UAQ INDEPENDENT WATER PROJECT –

150 MIGD

METHOD STATEMENT AND RISK ASSESSMENT

FOR INSTALLATION & PRESSURE TEST OF SS/CS
PIPES & FITTINGS
(GENERAL – ALL AREAS)

A 19/06/20 For approval FDPLS EBI ASHOKA

 Rev Date Issue, Modification Prepared Checked Approved

TABLE OF CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 ROLES & RESPONSIBILITIES

4.0 INSTALLATION PROCEDURE

5.0 INLINE INSTRUMENTS

6.0 HSE REQUIREMENT

7.0 QUALITY REQUIREMENT

8.0 INSPECTION & DOCUMENTATION

9.0 PRESSURE TEST OF SS/CS PIPELINE

10.0 REINSTATEMENT OF PIPELINE

1.0 Purpose:
Purpose of this document is to give methods and guidelines for proper execution of Installation
and pressure test of SS & CS pipes and fittings, with required inspection and documentation,
according to project specifications.
Further purpose of this Method Statement is the following:

• Intends to define the responsibilities of the project personnel involved at different

levels for execution of the activity.
• Shows correct procedure of identification and selection of material and right method
for material traceability maintenance throughout the fabrication stages.
• Gives proper method for performance of every activity
• Precautions and controls to be adopted to complete an activity according to the
requirements
• Quality control requirements in an activity
• Ensure pipe internal cleanliness at the end of every activity.
• Safety and risk assessment of the activity and mitigations actions
• Fulfilling the above purpose should lead to timely, flawless, trouble-free completion
and start- up of the project.

2.0 Scope:
This document defines the methods to be adopted for material storage, Installation, testing,
inspection and documentation of SS & CS Pipes and Fittings at IWP Project in UAQ, U.A,E

3.0 Roles & Responsibilities:

3.1 SITE MANAGER:
The Site Manager is responsible for the entire site works including controlling of materials,
labour and plant. He must:
• Ensure his subordinates maintain good time keeping of the workforce and maintain
daily attendance of operatives.
 • Always ensure that construction activities progress in line with the Contract
Schedule and plans.
• Ensure that his subordinates keep track of all materials received, checked,
unloaded, stored and preserved properly to minimize material wastage.
• Monitor all activities to ensure that only safe practices are being utilized and correct
as necessary.
• Monitor standards of works to ensure all stipulated tolerances are being achieved.

3.2 SITE ENGINEER:

Subordinate to Site Manager and responsible for the overall control of storage of materials
(pipes & fittings}, installation & jointing. He is also responsible for the coordination with QC
and preparation of Risk Assessment Report in consultation with HSE team and reporting.

3.3 SITE SUPERVISOR:

Subordinate to the Site Engineer and responsible for direct supervision of the piping work,
ensuring that the piping work is done in accordance with the project specifications and quality
requirements. Further responsible in ensuring that all materials used are in a clean and dry
condition
He is also responsible for the maintenance of a clean and safe working (House Keeping)
environment for his people and people around him at his area. He is also responsible for
implementing of project approved HSE procedure, carry out toolbox talks, correct potential
hazards and shall stop any work deemed unsafe.

4.0 INSTALLATION PROCEDURE:

4.1 Material Storage

• The metallic pipes and fittings shall be offloaded in the designated lay down yard.
• Separate dedicated area shall be assigned for the storage of Carbon steel and
stainless steel materials.
• Mobile crane shall be used for offloading of the pipes and fittings.
 • The pipes shall not have direct contact with the ground and shall be placed on
temporary wooden supports.
• Supports shall be adequately to minimize sagging.
• The piping end covers shall be kept in place to prevent foreign particle entry into
the pipes.

4.2 Fabrication of Pipe

Pipe Spool Cutting, Grooving & Bevelling

• The cutting of pipes, edge preparation, joint alignment, and fit-ups shall be done
as per the WPS.
• 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.
• Extra length shall be considered while cutting the spools for field adjustment.
• The pipe edge shall be cleaned and bevelled as per requirement.

