Method Statement

For
Piping Works at Site
 TABLE OF CONTENTS

1. PURPOSE

2. SCOPE

3. REFERENCES

4. DEFINITIONS

5. RESPONSIBILITIES

6. SEQUNCE OF WORKS

7. QA/QC

8. RESOURCE

9. HSE REQUIMENTS

10. EMERANCY CONTACTS

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1.0 Purpose:
 The purpose of this methodology is to provide a systematic control and direction for the
activity for the installation of piping at site. This method statement provides the expectation to
execute work in safe, eco-friendly manner and in compliance to the ELCREST/NPDC
and Quality requirements.

2.0 Definitions

 Client - ELCREST/NPDC
 QHSE - Quality, Health, Safety & Environment
 QCI - Quality Control Inspector
 ITP - Inspection and Test Plan
 WPS - Welding Procedure Specification
 NDT - Non Destructive Testing
 PWHT - Post Weld Heat Treatment

3.0 Responsibilities
TECHRON ENERGY shall arrange all the resources deemed necessary for carrying out the
works related to the piping installations. In addition to the above TECHRON ENERGY will
also ensure that adequate safety precautions are put in place in order to carry out the job in a
safe manner.

Construction Manager:
The Construction Manager is responsible in executing the works as per ELCREST/NPDC
procedure and approved method statement.

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Supervisor/ Foreman:
 Ensure that welding equipment, baking oven, quiver are in good condition.
 Ensure welding is done as per the approved WPS and approved for construction
drawings and in line with ELCREST/NPDC HSE requirements.
 Ensure that weld maps / spool drawings are available.
 Coordinate with QC personnel to study the cause of any reported weld defects and
arrange to take corrective and preventive action.
 Adhere to the ELCREST/NPDC HSE requirements.
 Comply with ELCREST/NPDC PTW requirements.

QC Inspector:
 Carry out the inspection as per the Inspection and test plan.
 Approving/ rejecting the item based on inspection.
 Submitting the quality records to the client and getting their approval.
 Responsible to keep records of all inspection related activities & Material traceability.
 Adhere to the HSE requirements.

HSE Officer:
 Advise the construction crew on HSE aspects and ensure their safety.
 Arrange through Job performer for tool box talk covering risk assessment in language
understandable by workers.
 Cross checking certified material devices and equipments are used.
 Do weekly, monthly HSE audit.
 Ensure appropriate safety measures are taken as per the risk assessment and controlled
documents.
 Ensure that all staff adhere to the HSE plan and HSE requirements.

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4.0 Sequence of Works
4.1 PTW Issuance
 A Hot Work permit will be issued to carry out the works, along with the permit will be
the attached crane certificate, approved method statement, risk assessment, and
approved drawings shall also be attached.

4.2 Safety Setup

 Arrange the required safety signs, barricades and other related safety precautions
highlighted in the risk assessment and permit prior to commencing the works.
 The works shall only commence after the job performer has checked and ensured that
all safety precautions and safety requirements are in place.
 Ensure employees understand the hazards and control measures related to the critical
activities, i.e. lifting, welding.
 Ensure personnel stay away from lifting zone and do not enter under the suspended
loads.
 Qualified First Aider must be on site and identified by a sticker on his helmet.
 Display Emergency Contact number on site.

4.3 Site Works-Field Joints

 Prefabricated pipe spools shall be carefully loaded and transported to site. The
transported spools will be tied down with ample support to prevent any damage. Spools
will be tied down using nylon straps/belts. Under no circumstances will the pipes be
tied down using chains or cables to prevent any scratches or damage.
 Upon receiving the pipes at site, they shall be offloaded and placed either in position
on the pipe supports or placed on the ground on top of wooden supports. All flanged
ends or open ends will remain sealed to prevent any sand or debris from entering.

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  Lifting of the pipe spools shall be done by using either a HIAB or Crane. Third Party
certified slings and riggers shall be used during the lifting operations. All lifting tools
and tackles shall be color coded based on the current color code.
 Once the spools are lifted into position, the fabricator/pipe fitter shall ensure that proper
alignment is achieved, lengths of spools are correct as per the piping layout and
isometric sheet prior to either bolting the spools together or welding any field joints.
 Welding and grinding of field joints shall be carried out inside a closed habitat made
of fire retardant material. Any live facilities will be covered with the fire retardant
blanket as an additional precaution.
 Welding shall be done as per the approved procedure, specification and approved for
construction drawings.
 Approved welders for the specific WPS shall be used for welding.
 Welded surfaces shall be clean and free from grease, oil, paint or other foreign material
which are detrimental to welding.
 When the weather does not permit satisfactory workmanship welding shall not be done,
on site in windy condition the pipe ends shall be closed to prevent through draughts
during welding. Suitable covering using tarpaulin (fire retardant) shall be provided.
Welding shall not be done when the weld surface is wet or when the area is exposed to
rain and strong windy conditions. Preheating to be done properly during cold weather.

4.4 Site Works - Welding of Pipe Supports

 As required some structural steel pipe supports are to be welded to the base plates
inserted into the precast foundations. Other pipe supports are to be welded to the
existing pipe support structural steel racks.
 Locations to be welded will be covered as required with a fire proof tarpaulin.
 The base plate or support shall be cleaned by grinding to remove any surface debris, or
paint.

