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METHOD STATEMENT
DOCUMENT TITLE:
METHOD STATEMENT FOR INSTALLATION OF JET FUEL PIPING
Date:
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TABLE OF CONTENTS
Doc. No: TAB-BAH-MAD-001 Rev No: 01 Rev. Date: 16-June-2021 Page 1 of 20
1.
SCOPE 3
2.
REFERENCE 3
3.
DEFENITION AND ABBREVIATION 3
4.
RESPONSIBILITIES 4–6
5.
RESOURCES 7
5.1 MANPOWER 7
5.2 EQUIPMENT 7
5.3 MATERIALS 8
6. WORK SEQUENCE / METHODE 8
6.1 GENEREL 8
7. WORK METHODOLOGY / PROCEDURE 8
7.1 MATERIAL RECEIVING, STORAGE AND DELIVERY 8–9
ON SITE
7.2 MATERIAL TRACEABILITY 10
7.3 PIPE INSTALLATION METHOD 10
7.4 ISOMETRIC MARK-UP 10
7.5 CUTTING AND BEVELING 11
7.5.1 CARBON STEEL (C.S) 11
7.5.2 STAINLESS STEELS (S.S) 12
7.6 FIT UP AND TRACK WELDING 12
7.7 BRANCH CONNECTIONS 12
7.8 FLANGE CONNECTIONS 13
7.9 CLEANING OF SPOOLS 13
7.10 PIPE SUPPORTS 14
7.11 METHOD OF WELDING 14
7.12 NON DESTRUCTIVE TESTING (NDT) 15
7.13 PNEUMATIC TEST 16
8. QUALITY 17
9. HEALTH, SAFETY AND ENVIRONMENT CONSIDERATIONS 17
9.1 MANPOWER 17
9.2 EQUIPMENT 18
9.3 SAFETY MEASURES DURING EXECUTION 18
9.4 ENVIRONMENTAL 18
10.APPENDIX 18
This Method Statement describes the specific safe working methods which will be
used by Mad Construction Installation Team to carry out the Jet Fuel Steel Pipe
Works for Project # C108-01, Qatar.
This document covers the scope of work required for the execution of the piping.
The method statement is in the following sequence as the work will be carried out.
2. REFERENCE
Approved Drawings
Inspection & Test Plan
PROJECT MANAGER
CONSTRUCTION MANAGER
Organize the site so that work is carried out to the required specifications with a
minimum risk to men, equipment and materials.
Adhere to the Project Specific Quality Management Program, HSE Requirements,
Method Statements, Project Specification and Drawings.
QA/QC MANAGER
Identify the Projects Specific Quality Requirements, Develop the Project Specific
Quality Plan (Project Quality Plan), Inspection and Test Plan (ITP), Project Specific
Procedures, Checklist and Quality Control Forms and ensure effective
implementation of the same.
Resolving day to day Quality issues with Client or Client Representative.
Organize Project Quality Management Review Meetings and follow up
implementation of the Management decisions/ recommendations concerning
Quality of work and costumer focus.
Ensure compliance with applicable National and International Standards as well as
relevant statutory requirements.
Monitoring/Evaluate the performance in terms of Quality requirements for Sub-
Contractor.
Responsible for the work entire Quality Assurance, Quality Control & inspection
programs.
Produce all Quality related documents & necessary quality reports as requested.
Provide written procedures & to coordinate in formalizing the Method Statement
with the Project manager/Site Engineers to describe the job specific procedure for
each stage/activity.
Direct QC Inspector on site.
Monitor performance of site team to ensure compliance with quality procedure.
HSE MANAGER
Responsible for entire HSE matters and reviewing Hazard Identification (HI), Risk
Assessment (RA) in line with Method Statements for particular activity.
Liaison with Client or Client Representative for HSE issues.
Monitoring the HSE requirements as per Project Specifications and Client or Client
Representative’s requirements.
HSE OFFICER
Ensure that all workers have a safe place of work, advice safe system of work and
provide adequate instructions, training and supervision to enable employees to
work in safety.
Carry out site survey on daily basis to ensure that the HSE Methods of working are
in operation & that all regulations are being observed.
Report, determine & analyze the cause of any accident or dangerous occurrence
and recommend measures for preventing recurrence.
SITE ENGINEER
CHIEF SURVEYOR/SURVEYOR
CHIEF SURVEYOR: Chief surveyor will be in-charge of the Topographic survey. He will
lead the survey team and will coordinate with all the concerned parties and ensure
survey work is in time and with proper quality.
