OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY

DOC NO: SRIP/TE /JI-02022/03-

003/MS/PP/ METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

SOHAR REFINERY IMPROVEMENT PROJECT

CONTRACT NO. – JI-02-022/03-003

METHOD STATEMENT
FOR
TIE-IN PACKAGE - 50002

SUBCONTRACTOR:

TOWELL ENGINEERING SERVICES CO. LLC

PO Box: 1040, Ruwi
PC 112, Sultanate of Oman

PRO. Eng. SIGN.

Rev. Date Description Prepared By Checked By
DP-JV APPROVAL

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

LIST OF CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS AND ABBREVIATIONS

5.0 ROLES AND RESPONSIBILITIES

6.0 HSE

7.0 PERSONNEL, EQUIPMENT&TOOLS

8.0 METHODOLOGY

8.1 SHIOP FABRICATION ACTIVITIES

8.2 MATERIAL LOADING/UNLOADING.
8.3 PRE SHUT DOWN ACTIVITIES
8.4 SHUT DOWN ACTIVITIES
8.4.1 CUTTING & INSTALLATION
8.4.2 NDE
8.4.3 HYDROTEST
8.4.4 RE-INSTATEMENT

8.5 WELDING ACTIVITIES

8.5.1 QUALIFICATION OF WELDERS
8.5.2 WELDING ENVIRONMENT
8.5.3 FIT-UP
8.5.4 WELDING
8.5.5 WELDING TECHNIQUE
8.5.6 WELDING ELECTRODES AND CONSUMABLES
8.5.7 EXAMINATION OF WELD
8.5.8 WELD REPAIR
8.5.9 PAINT TOUCH UP

9.0 ATTACHMENTS

Tie-in package
JHA

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

1.0 PURPOSE
The purpose of this method statement is to ensure plant air line modification for providing
access to the new parking near security gate of SR, which includes general welding
activities and installation of new fabricated pipe spool on existing PA line PA50022202-2”-
MS01 in E-200 Area of ORPIC SR. Line PA50022202-2”-MS01 shall be installed as per the
AFC Drawings, in accordance with good working practices, ORPIC requirements,
approved procedures, project specifications and also as per Quality, Health, Safety and
Environment Protection system for Sohar Refinery Improvement Project.

2.0 SCOPE

This method statement covers all content regarding the execution of piping works near E-
200 area of ORPIC, Sohar Refinery, which is a part of SRIP.

3.0 REFERENCES

 ITP-Piping pre fabrication and welding spool release. : S-000-5530-061 Rev-3

 ITP-Erection and testing of above ground and
underground welded piping : S-000-5520-063 Rev-4
 ITP-Piping TIE-IN. : S-000-5520-123 Rev-0
 ITP-Structural Steel Erection Works : S-000-5530-058 Rev-0
 ITP-Painting of Metal Surfaces. : S-000-5520-129 Rev-0
 QCP- Incoming Material Inspection : S-000-5520-110 Rev-0
 QCP-Welding Consumable Control. : S-000-5520-125 Rev-0
 QCP-Welding Control. : S-000-5520-126 Rev-0
 QCP-Installation of Static and Packaged Equipment : S-000-5520-154 Rev-0
 Approved Method Statement
 Technical Query - Closure weld (Golden joint) approval.
 Project / Construction HSE plan

4.0 DEFINITIONS AND ABBREVIATIONS

DPJV Daelim Petrofac Joint Venture

TESCO Towell Engineering Services Co. LLC
TIPCO Towell Infrastructure Project Co. LLC
P&ID Piping & Instrumentation Diagram
PFD Process Flow Diagram

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

PQR Procedure Qualification Records

WPS Welding Procedure Specification
PTW Permit to Work
UT Ultrasonic Testing

5.0 ROLES AND RESPONSIBILITIES

Piping Superintendent: Responsible for managing all the activities as mentioned in

method statement.

Piping Supervisor: Responsible for the execution of the work as per

the instructions of the Piping Superintendent.

QA/QC Manager: Responsible for controlling and directing quality activities by

applying the quality requirements given in the quality
documents, also responsible for maintaining the records
related to job specification and ITP.

QC Coordinator: Responsible for the ensuring the quality of the

work by coordinating with execution team.

QC Mechanical Inspector: Responsible for the inspection jobs and preparation of

the QC documents as per the ITP.

