Doc No : SEN-MS-MECH-002

PIPING FABRICATION & ERECTION Rev

Page
: 00
: Page 1 of 12

Date : 23 July 2016

SABIC /GAS # MP-15320002

Project Title GAS PHASE IV DBN PROJECT
Client WISON
Location GAS PHASE IV

METHOD STATEMENT
FOR
PIPING FABRICATION AND ERECTION
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Contents
1. OBJECTIVE:.......................................................................................................................................................................3
2. SCOPE: .............................................................................................................................................................................3
3. REFERENCES ....................................................................................................................................................................3
3.1 Project drawings .....................................................................................................................................................3
3.2 Project specification ...............................................................................................................................................3
3.3 Project quality plan (PQP) .......................................................................................................................................3
3.4 Codes and standards ..............................................................................................................................................3
4. ABBRIVIATIONS/DEFINITIONS .........................................................................................................................................4
5. RESPONSIBILITIES ............................................................................................................................................................4
6. PROCEDURE .....................................................................................................................................................................4
6.1 RECEIPT & STORAGE OF PIPE RAW MATERIALS ......................................................................................................4
6.2 PAINTING ................................................................................................................................................................5
6.3 SPOOL BREAKDOWN ...............................................................................................................................................5
6.4 PIPING FABRICATION ..............................................................................................................................................5
6.4.1 Cutting and Beveling ......................................................................................................................................5
6.5 WELDING ................................................................................................................................................................7
6.6 POST WELD HEAT TREATMENT (PWHT) .................................................................................................................8
6.6.1 General ...........................................................................................................................................................8
6.6.2 Post weld heat Treatment .............................................................................................................................8
6.6.3 Precautions ....................................................................................................................................................9
6.7 Inspection ...............................................................................................................................................................9
6.8 Identification.........................................................................................................................................................10
6.9 Storage ..................................................................................................................................................................10
6.10 Pipe Supports, Fabrication ....................................................................................................................................11
7. TOOLS & EQUIPMENTS ..................................................................................................................................................11
7.1 Execution ..............................................................................................................................................................11
7.2 HSE ........................................................................................................................................................................11
7.3 Testing ..................................................................................................................................................................11
8. HSE INSTRUCTIONS ........................................................................................................................................................11
9. ATTACHMENTS ..............................................................................................................................................................12
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1. OBJECTIVE:
The purpose of this generic method statement is to define the procedure for fabricationand
erection of piping.

2. SCOPE:
Scope of this method statement covers the following activities.

• Material handling
• Fabrication and erection
• Welding
• NDE
• Inspection

3. REFERENCES

3.1 Project drawings

• Project drawings.
• Others.

3.2 Project specification

• Applicable Project Piping Isometrics.

• Project Piping Layout drawings.
• Others.

3.3 Project quality plan (PQP)

• Inspection / Testing shall be in accordance with PQP

3.4 Codes and standards

ASME B31.3 Process Piping

ASME B31.1 Power Piping
ASME Section V Non Destructive Testing
ASME 16.25 Butt Welded Ends
ASME 16.5 Pipe Flanges and Flanged Fittings
SNT-TC-1A Guidelines of American Society of NDT
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4. ABBRIVIATIONS/DEFINITIONS
CL Client
PM Project Manager
SM Site Manager
CM Construction Manager
DE Discipline Engineer
QA&QC Quality Assurance &Quality Control
QCI Quality Control Inspector
PQP Project Quality Plan
PPE Personal Protection Equipment
HSEP Health Safety & Environment Plan

5. RESPONSIBILITIES
 It is overall responsibility of PM/SM to organize resources to performconstruction
activities as per project specification, in compliance with quality,schedule & HSE
requirements.

 It is the responsibility of CM that construction activities are executed accordingto the relevant
project specifications, in compliance with quality, schedule& HSE requirements.

 DE will ensure that all the works are performed safely as per latest Approvedfor
Construction (IFC) drawings & specifications.

 The relevant DE and Supervisor will ensure that all the piping work is conducted in
accordance with this method statement and project specifications.

 The QCI will ensure that all work is executed according to PQP and thatrequirements of
quality dossier are full filled.

 HSE and construction supervision will be carried out under responsibility ofClient.

6. PROCEDURE
6.1 RECEIPT & STORAGE OF PIPE RAW MATERIALS

 The All piping material received from client shall be offloaded in designated lay down
yard.

 During offloading, pipes shall not be dropped on the transport. A crane andsuitable
certified slings shall be used. Nylon slings will be used to handle SSand coated piping &
fittings.