SURVEYORS: The surveyor will be responsible for all survey work and will report to
chief surveyor.
Responsible for daily activities and resources (labor, machinery, material etc...) are
effectively utilized and monitored in order to achieve HSE & Quality requirements.
WORKFORCE (LABOR)
Carry out their work under direct supervision by their Foreman and charge hand
and under instruction from the Site Engineer to ensure all works are undertaken in
a safe manner.
The workforce to attend a daily Tool Box Talks and morning task briefs prior to
starting any new works.
The workforce shall receive a full Project briefing and site rules induction prior to
commencing any work on site.
5.1 MANPOWER
Project Manager
Construction Manager
QA/QC Manager
QA/QC Chief
QA/QC Engineer
HSE Manager
HSE Officer
Surveyor
Site Supervisor
Piping Foreman
Welder Foreman
Pipe Welders
Pipe Fitter
Rigger
Sand Blasters
Operators
5.2 EQUIPMENT
Forklift
DC welding machines (400A)
Air compressor
NDT Equipment
Scaffolding
Pipe Cutter
Hand tools
7. WORK METHODOLOGY/PROCEDURE
Identification code or File number shall be clearly marked on each plate, pipe
and nozzle item by the Material Controller / Storekeeper.
QC personnel shall monitor the transferring of heat number for Stainless Steel
material.
To prevent loss of traceability during paint / coating process, QC personnel shall
make sure that the identification numbers transferred to the QC record prior to
blasting.
Piece marks and weld identification number shall be marked on each pipe /
plate by suitable paint which shall be compatible with the base material to be
marked and recorded on the relevant documents.
The heat number shall be transferred before the Plate or pipe is cut
Color-coding shall be applied for easy identification to permit quick material
handling/
segregation and visual check/ monitoring during construction phrases.
Ensure that the document received bear the stamp Issued for Construction" and
are of latest revision.
The documents submitted/referred with this method statement shall be
considered as an integral part of this method statement and shall be read in
conjunction with the same.
Make sure that all the Quality control and Preparatory meetings, approvals, and
preparations are done sufficiently in advance to start the construction activity
as per the schedule.
All lines shall be clearly marked to easily identify the flow direction service, line designation
number size, class and specification.
The weld map shall be unique and separate for each line, system component or assembly
number.
The line diagram shall include weld location, weld numbers, tie point location, piece
numbers
and weld type, including. Field weld shop Weld, tie point butt joint socket joint fillet weld.
Straight run or pipe shall contain the minimum number of welds. The use of off-cuts in
straight
run shall be avoided.
Care shall be taken to ensure that the longitudinal welds clear branch connections.
All pipes and fittings shall be cleaned before prefabrication by air blowing, in addition, for
large diameters pipe rag cleaning should be conducted if found practical.
Based on spool breakdown of piping isometrics, pipe length shall be cut. Extra length for
pipe shall be provided in spools for field adjustment.
Pipes shall cut using Oxy acetylene cutting or plasma as per project requirement. Flame
cutting of Stainless Steel is not allowed. Stainless steel shall be cut with Stainless Steel
cutting disc. The edge cleaning and beveling shall be done using abrasive grinding disc.
The edges to be welded shall be prepared to meet the joint design requirements by any of
the following method recommended:
Machining or grinding methods shall be used. After cutting, cut surface shall be machined or
ground smooth.
Fit-up assembly and joint alignment shall be carried out, by using couplers or Fit-Up
mushrooms. All the required pipe holding work benches, assembling brackets, 'U
bolts etc. would be made to suit the pipe sizes.
For butt welds a uniform root gap shall be maintained as per WPS.
For all socket weld joints the pipe end shall be free from cutting burrs, the axial gap
between male and female component shall be maximum of 3 mm and minimum of
1.5 mm
All welding ends shall be bevelled with and angle of 35 degrees, ±5 degrees, and a
root face of 1.6mm
Welding end plane shall be normal to pipe axis as defined in the piping drawing,
within 0.25 degree.
The inside misalignment shall not exceed 1.5 mm (1/16)
The maximum tolerance for axial dimensions, face to face, center to face and
locations of attachment shall be ± 3 mm.