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  The support will then be placed in position, aligned, and tack welded. Once tack
welding is completed, the alignment will be rechecked and final welding will be carried
out.
 Welding shall be done based on the approved welding procedure for structural steel.

4.5 Site-Works-Valve Installation

 Where ever valves are to be installed, the installation/orientation of valve handles and
flow direction shall be according to the piping layout.
 All valves to be installed will be cross checked according to the mesc number to ensure
that the proper valves are installed in the proper location.
 Valves shall be installed in the closed position except for ball valves and plug valves.
 New gaskets will be installed between the valve flange and pipe flange. Final tightening
of all nuts shall be done once proper alignment is achieved.
 Bolting of flanges will be done in a cross pattern.
 All bolts, gaskets and valves shall be properly stored to avoid contamination with the
environment. Valve ends will be sealed until installation and gaskets and bolts shall be
kept clean of any debris such as sand.

4.6 Scaffolding
 Scaffolding if required shall be erected by qualified personnel in a safe and suitable
manner.
 Scaffolding above 2 m in height shall be inspected by a scaffolding inspector and a
scaff-tag shall be signed and provided on the scaffolding near the ladder. No one shall
use the scaffolding without the scaff-tag being approved.
 Scaffolding material to be used shall be in good conditions, brass hammer shall be used
to assemble and tighten the scaffolding locks.

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5.0 QA/QC
5.1 Weld Identification
 Each weld shall be uniquely identified with the joint number and welder number.
 After completing the weld the welder shall mark the joint no: & welder no: near the
weld using paint or indelible crayon.
 After welding each spool the line no, spool no & etc shall be marked / tagged on the
spool and stocked over wooden sleepers or other suitable material above ground.

5.2 Non Destructive Testing

 Non destructive testing shall be done as per the approved procedure using approved
sub contractor.

5.3 Alignment Circumferential Welds

 Butt weld alignment shall satisfy the requirement of ANSI B 31.3 and conditions
stated below.
 Internal misalignment of pipe work shall not exceed 1.6 mm in order to facilitate
welding of the root pass. When a GTAW process is to be used maximum misalignment
shall not exceed 0.8 mm. If there is excess misalignment tapering of the internal diameter
of the thicker member to a taper of 1:4 shall be done. Ensure minimum wall thickness is
maintained.
 If misalignment up to 3.2 mm exists, internal grinding or machining may be conducted
to improve root alignment, provided the taper does not exceed 1 in 4 maximum and the
minimum required wall thickness is maintained.
 External or internal clamps shall be used not only for misalignment correction but also
for alignment in general. Misalignment correction using heavy hammering or heating of
the pipe shall not be done.

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5.4 Weld Separation
 Circumferential welds (Girth welds):
Distance between weld shall be measured between the adjacent edges of the cap passes.
Circumferential butt welds (Girth welds) shall be separated by maximum possible distance.
However between fittings, short pipe lengths may be required. In this case, butt welds shall
not be within 75 mm of adjacent girth weld for nominal pipe sizes of 75 mm and above.
For pipe sizes less than 75mm nominal, girth weld shall not be within the greater of 4 times
the wall thickness or one pipe diameter of adjacent girth welds. Girth welds closer than the
above limit shall require approval of the client and may require PWHT solely at the
discretion of the company.
 Branch / Nozzle / attachment welds.
Branch / nozzle and other pressure attachment welds shall have minimum 3” distance to
adjacent pressure welds. Non pressure containing attachment welds shall be separated by
2” from adjacent pressure containing welds.
 Longitudinal seams of adjacent pipes shall be separated by at least 4”.

5.5 Repair Welding

 Any defects which require repair shall be entirely removed to sound metal. Metal shall
be removed 1” on both side of the defect without substantial removal of the Base metal.
 By grinding, the metal shall be removed and the groove shall be smooth without any
undercut. Visual examination and magnetic/dye penetrant test shall be done on the
grove.
 If repairs are done after hydro test / PWHT, the same will be repeated after repair.
Welding repair shall be done only twice. After second repair if the weld is not
acceptable the weld shall be removed, re beveled and re welded.
 Same NDT technique & acceptance criteria for the original weld shall be done after
repair welding.
 Proper cutting disc shall be used. Grinding disc shall not be used for cutting purposes.

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 6.0 Resources
 Welding machine
 Grinding machine
 Preheating torches with propane gas cylinders
 Holding ovens/baking ovens
 PWHT equipment
 Hiab, Crane, trailer
 Cutting tools
 Generator

7.0 HSE Requirements

7.1 Risk Rating
 Risk Rating is Medium: Job will have to be closely supervised by Job Performer, Safety
officer and Supervisor.
7.2 HSE Requirements
 Basic PPE, such as coverall, helmet, safety shoes, gloves, goggles and face mask (during
windy days).
 Appropriate approved PTW and certificate shall be obtained prior to commencing the
job.
 Standby vehicle will be present for emergency purposes.
 Daily TBT
 Approved and valid fire extinguishers (dry powder) shall be available.
 Sufficient cold drinking water to be available at all times.
 Third party certificates of all riggers and cranes
 Proper color coding of all lifting tools, tackles

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8.0 Emergency contacts
TO BE ASSIGNED.

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