SAUDI ARAMCO RAS TANURA REFINERY

CLEAN FUELS PROJECT

(PACKAGE-2-MECH WORKS)

METHOD OF STATEMENT
FOR
TIE-IN NO. 054-061

(EGE-TR-MS-061)
 Revision Number 1 Reference EGE-TR-MS-061
Number
Amendment 0 Date 23-Oct-2018
Document Title METHOD STATEMENT OF PIPING TIE-IN NO. 054-061 AT UNIT
054 FOR RASTANURA REFINERY CLEAN FUELS PROJECT

REVIEW & APPROVAL SIGNATURE RECORD BY EGE

ROLE TITLE SIGNATURE DATE

Prepared by Engineering Dept.

Reviewer 1 QA/QC Manager

Reviewer 2 Safety Manager

Approved by Construction Manager

REVIEW & APPROVED BY TR

ROLE TITLE SIGNATURE DATE

Reviewed by Project Engineer

Approved by Construction Manager

RECOD OF REVISION
REVISION DESCRIPTION DATE
0 ISSUED FOR REVIEW & APPROVAL 13-Sep-18
1 ISSUED FOR REVIEW & APPROVAL 23-Oct-18
 METHOD STATEMENT OF PIPING TIE-IN NO. 054-061 AT UNIT 054
RASTANURA REFINERY CLEAN FUELS PROJECT

Table of Contents

1.0 SCOPE ................................................................................................................... 2

2.0 PURPOSE ............................................................................................................... 2

3.0 DEFINITION & ABBREVIATIONS ............................................................................. 2

4.0 RESPONSIBILITIES .................................................................................................. 2

5.0 MANPOWER.......................................................................................................... 4

6.0 TOOLS AND EQUIPMENT ....................................................................................... 4

7.0 WORK METHODOLOGY ......................................................................................... 5

7.1 Engineering Preparation...................................................................................................................... 5

7.2 WORK to be executed before Shutdown Time for TIE-IN 054-061 ......................................................... 6

7.3 Work to be executed during the shutdown time for Tie-In Work for 054-061.................................. 8

7.4 Post tie-in Activity ............................................................................................................................. 8

8.0 RFI for Layup & Reinstatement ............................................................................ 8

10.0 SAFETY INSPECTION ............................................................................................ 9

11.0 APPLICABLE REFERENCES..................................................................................... 9

12.0 APPENDICES ...................................................................................................... 10

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 METHOD STATEMENT OF PIPING TIE-IN NO. 054-061 AT UNIT 054
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1.0 SCOPE

This Method Statement covers the methodology of Tie-In No. 054-061 pipe spool at unit
054 for Rastanura Refinery Clean Fuel project. The work consists of furnishing of all
supervision, labor, materials, tools and equipment necessary for all Tie-in works.

2.0 PURPOSE

The purpose of this Method Statement is to show the methodology and describe the
sequential steps for execution of Tie-In No. 054-061. It is the intention of this document to
ensure that safe practices are being imposed on the tie-in works considering the protection
and safety of personnel & utilities from hazards that might occur during execution of works.

3.0 DEFINITION & ABBREVIATIONS

TERM DESCRIPTION
A written document that explains the planned execution method
Method Statement to control the work at various stages and to assure quality, and
delivery on time of the work.
Company Saudi Aramco
Contractor TR (Tecnicas Reunidas)
Sub-Contractor EVERGREEN CONTRACTING CO. (EGE)
WPS Welding Procedure Specification
PQR Procedure Qualification Record
ITP Inspection & Test Plan
Work to be performed with piping or equipment out of service,
Cold Tap
depressurized and vented.

4.0 RESPONSIBILITIES

POSITION TITLE ROLE DESCRIPTION OF TASK

Project Manager Coordination & Control Responsible for the over-all direction,
coordination and control of all Tie-In
activities.

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Construction Direct management of Implementation and control of construction

Manager activities as planned and scheduled. Over
site construction.
all responsible for on-time completion of
work.
Project Project planning, Responsible for the overall planning and
direction of craftsmen activities related to
Engineer implementation
Tie-In works including determining method
and Monitoring of works, manpower levels, and equipment
requirement & work schedule. Monitoring of
all Tie-In work related activities.

Piping Engineer Technical Support, Review and interpretation of Codes,

Standards & Specifications, Technical
Monitoring manuals and drawings. Prepare, develop
and/or update work procedure as required.
Provide technical direction to supervisors
assigned to area of work and craftsmen to
ensure work is completed in proper
sequence.
Piping Supervisor Supervision and Involve in the planning, organizing and
execution of all Tie-In activities. Prepare
Execution
safety and quality action plan that must be
implemented and observed during the Tie-
In installation activities.

Piping Foremen Direct execution of the Responsible for the direct execution at site
work. Instruct working and ensure that the work is performed in
accordance with latest approved Tie-In IFC
personnel. drawing and Proper usage of tools,
equipment, wearing of PPE and daily
housekeeping of the work area.