Lateral transition of branches and connections from centerline of the run shall not
Exceed ± 1.6mm
Internal misalignment shall be limited to 1.6mm for pipe up to 24”, 3.2 mm for pipe
diameter 26” and above.
In case of pipes with different thickness, the larger thickness shall be tapered in
compliance with standard to match smaller thickness.
Line numbers, Sheet numbers, Spool numbers, material code and Joint numbers are
to be clearly marked on the sp0ols with the welder identification for each joint.
Unless otherwise indicated on the drawings, the bolt holes of all flanges shall be
offset to vertical and horizontal centre lines. The maximum angular deviation of bolt
holes shall not exceed 1.5mm measured across the bolt pitch circle.
The flange faces shall be square to the pipeline in which they are fitted.
Shop fabrication of flanged spool pieces for connection to existing pipe work or
equipment shall have the mating flange tack welded to the spool and an additional
allowance of 10Omm of pipe shall also be provided the correct field fitment.
The fit up of pipe ends and weld neck flanges shall be done to obtain uniform root
opening The criteria given in related WPS shall be followed.
All pipes shall be internally cleaned by air blowing. In addition, for large diameters
pipes rag cleaning should be conducted if found practical.
All prefabricated pipe spools shall be visually inspected for cleanliness, and shall
have foreign material removed from the inside.
The piping ends shall be covered after inspection to prevent unauthorized removal of
the end cover prior to making the joint to the succeeding section of piping.
During installation, the construction agency shall ensure that no foreign materials
(such as welding consumables, lumbers, gloves, etc.) are left inside the piping
System.
After assembly and installation, the piping shall be cleaned inside to remove all loose
material. The cleanliness shall be verified visually and/or by video inspection
techniques.
Fabrication and installation of all pipe supports, hangers, guides and other support
attachments shall be done in accordance with the details in the IFC drawings.
Welding preparations for the pipe to pipe supports and structural steel welding for
pipe Supports shall be in accordance with corresponding WPS.
All pipe support shall be individually identified by number and this number shall be
marked on the piping layout plans.
A 6mm weep hole shall be drilled for dummy supports and shall be located near the
base plate for all vertical dummy supports, and near the run pipe at 6 o clock
position for all horizontal dummy supports.
GENERAL REQUIREMENTS:
It specifies the welding, heat treatment, Non-destructive Testing (NDT), and hardness
testing requirements tor welding pipe lined and related equipment’s to ASME 31.4 and
ASME 31.8, API STD 1104 and ASME SEC IX
CODES AND STANDARDS:
Specific ASME, AWS, ASTM, API Standards.
PROCEDURE OF WELDING:
Before starting welding, the assigned people must wear proper PPE and adequate
safety procedure must be implemented.
All welding electrodes shall be kept in required condition in both storage and
welding.
The ends to be welded shall be properly cleaned to remove paint oil, grease, rust,
oxides sand, earth and other foreign matter. The ends shall be completely dry before
the welding.
On completion of each run, craters, welding irregularities, slag etc. shall be removed
by the grinding and chiselling. Separate grinding wheels and wire brushes should be
used for Carbon steels & stainless Steel.
The welding work piece shall be shielded against high winds and rain.
Doc. No: TAB-BAH-MAD-001 Rev No: 01 Rev. Date: 16-06-2021 Page 14 of 20
The welding face shall be prepared in such a way that, the face must be cut and grind
Smoothly and the imperfections (Slots spatters, surface oxide due to cutting and
rusting) shall be removed from the welding area.
For the fabrication & welding of Stainless Steel pipes, only Stainless Steel tools &
consumables (Wire Brush Chipping, Hammer, and Abrasive disc) shall be used.
The pipe line joints shall be aligned as accurately as possible and the pipe must be
supported properly to avoid bending and displacement during welding.
The fit up joint shall be welded after checked by the QC inspector for acceptance and
registered.
Welding shall be done as per approved WPS for the particular piping. Pre heating
and welding consumable shall be checked before starting of welding
Each weld layer shall be cleaned before starting to weld next layer. The cleaned area
shall be free from slag. Any visual defects like cracks, pores, spatters weld shall be
removed by grinding before the next layer is applied. The ends of weld layer shall be
removed by grinding at take up points of each weld.
All parts that may be affected by the welding operations, such as accessories,
insulation joints and such, shall be adequately protected.
For flange to pipe connections if welding shrinkage can lead misalignment, two
similar flanges shall be joined by inserting a temporary gasket and then welded.