 The pipes shall be placed on concrete blocks with wooden packing in between..

 The piping end covers shall be kept in place to prevent foreign particle entryinto the
pipes.

 All material shall come with color-coding as per size, material & schedule.
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 The piping material shall be segregated accordingly to facilitate location of the items.
SS, Low Temperature CS, CS and Galvanized pipe &fittings to be stored separately.

6.2 PAINTING

 Painting shall be done according to project specifications.

6.3 SPOOL BREAKDOWN

 The piping isometrics shall be marked into number of spools to facilitate thefabrication
& erection work.

 Each spool shall be marked with a unique number.

 Each joint on the isometric will be given a unique number preparing a weldingmap for
traceability. Separate numbering system will be followed for butt welds,fillet welds,
threaded joints etc.

 The details of piping isometric breakdown into spools and joints will berecorded for
reference.

6.4 PIPING FABRICATION

 Material will be shifted from WISONto SendanLay downwork shop as per relevant
pipingisometric drawings.

 Carbon steel, low temperature carbon steel, stainless steel pipefabrication work will be
done in separate areas.

 Tools & equipment compatible with the material in fabrication shall be used.

 The piping material is to be used in a appropriate and economical way.

 All cuttings should be collected separately as per material code and place in orderto
make best use of these.

 Cuttings of other then alloyed material may be considered as waste up tomaximum

1000mm, and should be stored separately.

 Pipes for socket weld joints shall be cut square.

6.4.1 Cutting and Beveling

6.4.1.1 Butt Joint
 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 theisometrics.
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 Based on spool break down of piping isometrics, pipe lengths shall be cut100mm extra
length for pipe will be provided in spools for field adjustment.

 Thepipe ends for 2 inch & above shall be beveled as per approved WPS for thepiping
class.

 The cutting and beveling of pipes shall be done by mechanical means coldcutting
beveling machine/lathe machine, flame cutting or plasma/arc cutting,cutting shall be
acceptable provided the edges smooth.

 When torch cutting or arc cutting are used for alloy steel or stainless steel, aftergrinding
to sound metal a dye penetrate examination shall be performed toeliminate the
possibility of surface cracks.

 The fit up of pipe ends, fittings & weld neck flanges shall be done to obtainuniform root
opening. The criterion given in related WPS shall be followed.

 The joint should be free of grease, oil, scales, rust or other foreign material.

 The primer paint coat on pipe & fitting ends shall be removed prior to bevel
endpreparation.

 The pipes shall be tack welded by a qualified welder. If the pipes are of
differentthickness, the larger thickness will be tapered in compliance with standard
tomatch the smaller thickness.

 The adjacent section of longitudinally welded pipes that are to be joined by butt
weldsshall have longitudinal weld seams positioned such that they are at least30° apart
from horizontal centerline. The fabricator will also not locatelongitudinal weld seams on
top or bottom of the pipe so that branchconnections are not located on the seam.

 Reinforcement pads shall be fabricated only if required in the isometric. Thematerial for
reinforcement pad shall be same as that for the pipe unlessotherwise authorized by
Client. The size & thickness of pad will be as specifiedin the isometric. It is preferable
that the pad shape is circular; however, the padsize may be altered provided equivalent
cross-sectioned area is maintained asper ASME requirement. The pad shall have a 1/8”
NPT vent hole, drilled &tapped to NPT prior to installation of reinforcement pad.

 The Flanges indicated on isometric to be supplied loose should be tack weldedwith the
pipe. Full welding shall be made after site checking.

6.4.1.2 Socket Joint

 The pipe for welded sockets joint shall be ground to remove burrs due to cutting. A gap
between end of pipe & bottom of socket will be maintained as perProject Specifications.

6.4.1.3 Threaded Joint

 In case of threaded pipes (for utilities piping only) screw threads shall be concentric with
axis of pipes with no burrs or stripping. The threading dies shall be sharp & properly
designated for the piping material.
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6.4.1.4 Galvanized Pipes

 The pipe work 3 inch & larger shall be fabricated in flanged spools as per design. The
size of spools shall conform to dimensions of hot dip galvanizing bath. The same shall
be galvanized from both inside and outside.

 The threaded joints of galvanized pipes shall not be seal welded. Tape/sealant will be
used as per project specification.

6.4.1.5 Material Traceability

 Material traceability shall be according to the Method Statement of material traceability.