Pipe Spool Fit-up and Welding

• Spool fit-up shall be done according to the dimensions given in the approved
isometric drawing and to the joint details specified in WPS.
• All tack weld must be done by qualified welder only.
• All surfaces to be welded shall be thoroughly cleaned from any foreign matter.
• Dimensions shall be checked by the QC after fit up and then release for the final
weld.
• All the welding shall be carried out in accordance with the approved WPS.
• Between each layer of welding any cracks, pores or welding spatters shall be
removed by grinding the surface before application of next layer.
• Only qualified welders in accordance with the same requirements shall carry out
welding.
• NDT shall be performed and recorded as per project specification.

4.3 Field Erection

4.3.1 Work procedure

Piping shall be installed based on the latest revision IFC (Issued for Construction) drawing.
The IFC drawing shall be complete with, weld numbered isometric / spool drawing, weld map,
Bill of materials, support location, support detail and any additional information necessary.
The latest copy of the concerned drawing shall be available with the Supervisor/ Foreman/
Fabricator while installation of the piping.
All open ends shall be capped / plugged or covered to prevent ingress of debris / moisture.

4.3.2 Cutting and Bevelling

Cutting/grinding wheel shall be used for cutting and bevelling of metallic pipes. Heat number
shall be transferred to remaining pipe after cut-off and documented, clear identification of
material / spool no. shall be applied.
Weld bevels for butt welds of pipes and fittings shall be in accordance with approved WPS.

4.3.3 Fit-Up and Assembly

Piping components / spools shall be fitted up according to the dimensions given in the drawing
and to the joint details specified in WPS, with in the tolerances. An approved WPS shall be
applied for tacking the weld joints. All the related WPS shall be displayed in the installation
area for easy reference.
All surfaces to be welded shall be thoroughly cleaned from any foreign matter.
Qualified welders in accordance with the same requirements shall carry out tack welding and
full weld on the pipe.
Pipe assembly shall be carried as follows
1. Lift the pipe with the help of a suitable lifting equipment and position it on the pipe
support with proper rigging accessories.
2. Align and fit up the pipe as per the approved procedure.
3. Proper gap shall be maintained between the pipe for the welding.
4. After fit up, welding shall be carried out as per the approved procedure.
5. Welding records shall be maintained with proper identification of joints, welder.
6. After completion of complete welding, joint number shall be marked at locations.

Flange Connections:
1. Thoroughly clean the face of the flanges & the gaskets.
 2. Inspect the gasket (as per approved material) for any damage. Do not use
damaged gasket. Place the gasket in position and hold it in right place.
3. Insert the flange’s bolts.
4. Install washer and apply nut until it is hand tight
5. Number each bolt starting at the top in a clockwise direction.
6. Tighten all the bolts at 60% of the recommended torque using the diagonally
sequence for two rounds.
7. Tighten all the bolts at 100% of the recommended torque value using the
diagonally
8. Do not over torque the flange bolts
9. Calibrated torque wrench with required socket size and torque capacity shall be
used

4.3.4 Inspection of Fit up

All joints shall be inspected visually after completion of the welding to make sure that the
joints are clean, no visual defect present and not distorted.

4.3.5 NDT Pipe Testing Activity (10%)

• Method of Radiography
• Radiographic examination will be carried out in both Day & Night Shifts.
• Radiographic examination shall be carried out by only qualified & certified
Technicians.
• Obtain all required ES&H Induction and required trainings for all RT Crew Members
before entering to Site.
• Notice of Radiography Notifications will be sent out to all contractors at site in
advance.
• Obtain Radiography Permit, relevant Work Permit & RT Request for carrying out
Radiographic examination from ABJV.
• Identify the job & safe distance from job having acceptable radiation level.
• Establish Safe distance and Cordon off area 360° around the job by barricading
(Poly –Rope with Triangular yellow and black flags with radiation warning signs),
 also display radiation warning sign boards & blinker lights at night to avoid
unauthorized personnel in the radiation zone.
• Mobilize the RT Crew to site with radiographic isotopes & equipment.
• Carry out Radiographic exposure for offered welds only.
• After radiographic exposure, carefully retract radioactive source in the projector.
• Demobilization of RT crew from site & keep the source back into the storage pit.
• Developing of films in Dark Room at Site.