HSE Manager: Responsible for the implementation of the

HSE Plan and management system.

HSE Officers: Officers will be monitoring the job at site and ensures
that the job is carried out safely as per the HSE plan.

6.0 HSE
• All personnel involved in the work shall be made familiar with this method statement and
its risk assessment.

• Equipment shall not be refueled while in operation.

• All lifting equipment shall be tested, certified and color coded. Valid color code shall be
made available throughout work area.

• All personnel shall undergo the required safety training and must wear appropriate
PPE’s.

• Work over 1.8 metre height shall be considered as “Work at Height”.

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

• Only certified scaffolders shall install, modify and dismantle the scaffolds.

• Welders shall use non-combustible type blankets under the welding area to prevent the
fire risk.
• All riggers and crane operators to be certified.

• The areas shall be barricaded with caution tape where pipe loading and unloading
operations, scaffolding works are carried out.

• All works shall be carried out in accordance with the relevant project permit to work
procedures and system.

7.0 PERSONNEL, EQUIPMENT AND TOOLS

 Riggers
 Crane operators
 welders
 Fabricators etc.
 Crane
 Trailer
 Fork lift
 Welding machines
 Spanners/Torque wrench
 Alignment Inspection tools
 Lifting tools & tackles
 Test Manifold
 Pressure gauges/Recorders
 Spirit level, Measurement tape
 Cutting set
 Grinding Machine
 NDT source

8.0 METHODOLOGY

8.1 SHOP FABRICATION ACTIVITIES

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

 Before to start fabrication, Ensure pipe and fittings shall be selected as per approved tie in
ISO drawings.

 Field dimensions of the Tie in spool to be checked with the dimensions given in Isometric
drawing to ensure that the spool will fit in the tie in location as per the drawing. Changes in
dimensions shall be mentioned in as-built drawing. Care shall be taken to avoid clashes with
existing facilities. Checks are to be made for valve access and operation.

 Piping spool shall be given spool number and tie the tag number on spool to identify, which
will be shown on weld map Isometric drawing.

 Spool Lay down area shall be identified prior to shifting inside the plant.

 Lay down area shall be barricaded and signage shall be kept.

 Preservation and storage of piping spools, supports and erection materials shall be ensured in
accordance with project specification.

 Once the preparation is achieved and confirmed that it is safe to start hot work, fit up the
spool with some more length for hydro test purpose and the same shall be inspected as per
ITP and then released for welding.

 NDE shall be performed for the completed joint. After the successful completion of NDE, tie in
spool shall be subjected to blasting & painting.

 Blasting and painting shall be completed as per project specification. Ensure sufficient length
from the bevel end left unpainted. Unpainted joints shall be completed after field welding and
NDE during shut down. Ensure flange face and piping internals are protected from blasting
and painting.

 Wrapping and coating is done using the approved specification and materials on the new
underground tie-in spool

 The Tie in spool shall be tagged properly for easy identification and shall be stored in
allocated Lay down area.

 Pipe spool shall be kept clear from the ground. Before transportation of fabricated spool at
site, necessary clearance (Spool ID, Dimension and NDE) shall be obtained as per ITP.

8.2 MATERIAL LOADING AND UNLOADING

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

 Valid PTW shall be obtained for loading and unloading activities

 Third party inspection certified crane, operator, riggers and lifting tackle shall be
deployed for lifting activities.
 Pipe spools and other related materials shall be unloaded in a suitable place near the
erection area by using crane.
 Spool nos. given in iso drawing shall be tagged on the spools with markers for easy
spool tracking at site.
 Pipe spools shall be inspected, prior to the installation.
 Pipe spools shall be covered with End Cap.
 Prior to Erection, each spool shall be cleaned internally by blowing air and inspection
shall be done before erection/installation.

8.3 PRE SHUT DOWN ACTIVITIES

 PTW for pre shutdown activities shall be prepared by CONTRACTOR/SUB CONTRACTOR

and shall be submitted to ORPIC for acceptance well in advance of scheduled start date.

 Minimum wall thickness examination shall be carried out at the Tie-in location, the full
circumference of the pipe to be checked for the wall thickness on the existing line. Pipe
surface shall be properly prepared and paint should be removed. The surface preparation
shall extend at least 150mm in excess on each side of marking (weld line) on existing pipe for
UT scanning to check for laminations.

