROCEDURE

• The CONTRACTOR will have the related COMPANY Engineering Standards,

7.2. SPOOL MARKING

7.6. WELDING TIE-IN

10. WORK PERMIT SYSTEM

11. PERSONNEL QUALIFICATION & TRAINING

12. LIST OF EQUIPMENTS REQUIRED

13. TIE IN INDEX

Existing Service Line Location Type of

Existing Service Line Location Type of

Existing Service Line Location Type of

Existing Service Line Location Type of

14. HEALTH & SAFETY REQUIREMENT

• Take appropriate work permit from the safety Department.

1. Job Safety Analysis.

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