` NASSER S AL HAJRI CORPORATION

SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A

CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

CATEGORY METHOD OF STATEMENT

TITLE METHOD STATEMENT FOR PIPING FABRICATION

DOCUMENT REFERENCE NSH-SAOMPP-CMS-PI-001

TABLE OF CONTENTS

1.0 SCOPE

2.0 PURPOSE

3.0 REFERENCES

4.0 DEFINITION

5.0 RESPONSIBILITIES

6.0 MATERIAL STORAGE AND HANDLING

7.0 FABRICATION PROCEDURE

8.0 GENERAL

9.0 INSPECTION

10.0 SAFETY ACTION PLAN

11.0 ATTACHMENTS

0 22/02/2015 For Approval Harikumar Yohannan Chacko Bobby Paul

Revision Date Description Prepared By Reviewed By Approved By
REVISION HISTORY

1.0 SCOPE:

Copies with no seal are Uncontrolled copies. Page 1 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

1.1 The scope of this procedure will provide all details involved in the fabrication and
inspection of pipes and fittings of the pipelines for SAOMPP.

2.0 PURPOSE:

1.1 The purpose of this procedure is to provide a systematic method of performing

Pipe Fabrication Works.
2.2 To ensure that all required inspection and tests have been performed
during construction and the work complies with all project specification and
Drawing requirements

3.0 REFERENCES:

3.1 The following documents are referenced.

API 5L - Specification for Line Piping.
ANSI/ ASME B31.3 - Process Piping
ANSI/ ASME B31.4 - Piping Transportation System for Liquid
Hydrocarbons and other liquids
ANSI/ ASME B31.8 - Gas Transmission & Distribution Piping System
01-SAMSS-010 - Fabricated Carbon Steel Piping.
SAES-L-105 - Piping Material Specification.
SAES-H-200 - Storage, Handling & Installation of externally
coated pipe.
SAES-L-350 - Construction of Plant Piping.
SAES-W-011 - Welding requirements for on-plot piping
SAES-W-012 - Welding Requirements for Piping.
SAES-A-004 - General Requirements for Pressure testing.
SAES-H-201 - General specifications for over-the-ditch external
and internal FBE coating of field girth welds.
SAES-H-002 - Internal & external coatings for steel pipelines &
piping
SAES-A-206 - Positive material identification
ASME V - Non-Destructive Examination

Copies with no seal are Uncontrolled copies. Page 2 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

4.0 DEFINITIONS:

SAOMPP - Saudi Aramco Onshore Maintain potential Program.

NSH - Nasser S. Al-Hajri Corporation

WPS - Welding Procedure Specification

FBE - Fusion Bond Epoxy

NDE - Non Destructive Examination

NCR - Non Conformance Report

5.0 RESPONSIBILITIES:

5.1 Project Manager

Project Manager shall be responsible for the overall implementation of the

company safety & Quality plan and ensure efficient execution of works in
accordance with project specifications.

5.2 Site Construction Manager

Site Construction Manager is responsible for all construction related piping

activities including fabrication accordance with the specified Engineering
Design; Standard, in order to coordinate with all discipline’s activities for comply
with the Specified Project Requirements including safety & Quality. Site
Construction Manager will report to Project Manager.

5.3 QA/QC Manager

QA/QC Manager is responsible for the implementation of all required construction

works and Assured on Quality, in order to meet the project requirement including
Fabrication accordance with the project specified engineering & Standards etc.
and to control for the specified Piping activities including test and inspection etc.
for this particular job. He will coordinate will all discipline heads for this related
activity & report to General Manager.

5.4 Piping Manager

Copies with no seal are Uncontrolled copies. Page 3 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

The Piping Manager is responsible for the total piping fabrication works as per the
project related approved documents at site/shop and plan for the weekly work
schedule and controlling for all the piping works comply with the project
requirement including safety & Quality . He will report to Site Construction
Manager.

5.5 Piping Superintendent

The Piping Superintendent coordinates with personnel at Shop & Site to Plan for
the fabrication of daily, weekly piping works as per baseline schedule, and
allocates the job to the concerned supervisors, and control the piping works
including daily monitoring etc. in all the areas accordance with safety, Quality and
Productivity respectively. He will report to Piping Manager.

5.6 QC Engineer

The QC Engineer will be responsible for the necessary inspections and tests at
shop and specified place and to be carried out for all the activities involved in the
above ground piping fabrication works as per the specified Inspection & Test Plan
(ITP). He will report to QA/QC Manager.