6.5 WELDING

 All welding work will be according to approved WPS and B31.3 and only qualified
welders shall be employed.

 Heat treatment will be indicated on WPS, where required.

 The welding work piece will be shielded against high winds and rain. The windspeed
exceeding 10 m/sec and 3 m/sec for SMAW & GTAW respectively.

 The weld surface shall be cleaned with wire brush or grinding prior to weldingoperations
to give a surface free from rust, scale or mill coating.

 Between each layer of welding any cracks, pores or welding spatters shall beremoved
by grinding the surface before application of next layer.

 The appearance of finished welds shall conform to ASME B31.3 code & WPS and shall
exclude any under cuts, spatters, and cracks.

 All branch connections shall be joined to headers with full penetration welding.The bore
side shall be ground smooth, free from cracks.

 For flange to pipe connections if welding shrinkages can lead to misalignment,two

similar flanges shall be joined by inserting a temporary gasket and thenwelded.

 For socket welding the pipe ends shall be cut straight.

 The distance between centerlines of adjacent girth butt welds and staggering of
longitudinally welded pipe for making butt weld shall be according to project
specification.

 Preheating shall be done in accordance with the welding requirement related toeach
class of piping base metal material.
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 Welding shall be performed to ensure complete fusion of the weld deposit andthe base
metal in order to obtain homogeneous bound over the entire crosssection area of the
weld.

 Welding current and polarities shall comply with the instructions given by
themanufacturer of the filler metal.

 Number of layers shall never be less than two.

6.6 POST WELD HEAT TREATMENT (PWHT)

6.6.1 General

 Before starting any heat treatment process, it will be checked that welding hasbeen
completed.

 The temperature can be checked with the aid of thermo-chrome crayons

orthermocouples.

 The preheating temperature shall be maintained throughout the welding cycleand it

should be done over sufficient width on either side of welds.

 If ambient temperature of 0 C or below preheating is mandatory even if notspecified. No

heat treatment is required for austenitic stainless steel.

 Thermocouples and their location on the job to be heat treated shall bechecked.

 Calibration certificates of the heat-treating equipment shall be checked.

6.6.2 Post weld heat Treatment

 Stress relieving shall be performed as per project specification when specifiedfor

relieving residual stresses caused by welding, cold working etc.

 Stress relieving shall be performed when specified to obtain softer, more ductilematerial
than

 is obtained by stress relieving. Normalizing is the usualcommercial annealing operation

for
 low carbon steels. It shall be formed asfollows.
A) Heat material up to 1650F
B) Hold at temperature one hour per inch of thickness (but not less than1/2 hour).C) Air
cool at room temperature. Normallyaustenitic stainless steel is not stress relieved, if
relief of stress ismentioned in the project specification, that a full anneal shall be
specified.
 Full annealing of austenitic stainless steel shall be performed when specified toobtain
solution of carbides and maximum softness and ductility with adequatecorrosion
resistance. It shall be performed as follows.

 Heat material to 2000F).

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 Hold at temperature one hour per inch. of thickness (but not less THAN1/2 HOUR).
 Water steam or air blast quenched to room temperature. (If distortion isexcessive rapid
air cool may be used, although this will result indecreased corrosion resistance).

 Annealing shall be performed when specified to obtain maximum softness andductility.

Full annealing is used on low carbon steels only where maximumformability is needed
but is used on medium carbon and low alloy steels wherenormalizing may not produce
the desired properties. It shall be performed asfollows:
A) Heat material to 1750F
B) Hold at temperature for one hour slow furnace cool to 1000F.
C) Air cool from 1000F to room temperature.

 When local annealing is applied the zone to be heated to annealingtemperature shall be

at least four times as wide as the weld.

 No further heating or welding shall be done after annealing.

 For welding sensitive materials a hardness test shall be performed to evidencethat

annealing was carried out perfectly.

 After heat treatment hardness of weld will be checked as per specification (ifrequired)
and hardness test report shall be prepared.

 A record of temperature levels and period of treatment should be maintained

forreference.

 After completion of process resultant graph of time and temperature will beverified and
heat treatment sheet shall be prepared.

6.6.3 Precautions

 Heat treatment operations involve electrical heating up to 2000°F bringinghazards of

burning & electrocution due to a lot of cables & other electricequipment. Following
precautions shall be taken.

A) Appropriate visual & physical barrication of area to avoid unauthorizedpersonnel's entry

B) To avoid physical hindrance due to other nearby activities.
C)Warning signs / boards shall be installed on barrications.
D) Proper dressing up of cables through appropriate routes to avoid entangling with other
activities.
E) ELCB’s shall be installed on power supplies.