5.1 INLINE INSTRUMENTS:

• In-line instruments shall be installed as per the related Project Specification or
vendor's instructions.
• Where flowmeter & sensitive valves are to be installed, care shall be taken not to
damage the bonding sockets and internal gaskets.

5.2 VISUAL INSPECTION:

All joints shall be inspected visually after completion of the jointing to make sure that the
joints are clean, no visual defect present and not distorted.

QC Inspector shall review in accordance to the drawing and to the requirements of the project
specifications. These data shall be entered in the inspection sheet and to be attached in the
Test Pack documentation.

6.0 HSE Requirement:

• The job site should be subjected on the safety rules as mentioned in the Project
safety Procedure.
• During the offloading, lifting, installation of the piping spools I equipment's I
Structures necessary safety measures should be implemented
• Safety meeting shall be conducted prior to any lifting I rigging activity
• Safety boundary and the warning signs should be installed in the lifting I rigging
area and only authorized personnel involvement should be allowed to enter the
barricaded area.
 • Rigging plan should be submitted to all critical lifts
• All works in the installation and alignment works follow the attached job safety
analysis
• Certified cranes only will be used at site. The lifting capacity of the crane, to be
used, will be determined depending on the actual available area for the crane-
lifting radius and weight of the member to be lifted.
• Nylon Belts, as approved by third party and in accordance to the project
requirements, will be used.
• Wherever required, man lifts baskets will be used to hoist up the workers during
the erection. Man-basket inspected and certified by approved third party agency
will be used to transfer the workers to and from high level during erection.

7.0 QUALTY REQUIREMENT:

• Prior to start any Jointing & Installation activities the following documents will be
submitted to client for approval.
• Method statement.
• Inspection & Testing Plan
• All the Jointing works will be carried out as per the approved Project specifications.

8.0 INSPECTION & DOCUMENTATION:

All the inspections & Test documentations will be carried out as per the Inspection & Test Plan
for Installation and Pressure test of SS/CS Pipes & Fittings.
9.0 PRESSURE TESTING OF SS/CS PIPELINE:

A. PREPARATIONS

1. All joints shall be completed prior to pressure testing.

2. All supports, which are direct weld with pipe must be welded prior to test.
3. A ‘test package’ for the loop or section to be tested must be submitted for approval.
4. A formal risk assessment shall be carried out prior to system pressure test.
 5. A proper line check shall be carried out.
6. Bolts of the flanged joints shall be made up to the correct torque value.
7. Punch list A shall be cleared prior to pressure test.
8. High points shall be provided with vents.
9. Check pipe supports if it is installed according to piping isometric drawings. If not,
rectify first the supports before doing the test and water filling. If yes, proceed with
the test.
10. Note: Inline equipments can be kept at open position & tested upon based on supplier
requirements/ABJV requirements.
11. Required temporary piping arrangements like blind flanges and dummy spools will be
installed in appropriate location.
12. Pressure gauges and pressurizing pump are connected to the line at the blind flanges.
The pressure gauge shall be installed at the highest and lowest point of the piping
system being tested. The pressure gauge ranges shall be selected based on the test
pressure.
13. Appropriate PSV shall be used for testing.
14. For hydrostatic testing potable water shall be used as the testing medium and for
pneumatic test compressed air shall be used as the testing medium.
15. Piping section to be tested shall be filled from the lowest point. Vents or other high
point connections shall be opened to expel air from the line.
16. Vents should be closed only when clear water with no air bubbles comes through the
vent. All air shall be removed from the piping system by venting before hydrostatic
test pressure is applied.

