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Method For Spool Piping
Method For Spool Piping
PACKAGE 3
Document No. :
Revision :
Date of Issue :
YANBU II POWER &
WATER PROJECT
Document No. :
Contract No. :
Client :
EPIC CONTRACTOR
REVISION HISTORY
YANBU II POWER &
WATER PROJECT
Title :
Project :
Project Co. :
YANBU II POWER &
WATER PROJECT
EPC Contractor :
TABLE OF CONTENTS
1. PURPOSE
2. SCOPE
3. REFERENCE DOCUMENTS
4. DEFINITION OF TERMS
5. RESPONSIBILITIES
6. SAFETY
6.1 SITE SAFETY
6.2 LIFTING / RIGGING WORKS
6.3 WORK SITE CONDITION
7. GENERAL FOR PIPE FABRICATION
8. FABRICATION SEQUENCE
9. DOCUMENTATION
YANBU II POWER &
WATER PROJECT
1.0 PURPOSE
The purpose of this method statement is to provide a standard for the fabrication of steel piping constructed
by HANWHA in YANBU II POWER & WATER Project. This method statement defines the methods and
processes to be adopted, to ensure that all activities related to the above work are done in accordance with the
appropriate project specifications.
2.0 SCOPE
This method statement describes the general requirements for shop and field fabrication, and inspection of
all piping materials for the YANBU II POWER & WATER project. Pipe fabrication shall be performed in
accordance with the purchaser's Specification, drawings, codes and standards, in order to become higher
Quality of productions by exact operation.
5.0 RESPONSIBILITIES
5.1 The piping manager shall be responsible for the following:
1) Preparation, revision and the implementation of this method statement.
2) Establishment and execution of fabrication and erection schedule and sequence
3) Control of construction documents and drawings
4) Overall site safety management
5) Ensures that all fabrication and erection tasks are done as per specification.
5.3 HSE manager has the overall responsibility regarding development, implementation and monitoring of HSE
program capable of achieving lowest exposure to hazards and accidents on the site.
6.0 SAFETY
painting.
8.2 Marking
a) All materials shall be marked for identification and traceability
b) All materials shall be marked for identification and traceability purposes as follows :
1) Installation area
2) sheet number
3) Spool number
c) The cut pipe spools shall be marked with their respective spool numbers, in accordance with the marked up
fabrication drawing.
d) The method used for marking shall not result in contamination of the Material, significant strain hardening,
or sharp discontinuities.
e) Marking for cutting shall include all dimensions (diameter, Wall thickness, length) and the joint detail of
drawings and be done exactly taking into consideration allowance for welding shrinkage and cutting loss.
f) In case the original identification markings are unavoidably cut out or The material is divided into two or
more parts, the marking shall be Accurately transferred for each pieces prior to cutting to a location Where
the marking will be visible on the completed spool.
3) All materials cut by a flame or arc shall have the edge ground back to clear the affected zone. The grinding
wheel is marked by an impregnated red dye in the make-up of the disc which denotes chloride free
material when used for stainless steel. Wire brushes with stainless steel bristles will be used, dedicated to
stainless steel and high alloy materials. Files for use on stainless steels and non ferrous alloys shall be
NEW and dedicated to a particular alloy only.
4) All edges shall be accurately maintained as per design requirement with a smooth even surface with all
slag removed.
5) Beveling will be performed with a grinder. Separate machines will be used for carbon steel and stainless
steel. Preparation will be in accordance with the approved
6) The preparation of edge for welding shall be done by machining or grinding.
7) Edge preparation shall be performed in accordance with the approved WPS.
8) The surfaces of the edge preparation shall be free from tears, grease, oil slag, scale or internal burrs.
9) Stainless steel shall be beveled by a grinding. Separate machines will be used for carbon steel and
stainless steel.
8.4 Fit – up
1) Alignment for the fit-up of the piping components shall be executed on a steel floor or steel jack stand for
YANBU II POWER &
WATER PROJECT
carbon steel spools. For stainless steel spool fabrication the floor will be covered with wooden planks or
rubber. All stands will be insulated with clean rubber sheeting to prevent contamination of the spools. Under
no circumstances shall stainless steel materials be allowed to come into contact with carbon steel.