 Necessary tagging shall be done on existing line FW91010401-18”-MS01-N, at intended cut

out location.

 ORPIC permit shall be obtained for crane entry to the Tie in Location. Crane location shall be
marked on plot Plan drawing and submitted.

 ORPIC permit for excavation for the tie-in location is also obtained.

 The access to the Tie in location shall be checked well in advance. It shall be ensured that the
existing facilities shall not be affected in any way during transportation of materials, shifting of
equipment’s, crane entry or during execution of Tie in.

 Transport Tie-in spool, isolation valve and all erection material to tie-in location. During
transportation of pipe spool shall be covered with dunnage softeners and protected to the
satisfaction of company’s inspector.

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

 Cover with fire resistance blanket around Tie in joint and ensure all adjacent equipment’s and
live pipelines are protected from spatters flying around during welding, grinding or other
activities.

8.4 SHUT DOWN ACTIVITIES

 Valid PTW and crane entry certificate shall be obtained from ORPIC for Tie in preparations.

 ORPIC shall be responsible for line/system shut down, blinding, de pressurization, draining,
venting, purging, Hydrocarbon freeing of the line and shall ensure that the conditions are safe
for work to commence. Orpic shall also be responsible for the line de-blinding and
commissioning of existing line after the tie-in work is completed.

 After the isolation of system by inserting the spades in line as marked in P&ID, toxic gas and
LEL detection is confirmed in the line / system by ORPIC. Contractor shall ensure regular /
periodic gas tests to ensure safe conditions continue to exit for the tie-in activity. The
discipline supervision and HSE personnel shall be continuous to monitor the activity and to
ensure safe working conditions.

 ORPIC shall provide line isolation certificate prior to commence the tie-in, and it shall be
attached with PTW along with approved MS & JHA during tie-in execution.

 Cover with fire resistance blanket around Tie in joint and ensure all adjacent equipments and
live pipelines are protected from spatters flying around during welding, grinding or other
activities.

8.4.1 CUTTING OF EXISTING PIPE LINE & INSTALLATION OF NEW LI NE

 The cut out location of the existing pipe line (FW91010317-8”-MS01-N) shall be
verified as per the IFC drawing and the same shall be confirmed by DPJV.

 Wall thickness of the existing pipe on cutting location shall be verified by UT for
thickness prior to cutting.

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

 Option 1 – Cutting of the cut out location will be done by using oxy-acetylene gas
cutting method. Beveling of this cut out shall then be carried out using grinding
machine and penetrant testing shall be performed on the bevel to check for any
defects.
 Option 2 - TESCO shall proceed with pipe cutting and beveling by grinding machine.
Penetrant testing shall be performed on the bevel to check for any defects. Multiple
holes are drilled within the cut out location for the convenience of cutting.
 The above mentioned options shall be used based on the client’s suggestion.
 The existing pipe is removed and the existing civil support shall be demolished
 The excavation of the new tie-in spool location shall be done as per the depth
mentioned in the isometric. Width of the excavated area will be kept sufficient for the
ease work inside the excavated area.
 The new tie-in spool is lowered into the excavated area using crane and remaining
field joints are fitted up and welded. Relevant inspection shall be made as per the ITP.

 Temporary blinds are provided and hydrostatic test of field joints and shop joints are
carried out as per the pressure mentioned in the isometric drawing.

 Upon completion of the hydrostatic test, the temporary blinds are removed and the
new tie-in line is drained and cleaned.

 The new flange fit up welding at the existing line shall be carried out simultaneously.

 The tie-in spool is then bolted in line with the end flanges in the existing line.

 After the tie-in works are completed, the backfilling as per specification shall be
carried out.

8.4.2 NDE

 Intended tie-in location shall be ultrasonically (UT) scanned for pipe wall thickness & pipe
lamination.
 Penetrant testing shall be carried out on the beveled surface and field welded joints as per
project requirements.
 Holiday testing for wrapping and coating of underground materials will be done.
 The field tie in joints shall be identified as Golden joint. However prior approval shall be taken
from ORPIC for classifying the joint as Golden joint.

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

 Golden joint shall follow as per closure weld procedure.

8.4.3 HYDRO STATIC TEST

 Valid PTW shall be obtained for hydro static test.