5.7 Piping Inspector

Piping Inspector is responsible to inspect all the piping materials related the
specified areas he will do the dimension check, Grade, etc. as per IFC prior to
fabrication. He will inspect the beveled ends and giving clearance for fit-up etc. He
is also responsible for Calibration of all testing instruments/machineries and using
necessary precision tools etc. to meet accordance with the Quality on specified
piping works He will report to QA/QC Manager.

5.8 Welding Inspector

The Welding Inspector inspects the joint after fit-up and gives clearance for
welding. Once welding is completed, visual inspection will be done and non-
destructive inspection shall be carried out as required by the specification. The
welding report shall be prepared by QC Inspector and submitted to SAOMPP. He
will report to QA/QC Manager.

5.9 Site Supervisor

Copies with no seal are Uncontrolled copies. Page 4 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

The Site Supervisor will be directly involved in the planning and execution of the
activities involved in the fabrication works. He will be responsible for the
preparation of fabrication plan, Safety Action Plan, Safe Work Plan and work
permits if required prior to commence of any activities. He should raise Request
for Inspection (RFI's) to the QC dept. at appropriate stages of the work as detailed
in the ITP. He will report to piping Manager.

5.10 Foreman

The Piping Foreman will be responsible for the direct execution of works involved
in the fabrication process according to the plan and will directly control and issue
instructions to the working personnel. He will provide written instructions to
welders by issuing "Welding Instruction Sheets" that cover the fundamental
requirements of the Welding Procedure Specification (WPS). He will also ensure
that works are performed with proper tools/equipment and good housekeeping
around the working area. He will report to Piping Manager.

5.11 Safety Manager / Supervisor

Safety Manager / Supervisor will make sure that all the safety requirements are
fulfilled prior to start of the job. Job Safety Analysis/Safety Task Assignments will
be strictly implemented by daily basis in order to avoid any loss of time.

5.12 Planning Department

Planning dept. will receive all the drawings from Document Controller and the
same will be kept updating as per the latest revisions. Weld maps will be
prepared. As per the latest drawings, Bill of Materials & Material Take Off
(BOM/MTO) will be prepared which will be forwarded to materials department
prior to Make PR etc. Preparation of weekly, monthly and overall schedule will be
done and the same will be monitored on daily basis accordance with the baseline
schedule and will monitor the daily/weekly/monthly delay concern etc. he will
report to Site Construction Manager & Project Manager.

5.13 Materials Department

Copies with no seal are Uncontrolled copies. Page 5 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

The materials Dept. is responsible for shifting all materials from store yard to
fabrication yard as per material requisition made by fabrication supervisor. Also
the fabrication completed spools shifted to erection site. All the documents and
records in connection with materials shall be maintained for traceability. Records
will be made as per isometrics for material shifting and an updated status of
materials stock and transfer to site will be done on daily basis. Material
department will report to Material Manager.

6.0 MATERIAL STORAGE AND HANDLING:

Material Identification:

Before cutting, required identification markings including material code no. and heat
number shall be marked on each of the cut part of materials by using permanent marker.
For stainless steel materials chloride free marker shall be used.

Storage & Transportation:

a) During the transportation of finished and painted spools to storage area, all
necessary precautions shall be taken to avoid damages.
b) All materials shall be stored on pallets or timber blocks, off the ground and above
level of standing water.
c) Piping components and spools shall be stored and handled in such a manner to
avoid damage or mixing of material types and grades.
d) Stainless steel piping material shall be separated from carbon steel piping
material storage to avoid any contact.
e) Pipes and fittings shall be end capped to prevent ingress of water and any foreign
matter. Threaded ends shall be plugged and sealed with tape.
f) Flange raised face shall be secured from damage by masking tape or plywood.
g) Lifting shall be done by using sling belts for all spools and pipes.
h) Material allocated for fabrication will be shifted to storage area near the fabrication
shop as indicated in the temporary lay out. All stored materials will be covered for
dirt enclosure.

i) Materials will be stacked and stored properly with ends covered for piping and
flange face protected.

Copies with no seal are Uncontrolled copies. Page 6 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

j) Fabrication crew will shift the materials to the cutting area as per requirement.