2) Pipe shall be properly supported at least 150mm off the ground and aligned by jigs or clamps in order to
eliminate strains prior to tack welding. Where jigs or clamps are used for stainless steel fabrication, these
items will be lined with clean rubber or stainless steel material to eliminate the possibility of contamination
with other project material.
3) The number of welds in a spool shall be kept to a minimum. Minimum spacing of circumferential welds
between center lines shall not be less than four (4) times the pipe wall thickness, or at least 2 inches.
4) The bolt holes of flanges shall straddle the normal horizontal and vertical centerline of pipe.
5) Holes for attachment of weldolets and nippolets shall be performed made using gas torch and all burrs shall
be removed.
6) Adjacent sections of welded pipe that are joined by butt welding shall have the longitudinal weld seams
positioned so that they are least 15 degrees apart.
7) Prior to performing main welds, tack welds shall be done by this procedure
8) Tack welds shall be made by qualified welders.
9) The length and number of tack welds for the diameter of pipe being welded shall be specified as follows
10) Permanent tacks of the desired penetration and workmanship, and conforming to need not be removed
before welding unless handling may have caused the tacks to crack. Any crack tacks will be completely
removed by grinding and grinding areas to be checked by MT or PT.
8.5 Welding
1) All welds shall be performed in accordance with the approved WPS and Welding material control procedure
which shall be displayed on a notice board close to the work.
2) Any cracks, blowholes, cold laps, unusual irregularities, slag, flux, or other impurities that appear on the
surface of any welding bead shall be removed by grinding or chipping before depositing the next
successive bead. In the case of submerged arc welding of carbon steel the removal method used may be
air arc gouging, which shall be cleaned out by grinding to shiny metal.
3) The requirement of the finished weld reinforcement for all materials should comply with ASME B 31.3
specification for piping.
4) If arc strike occurs, this shall be removed by grinding with Company's prior approval. The ground area shall
be inspected by MT (carbon steel) or PT (stainless steels).The remaining wall thickness shall not be less
than the stipulated minimum, as stated in specification or ASME B 31.3 If pipe is ground severely to repair,
the damaged part of the pipe shall be removed.
5) Internal purge of argon shall be used for the GTAW process root pass on stainless steels as specified by
WPS
4) A sealant for threaded piping can’t use Teflon tape except for hydraulics where fluid thread sealing material
shall be utilized.
5) Screwed connections subject to seal welding shall be made without the use of sealing compound.
6) Seal welding of threaded connections shall be done by a qualified welder and seal welds shall cover all
exposed thread.
7) The joint shall be cleaned of all cutting oil and other foreign material and made up dry to full thread
engagement, before seal welding.
a) Thermo wells shall not be seal welded.
b) Seal welded and threaded piping shall not be substituted for socket weld piping connections without prior
written approval by Company.
c) Unless otherwise stated on approved drawing or specifications, pipe Threads shall conform to ASME B
2.1
1) Pipe Heat Treatment shall be performed in accordance with the approved Heat treatment control procedure
Table 331.3.1 of ASME B 31.3 and approved WPS.
6) Spools for installation; all pipe ends will be protected by plywood or equivalent methods attached to
flanges.
7) All threaded nipples and bosses should be protected using waterproof tape or equivalent material to
prevent damage to the threads.
8.13 Painting
Painting for piping shall be performed in accordance with the approved Painting Procedure for onshore
equipment
8.14 Inspection
Inspection will be done in accordance with the Company specification and the approved Inspection and test
plan for shop fabrication of aboveground piping.
9.0 DOCUMENTATION
All relevant documents shall be applied the latest version.
All relevant documents such as AFC drawing, method statement, ITP and HSE presentation shall be
maintained at the work site office.
The inspection and test record or check list verified by QA/QC inspector shall be maintained in QA/QC
office.