Welding Supervisor Site Supervision Directly in-charge and supervise all welding
work activities. Responsible for the daily
work progress, work quality and safety.
Welding Foremen Take the lead on Directly execute, lead and give instruction to
welders about the assigned work, work
assigned work.
procedure.

Rigging Supervisor Supervision and Responsible for direct execution of the

execution of all rigging rigging works, unloading of materials.
Ensure that lifting plan and procedures are
activities. strictly followed and executed.

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QC Manager Site management, Preparation of QC program & guidelines.

Ensure the work has performed in
program & guidelines.
compliance with approved Project Quality
Plan, TRS Quality documents, Saudi
Aramco Standards & Procedures. Monitor
QC personnel mobilization at site as per
Schedule. Over all responsible of project
quality issues.
Implement QC program and policies.
Supervise the daily QC site activities.
QC Supervisor Site Supervision
Responsible for all site QC matters and
issues.

QC Inspector Inspections, record and Responsible for the necessary inspection

and test to be carried out during Tie-In
document reports
activities. Record and document reports of
all inspection & testing in accordance to the
approved QC-ITP and QC Program.
Safety Inspector Ensure safety for the Responsible in inspection and monitoring
safety aspects and ensure that the work is
proper execution of done in accordance with TR/Saudi Aramco
fabrication activities Safety Standards and EGE Safety
guidelines.

5.0 MANPOWER

The Piping Supervisor will control the activities at the site and he will be directly reporting to
the Project Engineer. The basic manpower under him will consist of the following:

5.1 Piping Foreman

5.2 Pipefitters
5.3 Permit Receiver
5.4 Welding Foreman
5.5 Welders
5.6 Rigger 1
5.7 Riggers
5.8 Heavy equipment operators
5.9 Flag men
5.10 Fire watch
5.11 Helpers & Labors

6.0 TOOLS AND EQUIPMENT

Tools and equipment needed should be in good condition and must be checked by
Supervisor prior to use in the Tie-In area. These includes but not limited to:

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6.1 Welding Machines

6.2 Cold cutting machine (pneumatic cutting machine)
6.3 Grinders
6.4 Hilti Drilling machine
6.5 Nylon Slings
6.6 Chain Blocks
6.7 Pencil Grinder
6.8 Forklifts
6.9 Crane
6.10 Trailer Truck
6.11 Common Hand Tools
6.12 Air Compressor
6.13 Radiography (Weld Joints)
6.14 Hydro test pump
6.15 Flange Tester
6.16 Impact/Torque Wrenches
6.17 Hydro test manifold
6.18 Portable electrodes oven

7.0 WORK METHODOLOGY

7.1 Engineering Preparation
7.1.1 Review all references such as approved Tie-in Procedure and Packages
(construction drawings, project specifications, work permit requirements, and
work procedures Saudi Aramco standards GI-0002.100)
7.1.2 Ensure WPS, PQR, Tie-In packages are TR /Saudi Aramco approved
documentation prior to any tie-in activities.
7.1.3 Ensure drawings are IFC latest revision approved by TR/Saudi Aramco
prior to start tie-in works.
7.1.4 Conduct site verification to determine actual tie-in location and site condition in
reference to Isometric drawings No. CD-363071 SHT.001 rev.01B, P&ID No.
641518 SHT.011 rev.9A1 and Piping Plan NA-821575 SHT.001 rev.03.
7.1.5 Prepare tie-in package with the latest revision of IFC drawings in
reference TR / Saudi Aramco requirements.
7.1.6 Prepare Job Safety Analysis. (shall be submitted separately)
7.1.7 Prepare lifting plan / rigging plan and shall be approved prior to the Tie- In
works.
7.1.8 Ensure that Manifold testing are approved including the verification of the
calculation of the test pressure against existing T min results by Engineering.
7.1.9 Ensure that Relief pressure valves are set as per pressure calibration,
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based on the calculated test pressure.

7.1.10 Prepare Hydrotest Procedure for TRS / Saudi Aramco PMT approved prior
to start of Hydro Testing.
7.2 WORK to be executed before Shutdown Time for TIE-IN 054-061
7.2.1 Inspection of Material
Subcontractor / Contractor will perform during the Receiving form TR
facilities warehouse. The inspection shall be based on SAIS-L-2-29 but not
limited to:
7.2.1.1 Tie-ins pipe and fitting shall have the material specification and grade
stamped.
7.2.1.2 Pipe shall be free of handling and fabrication damages and manufacturing
defects.
7.2.1.3 Support material will have inspected and approved.
7.2.1.4 Inspect the existing pipe in order to perform the tie-ins