7.0 FABRICATION PROCEDURE

a) Marking shall be done according to drawing requirement and the same shall be
checked by concerned supervisor prior to cutting.
b) The cutting shall be generally done as follows:
Carbon Steel pipes - By gas cutting & grinding.
Alloy Steel pipes - By grinding or flammable cutting.
Stainless Steel Pipes - By grinding or plasma cutting.
c) Before cutting the pipe Heat Number will be transferred to the cut pieces by low
stress dye stamping, Paint marking or Tagging.
d) End preparation and fit-up shall be done at shop as per the approved SAOMPP
Specification and WPS.
e) Care shall be taken to make sure that longitudinal seams on the joining pipes will
not come in one line in a butt joint. Seams will be staggered at least 100mm apart
and also will clear the branch connections. Care shall be taken to make sure that
longitudinal seams are not resting on the steel structure.
f) Pipes and Fittings for fit-up will be placed on temporary pipe bed and will make
sure that supports are secured properly.
g) Welding of the joint will be done after getting NSH QC fit-up Inspection clearance
and the same shall be offered for SAUDI ARAMCO inspection randomly.
h) All flange connected to equipment shall be tack welded only.
i) Line No, Component Heat No., Joint No., Fit-up inspection signature, Welder No.,
Visual inspection signature and date of welding will be marked near to the joint
with metal paint marker.
j) Spool No. will be marked with paint marker and aluminum tag will be tied to the
spool. Fabrication completed spools will be shifted from shop to lay down area.
k) NDT shall be performed as required by SAOMPPP specification. After NDT
clearance, spools shall be released for erection / painting with release notice.
l) NDT rejected spools will be identified with yellow I black tag and the repair will be
done immediately and NDT will be executed on repaired weld areas as required.

Copies with no seal are Uncontrolled copies. Page 7 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

m) After painting, field inspection shall be offered for SAOMPP and the same shall be
QC recorded in the prescribed format.
n) After painting inspection, the spool shall be released for erection.
o) Stainless Steel fabrication will be done in the shop with an isolated area from
carbon steel and alloy steel.
p) No tools, tackles, equipment will be used for SS which has been used for CS. All
tools and equipment dedicated to SS work shall be clearly marked "For Stainless
Steel" only.
q) For Stainless steel materials, stainless steels tools will be used for grinding,
brushing and clamping etc.
r) Pre heating and PWHT will be done at shop and field as per specification
requirements.
s) All flanged raised faces of completed spools will be fitted with plywood blinds for
protection and spool ends shall be fitted with proper caps.
Fabrication of Pipe Supports:
a) All supports, anchors, guides and other support attachments shall be fabricated in
accordance with details indicated in the pipe support drawings, isometric drawings
and manufacturer requirements, etc.
b) Fit-up & welding shall be done at shop as per the approved SAOMPP
Specification and WPS.
c) Separate storage facility shall be made to store fabricated supports in area wise
and material wise,
d) Fabricated CS, AS and SS supports shall be placed separately with proper
identification like type of support, sequence No etc. with legible marking.
e) After painting inspection, the support shall be released for erection.

8.0 GENERAL

Piping construction works shall be carried out according to the following drawings.
 Plot Plan
 Piping General arrangement drawings
 Standard Pipe Support

Copies with no seal are Uncontrolled copies. Page 8 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

 Drawings for Typical Detail

 Piping Hook-up drawings for instrument and processes.
 Line Schedule
 Piping & Instrumentation diagram
 Isometric Drawings
 Approved spool drawings
Piping materials, construction works & NDT requirements shall be in accordance with
"Project Specifications".
After receiving the isometric drawings from client, Spool generation shall proceed
(Welding maps and piping production reporting)
Planning Department will prepare the monthly plan and program in consultation with
Piping Superintendent and the same shall be given to Fabrication-In-Charge and Material
Controller with the required isometric drawings.
Machine finished surfaces shall be treated with adequate materials to prevent any
damages, rust, corrosion etc. Oil / Grease are not allowed for stainless steel and alloy
piping, in that case pipe end caps shall be used.
The marking shall be done in field for the piping materials for traceability.
Planning Department in consultation with Construction & QA/QC department will give
weekly requirement schedule of electrodes and other consumables to stores for making
arrangement for baking.
QC Inspector shall be responsible for reporting the welding and ensuring that full field
traceability is maintained and quality control methods are applied in maintaining
fabrication in accordance with specification and standards.

9.0 INSPECTION

The QC Inspector will make sure that the inspection is carried out as per the approved
ITP and specification requirement.

10.0 SAFETY ACTION PLAN

10.1 Tool Box/ Safe Work Plan

Copies with no seal are Uncontrolled copies. Page 9 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

 The safe work plan to be prepared by the site supervisor.

 Tool box talks to be observed before starting the work shift to discuss the
Safe Work Plan and other safety concerns for the task.
 Tool box talk shall be conducted by the site supervisor with the HSE officer
assisting and submitting the attendance sheet.
 Work can only start when all the provisions in the safe work plan are fully
complied, to include all safety precautions required.
 All tool box talk attendance sheets must be turned over for submission to
HSE department.