B. HYDRO STATIC TESTING

• Only qualified and authorizes personnel shall operate the pressurizing instruments.
• Pipes shall be visually inspected throughout the installation process to ensure the
correct methods are being employed.
• Supervise the test section of the pipeline by qualified supervisor at all times during
the test.
• Measuring instruments to be calibrated prior to its usage.
 • The pipe to be restrained against possible movement from sudden failure at a joint
or connection, and proper support / anchorage to be provided where required.
• Test pressure shall be 1.5 x Design Pressure as per project specification.
• Testing shall be carried out as follows:
▪ At the end where the test is to be applied (lowest end where possible)
a test gauge and pressure pump shall be attached.
▪ At the blank a test gauge and air valve shall be fitted. The temporary
air valve shall be fitted at the highest end of the pipeline being test to
allow trapped air within the line to be removed.
▪ The test gauge at the lowest end of the line shall be monitored for
pressure loss.
▪ The test pressure shall be maintained for a as per client
recommendation.
▪ The pressure test is considered complete after a steady specific pressure
has been held for the required minimum test duration time and the
examination are completed.
▪ If the section of pipeline fails, then the pressure shall be released and
the necessary remedial works carried out and retested.
▪ After testing, ensure that the line is depressurized and drain the line
completely.

C. PNEUMATIC TESTING

• Only qualified and authorizes personnel shall operate the pressurizing instruments.
• Visual examination of the piping to verify that the piping and other fitting are free
of any visual defects, etc.
• Verify that all piping is constructed in accordance with approved drawings.
• Verify that all the lines are installed properly as per requirement.
• All the flanges and other related bolted connections are tight
• Supervise the test section of the pipeline by qualified supervisor at all times during
the test.
 • The test equipment shall be in accordance with the applicable range and shall be
adequate to provide necessary test pressure at a safe rate of increase and it should
have valid calibration certificates.
• The pipe to be restrained against possible movement from sudden failure at a joint
or connection, and proper support / anchorage to be provided where required.
• Test pressure shall be as per project requirements.
• Testing shall be carried out as follows:
• Connect the compressed air to the piping systems with a
regulator and pressure gauge.
• A minimum of two calibrated pressure gauges will be used for
the test One gauge will be on the test Compressor.
• The test pressure shall be maintained for a as per client
recommendation.
• All joints (welded, threaded & flanged) shall be inspected for
leaks with soap suds.
• The pressure test is considered complete after a steady specific
pressure has been held for the required minimum test duration
time and the examination are completed.
• If the test fails, all defects revealed by the test shall be rectified
and a new test carried out until a satisfactory result is obtained
• Care shall be exercised not to allow the system to stand for
higher lengths of time without venting to atmosphere as
temperature variations may cause excess pressure build up or
create a vacuum.
• After testing, ensure that the line is depressurized.
• The system shall then be depressurized gradually in steps by
holding for sufficient time as done for pressurizing before fully
depressurizing.

D. SAFETY PRECAUTIONS

1. Necessary work permits shall be obtained prior to pressure testing.

2. Testing area must have proper signboards to be placed.
 3. To the possible extent, movement of men & equipment should be avoided.
4. Only authorized testing personnel will be allowed in the test area.
5. All precautionary measures stated in the risk assessment shall be strictly followed.

E. PERSONNEL RESPONSIBILITIES

The following are the main tasks to be conducted by experienced personnel.

1. Closing the line ends with blind flanges.
2. Filling the line with water and venting it.
3. Pressurizing the line gradually.
4. Monitoring the pressure and completing the test record.

F. TOOLS & ACCESSORIES

1. Pressure pump with connecting hose
2. Blind flanges with nipple opening for filling, venting and gauge fixing
3. Calibrated pressure gauges & air relief valves
4. Calibrated Torque Wrench for flange tightening
5. Ring Spanners with required bolt head size

G. GASKETS
The gaskets to be used in the test should be Kroll and Ziller type gaskets

10. REINSTATEMENT OF PIPELINE:

1. After completion of pressure test, all the system shall be reinstated as per the
approved drawings.
2. Temporary blind flanges, fasteners and other equipment installed for testing shall
be removed on completion of test.
3. The temporary gaskets installed for testing purpose shall be replaced with original
service gaskets
4. Check for the flow direction of reinstalled inline equipment’s.
5. Ensure that right gaskets are installed for all flanges.
6. Bolting shall be completed and torqued to required value.
7. Ensure that all supports are clamped.
8. Do a final line check