In case of threaded pipes, screw threads shall be concentric with axis pipe with no
blur or stripping. The threading dies shall be sharp and properly designed for the
piping
The criteria of NDT will be in accordance with Project General Specification for different
piping systems. The acceptance criteria shall be in accordance with ASME B31.4, ASME
B31.8, and ASME SEC V.
Welding and NDT records shall be properly recorded and maintained with proper
identification for each welded joint.
NDT shall be carried out as per approved procedure and the results shall be recorded
properly.
Surface irregularities including weld reinforcement, inhibiting accurate interpretation of
specified method of NDT shall be ground smooth.
Safety procedures shall be strictly followed in each NDT procedure, in handling the NDT
equipment’s and work environment.
Identify the test loops for the complete line system wise.
Test packages shall be prepared with all welding / NDT summary, P & ID marked with
Test limits, Isometric drawings, support details etc. for the completed lines of the
system and submitted for client's approval.
Inside of all pipes, valves, fittings and other associated equipment are clean and free
from loose foreign matter prior to commencement of the pressure test.
Upon obtaining mechanical clearance and test packages approval, Pneumatic test
shall be carried out as per project specification.
Test package shall be prepared as per method statement and procedures.
Reinforcing pads shall be tested with clean and dry oil free air for the weld surfaces
on the inside and outside shall be swabbed with a leak testing solution.
Non-return valves, it installed, will require that the piping network be pressurized
from the upstream side.
Two pressure gauges (minimum) shall be used for the test. The gauges shall be
calibrated and certificate attached to test package before pressure test. The
maximum range of gauge will be 1.5 to 4 times of the test pressure.
The Pneumatic pressure test shall be applied system in its entirety or in sections. All
openings in the piping shall be tightly closed by pipe plugs.
The pipe system shall then be applied pneumatic pressure using a compressor.
All the pipes shall be tested at 9 bars for 2 hours and to the full satisfaction of the
engineer
Once the pressure of the line is stable, inspection of the line shall commence. The
test pressure for process or power pipe work shall be for a minimum of 30 minutes
or as required to inspect the line.
In case of leakage, the line shall be retested after repair according to the related
procedure.
When the test has been successfully completed, lines are de-pressurized by
operating vent valves gradually. Then the complete discharging of the system
through the drain valves are taken up, keeping the vent valves always open, the line
shall be de-pressurized and drained completely.
All test blinds shall be removed and the line shall be reinstated with permanent
gaskets.
Each activity shall be inspected and approved as per Inspection Test Plan (ITP).
Ensure that latest approved shop drawings and documents are being utilized.
Ensure that only approved materials are being utilized.
Periodic check of works to ensure the work is accomplished according to Quality
Procedures.
Ensure all measuring devices are regularly calibrated.
HSE site specific induction courses shall be provided to all personnel and visitors
prior on commencing work or visiting the site.
All personnel will wear the required PPE in accordance with site regulations. The PPE
should at a minimum include the following:
Safety Helmet
Safety Glasses
Safety Vest
Safety Shoes
Ear Plugs (when required)
Occupational Health and Safety shall be fully implemented in accordance with QCS
2014 Section 1, Part 10.
The supervisor or foreman responsible for the job will be present at site during
working hours and a safety officer will also be present to monitor the activity.
First aid box will be available at designated areas throughout the site.
Regular tool box talks shall be conducted to explain the nature of works and
associated risks involved.
All plant and equipment shall be inspected by the HSE and the Plant Department
prior to commencement.
M/s Bahadir will also practice a daily visual inspection of all plant and equipment.
All vehicles and equipment used at site will be equipped with revolving lights.
9.4 ENVIRONMENTAL
All personnel will obey to the HSE requirements and will maintain a good
housekeeping on site.
All equipment and materials used on site will be used and stored in a manner
avoiding oil, fuel and sewage spillage. If required adequate dip trays will be
provided until any such leakage is repaired.
Dust control at the work sites is under the responsibility of the Main contractor.
3. APPENDIX
1.1. GENERAL
It is the intention of MAD CONSTRUCTION COMPANY that all work methods and
procedures are carried out in a safe manner in accordance with the Health and Safety At
Work Act and any other relevant legislation.
Health and Safety Data Sheets for all hazardous substances shall be kept in a
file for reference. Site personnel shall be issued with copies of Health and
Safety Data Sheets relevant to their work activities.