6.7 Inspection

 The fabricated pipe spool shall be checked against project drawings to verify itscompliance.

 The dimensions, angle and direction of spool and allowances for field weldingshall be according
to the ASME B.31.3 (chapter V).

 NDE shall be performed as per ASME section V after PWHT if specified onisometric drawings
or project specifications.
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 The acceptance criteria for visual inspection shall be done according to theASME B.31.3.
(Chapter VI).

 Visible small transverse cracks & star cracks of limited thickness shall beremoved by grinding &
repaired by welding. However circumferential cracksshall result in weld rejection. The defective
material will be cut out & re-weldingpreformed.

 NDE tests shall be performed & recorded as per Project WeldingSpecifications.

 The NDE result shall be interpreted by qualified inspectors (level II).

 Branch connections shall be examined by dye penetration or magnetic particleor ultrasonic

methods

 All welding records for each joint shall be maintained throughout the fabricationwork.

 Low temperature carbon steel material traceability shall be maintained throughout the
fabrication work such that location & heat numbers of all weldedpressure retaining pipe
component is maintained. Permanent marker willtransfer the heat number to all pieces cut from
main pipe.

6.8 Identification

 Each fabricated spool shall be clearly marked with a number. This number shallinclude
line number & spool number as shown on the piping isometric. Forpiping up to diameter
6 inch it will be hard marked on to a steel plate 2x 3x 1/16inch, which shall be securely
wired to the pipe. However for piping greater than6 inch diameter the number will mark
on inside of the pipe using a permanentmarker.

6.9 Storage

 The pipe spool complete in all respect shall be stored separately.

 All spools shall have their identification/piece number clearly designated oneach spool.

 The spool will be cleaned in an inclined position by tapping so that all foreignmaterials
are removed.

 The spool shall be placed on wooden baton to avoid direct contact with soil.

 The open ends shall be covered by polyethene sheets or end caps. In case offlanged
spools the same shall be covered by securely tied wooden blanks toavoid foreign
material entering the pipes.

 The spool shall be handled using nylon lifting slings.

 Alloy / SS to be stored separate form CS.

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6.10 Pipe Supports, Fabrication

 Pipe support as specified on isometrics & general arrangement drawings shallbe

fabricated according to pipe support detail drawings.

 The fabricated support shall be painted after surface preparation as per project
Specifications.

 The procedure of welding pipe support attachments to pipe work shall begenerally
similar as that for pipe work and qualified welders shall be employed.

 Pipe support welding on piping requiring PWHT shall be done prior to the heattreatment.

7. TOOLS & EQUIPMENTS

7.1 Execution

 Hand Tools
 Cutting, Beveling & Grinding Machines
 Cranes (Mobile)
 Welding Diesel Generator
 Hack Saw
 Trailer
 Welding Set
 Cutting Set
 Magnetic Drill

7.2 HSE

 Safety helmet
 Safety belt
 Safety Goggles
 Gloves
 Safety Shoes
 Welders Helmet
 Ear Plugs/Muffs (if required)
 Dust mask (If required)

7.3 Testing

 Radiography
 Ultrasonic Testing
 Magnetic Particle Testing
 Dye Penetrant

8. HSE INSTRUCTIONS
 During execution of the job all measure shall be adopted to ensure safe working.
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 Client site management system (latest revision) will be implemented.

 All personnel involved will use necessary PPE as required.

 The workers will be made aware of HSE requirements related to this activitythrough
daily, weekly and monthly toolbox and HSE talks.

 HSE notice board will be installed.

 All equipment will be inspected by HSE (SENDAN) prior to use.

 During transportation of pipes and other fittings, the material shell be properly supported
and tied on the Trailer.

 Ensure that pipes are properly wedged or blocked to avoid rolling.

 Correct rigging procedure should be observed.

 Properly insulated and nonconductive tools should be used for electric work.

 Access and good housekeeping should be maintained in all fabrication areas.

 Fire extinguisher should be available in all working areas.

 Proper storage, handling and use of gas cylinders will be observed.

 All cylinders shall be kept in trolleys and in an upright position.

 Wild and domestic life should not be harassed.

 Welding sets should be checked and maintained regularly for wear and tear.

 Waste Management should be strictly followed to keep the job site neat and clean.

 Never monkey with electric cables and appliances.

9. ATTACHMENTS
Nil