10.2 General Safety Requirements

Personal Protective Equipment’s:

 All personnel (sub-contractor, contractor and client) must wear the project
mandatory PPE (long pants, long sleeve shirt/arm sleeve, hard hat, safety
dark glass, safety clear glass, safety shoes, high visibility vest, hand
gloves).
 Special PPE for face protection, noise, hand protection, dust pollution, etc.
shall be provided to all concerned workers/personnel.
 All PPE must be inspected prior to use.

Housekeeping:

 Unwanted materials/supplies shall be removed from site to ensure clear

access. Temporary material store will be located.
 Proper barricading and signage shall be implemented.
 Maintain proper access and egress for workers, equipment and for
emergency.

Work Environment:

 Drinking water to be provided in 20-liter coolers in the working area, aside

from the water stations.
 During summer months, replacement drink (juice with salt, sugar and
glucose) provided to all workers twice during morning and afternoon to
minimize impact of heat exposure.

Copies with no seal are Uncontrolled copies. Page 10 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

 During high wind where visibility will hamper the operation, Construction
and Safety will advise the workers on approved actions to take.
 Dust control measure shall continue to be enforced at these times.

Tools and equipment:

 All tools shall be inspected color coded prior to use; replace damage tools
from store.
 Electrical tools/equipment must be properly checked color coded before
using (project standard is 110 volts supply/ 220 volts tools shall require
SAOMPP approval).
 Operate the tools according to the operations manual.
 Mobile equipment shall comply all safety requirements and inspected by
respective operators and drivers prior to operation.
 Flagmen shall be deployed to assist the moving equipment.
 All other non-mobile equipment shall be complied with all the safety
requirements prior to deployment.

Permit To Work:

 All permits to work required must be valid and approved before the start of
the job.
 Permit original copies must be in the site; inside the permit box.
 All conditions provided in the permit must be complied and maintained
form the start up to completion of the works.
 For night work, workers list shall be attached on all permits.
 When an unsafe condition or conditions occur, the task will be stopped for
immediate rectification of the condition.

Lifting and Rigging:

 There may be light lifting activity; contractor’s lifting and permit procedure
shall be strictly followed.
 All equipment must have valid certification and color inspection sticker.
 Operator to implement daily inspection with checklist prior to use.

Copies with no seal are Uncontrolled copies. Page 11 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

 Operator must possess the valid SAG heavy driving license, 3rd party
certification and medical examination fit to work.
 Certified rigger to be available during the operation.
 All lifting gears, sling and tackles must have valid certification and color
coding and inspected prior to use.
 Flagman shall be available; equipped with red and green flags and
whistles.

Electricity:

 Lighting facility (tower lights & flashing lights) for night work are provided.
 All energized equipment shall be properly grounded.
 Qualified mechanic/electrician shall be deployed during the operation to
respond the need for lighting relocation, etc. and also to act as fire
watchers.
 Panel boards or extension cords used in site shall be proper checked and
color coded.
 To mitigate tripping hazard, power/electrical cables shall be either installed
in between scaffold planks or elevated in access/egress portions.
 Lightings and generators locations shall be marked in the drawing
attached.

Road/ Traffic safety:

 All vehicles and equipment in the site shall observe strict road safety; that
is follow site speed limit 30kph and 15kph in congested areas, seat belt
fastened by driver and all passengers, pedestrians are respected and
allowed to pass first all the time.
 Passing other vehicles not allowed.
 All headlights on at all times.
 Signboards for speed limit are provided (30kph site speed).
 Crossing signs are provided in entrance and exit gates.

10.3 SAOMPP EMERGENCY NUMBERS

Copies with no seal are Uncontrolled copies. Page 12 of 13

 ` NASSER S AL HAJRI CORPORATION
SAUDI ARAMCO ONSHORE MAINTAIN POTENTIAL PROGRAM- NA1A
CONTRACT # 6600033948
NSH-SAOMPP-CMS-PI-001 METHOD STATEMENT FOR PIPING FABRICATION
Rev-00 Date: 22 Feb 2015

NSH Male Nurse XXXXXXXX

NSH Ambulance driver XXXXXXXX
NSH HSE Manager XXXXXXXX
NSH Construction Manager XXXXXXXX
NSH Project Manager XXXXXXXX
SAPMT HSE Manager/Emergency XXXXXXXX

10.4 Other Specific Safety Requirements:

a) For medical team/facility; Provide certified nurse, certified first aider,

ambulance driver, ambulance (to be parked near the Coker area during
night time).
b) Working in pair (“buddy-system”) is strictly required especially during night
works.

c) Construction to deploy Flagmen (equipped with flags and whistle) in

crossings, diversion access, Coker ramps and washing area.

11.0 ATTACHMENTS

a) Fabrication shop Drawing

b) Plot plan for Laydown Area

END OF THE DOCUMENT

Copies with no seal are Uncontrolled copies. Page 13 of 13