 Shop fabricated spool shall be subjected to hydro static test to examine integrity of shop joint
before field installation at test pressure 27 bar.

 Third party certified test manifold shall be used for hydro static test.

 Relief valve and pressure gauge should be calibrated.

 Competent personnel shall be deployed for testing activities.

 Provide necessary test vent and drain.

8.4.4 RE-INSTATEMENT (FLANGE, GASKET & BOLT)

 Flanges, gaskets material and rating shall be verified.

 Bolt material, length & size shall be confirmed with issued iso drawing.

 Isolation valve shall be bolted up as per the handle orientation marked in Isometric drawing.
Ensure the flange joints are aligned properly and bolts are been torqued or tensioned as per
the requirement. Sub contractor shall ensure that gaskets and flange faces are free from any
damage.

 For system pressure testing, line flushing, removal of temporary blinds

etc., temporary gaskets will be used.
 All temporary line isolation/spading shall be removed and reinstate the line.

8.5 WELDING ACTIVITIES

8.5.1 QUALIFICATION OF WELDER.

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

Only qualified welders shall be used to perform all welds including tack welds.

8.5.2 WELDING ENVIRONMENT

No welding shall be performed when rain is falling on the surfaces of the parts to be welded.
During period of high winds unless the work area properly is protected by proper arrangement
(e.g. tent, shed.)
Minimum preheats shall be carried out as per the approved WPS.

8.5.3 FIT-UP

Machining or cutting discs shall be used for joint preparation. Whenever flame cutting is used,
the cut surfaces shall be grinded for finishing. Internal cleaning will be confirmed prior to fit-up.
Surfaces and edges to be welded shall be uniform and free from fins, tears, laminations, cracks
or any other defects that would adversely affect the quality of the weld.
The surfaces of the parts to be welded shall be visually examined .Any such defects shall be
dressed out by grinding.
Clamps shall be used for fit-up of pipe line weld joints. Temporary welded attachments shall be
made from same pipe materials and same shall be removed by grinding only. Hammering shall
not be used under any circumstances to remove temporary attachments.
Dye penetrant or magnetic particle examination shall be done after removal of all temporary
welds.
The fit-up and alignment of the weld joints shall be within the tolerances as given in the related
specifications and approved procedures. Misalignment should be according to the approved
WPS and as per the Engineering Design.

8.5.4 WELDING

Welding details and the notes mentioned in the AFC isometrics and specification for the
welding of piping and fittings shall be applied. Welding shall be carried out with qualified

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

welders and as per approved WPS. Proper cleaning shall be done after completing the
welding.

8.5.5. WELDING TECHNIQUE

All welds shall be cleaned, on completion of each pass and also after completion of weld joint.
All tack welds shall be done by qualified welders. The required preheat temperature shall be
attained prior to tack welding. According to WPS tack welded area shall be thoroughly cleaned,
prepared at each end and inspected for cracks.

8.5.6 WELDING ELECTRODES AND CONSUMABLES

All welding electrodes/consumables shall be subjected to Client approval, as part of the WPS.
All welding electrodes/consumables shall be stored and used in accordance with the
manufacturers’ recommendations & DPJV Welding Consumable Control Procedure.

8.5.7 EXAMINATION OF WELDS

Weld joints shall be subjected to inspection and tested as per the code, specification and
Welding Inspection Procedure.

All information for related weld joints of pipe work including the weld date, welder IDs shall be
recorded on the Daily Welding Report and shall submit as part of final test pack.

8.5.8 WELD REPAIRS

NDT reports shall be submitted to the client for verification and analysis of defects. Defects
shall be marked and to be removed by grinding. Area to be repaired shall be 100% examined
visually and also by MT or PT to confirm complete removal of defects. Repaired weld joints shall
be examined in accordance with the requirements of the original weld.

8.5.9 PAINT TOUCH UP

Paint touch up shall be done for the spool and also for the field joints as per Isometric drawing
and as per project specification. No painting shall be applied on weld joint prior to pressure test.

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 OMAN OIL REFINERIES AND PETROLEUM INDUSTRIES COMPANY
DOC NO: SRIP/TE /JI-02022/03-
003/MS/PP/0 METHOD STATEMENT FOR TIE IN CONTRACT NO:
PACKAGE - 50002 JI-02022/03-003
Rev No: 00

9.0 ATTACHMENTS

 Tie-in package

 JHA

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