Tie-In Information

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NOTE; REFER TO ATTACHED P&ID MARKED-UP HYDRO TEST LIMIT FOR REFERENCE
P&ID DWG. No: NA-641518 Sht.011 Rev. 9A1 & Isometric Dwg, no.CD-363071 Sht.001
rev. 01B.
7.2.3 Pre-Tie-in/Site Activities:
7.2.3.1 Ensure that tie-in site verification has been carried out and tag the tie-in
location.
7.2.3.2 Initial Survey- UT thickness Survey and defect checks
After final cleaning and purging line will be handover to Contractor/Sub-
Contractor for Execution. Activities to carry out to conduct UT that
will be determine the thickness at Tie in location.
Submit and get the approval for Hot WP from company and follow
Operations Safety’s Instructions.
Mark exact tie-in using approved marking method.
External paint material shall be removed carefully from the run pipe
using power buffing in the proposed area.
The pipe surface shall be visually examined to confirm that there is no
circumferential weld with 150mm distance of propose pipe location by
Subcontractor and Contractor QA/QC.
The positive confirmation of wall thickness shall be obtained over the
circumference of existing pipe as per UT scanning procedure.
7.2.3.3 Storage and handling of Tie-ins spools and material

Subcontractor / contractor will perform inspection to ensure all tools

and equipment’s has valid calibration certificate / third party certification.
Tools box shall be placed in designed area in plant included manifold,
hoses.
Ensure equipment operators has valid license/certificate. Crane will
be used to unload the spools at site. After unloading the spools and
material will be inspected by Subcontractor/Contractor and SA
Operations in order to make sure the proper man power for the material
during the transportation from Workshop. Pipe shall be placed on
mounds or sleepers.
Valves, Gaskets, nuts and bolts will be inspected in EGE workshop. They
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will be stored in shipping crates or on racks. ALL material will be handled

with care during shifting to site. All documentation MTC, etc. shall be
carried with the material, isolation valves will be tested at shop.
Below find List of material
Valve
Bolts and nuts
Gaskets Flanges
7.3 Work to be executed during the shutdown time for Tie-In Work for 054-061
(Cold tap Tie-In)

7.3.1 Before any works is done, Work permit must be secured from Saudi
Aramco Operation Department.
7.3.2 Prior to cutting, check that tie-in location is gas free by following HOT
WORK PERMIT pr ocedur e and Operations instructions .
Precaution shall be taken care to prevent ignition of flammable or
combustible materials. Existing pipe will be cut with Cold cutting machine and
mobilized using crane as per approved lifting plan.
7.3.3 Perform PT test on existing pipe bevel at both ends to check for crack
indications or any other material defect.
7.3.4 Lift Reducer 24x36 of CD-363071 Sht.001 in proper position using crane as
per approved lifting plan.
7.3.5 EGE QC will raise and issue fit-up inspection request to TR prior to
commencement any welding works for joints 01 (for CD-363071 Sht.001 rev.
01B.
7.3.6 Hydro test will be conduct after erection of continue drawing’s spools.
7.3.7 RT needs to be performed of field joint 01.

7.4 Post tie-in Activity

7.4.1 Clean the area of construction debris, waste materials, tools and equipment.
7.4. 2 EGE shall close all related work permits.
8.0 RFI for Layup & Reinstatement

8.1 EGE assigned site QC/QA Inspector will perform quality inspection of tie-in
activities as per approved ITP.

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8.2 QC acceptance criteria shall be in accordance to the approved ITP as described in the
project specifications, Saudi Aramco QC Standard.
8.3 EGE assigned QC Inspector shall carry out all the inspection works related to
Tie-In activities and coordinate with TRS-QC representative on daily basis.

9.0 SAFETY ACTION PLAN

9.1 Prior to Start the Job, Supervisor /Foreman have to share the work scope,
identification of work location, associated hazards and mitigation with crew.
9.2 Equipment and Tools should be inspected prior to use and replace if found
defective.
9.3 Supervisor / Foreman / Safety Officer have to ensure the working crew are
wearing the right PPE as per the associated hazards with activities
9.4 Supervisor / Foreman have to ensure continues supply of drinking water at site and
Working crew are drinking the water and taking the rest frequently.
9.5 Supervisor / Foreman / Safety Officer / Permit receive should be available at site to
ensure work is going on safely as per the work permit requirement / JSA requirement.
9.6 Review the attached JSA

10.0 SAFETY INSPECTION

EGE assigned Site Safety Officer will implement safety program and policies at site in
accordance to Saudi Aramco Safety Standards. A Job Safety Analysis will be prepared by
EGE site safety representative for submission to TRS and for review and approval by Saudi
Aramco Ras Tanura Refinery Safety Department before start of tie-in works.

11.0 APPLICABLE REFERENCES

REFERENCE AUTHOR TATLE

SAES-A-004 Saudi Aramco General Requirements for Pressure Testing
Applicable Codes and Standards for Pressure
SAES-L-100 Saudi Aramco
Piping
SAES-L-105 Saudi Aramco Piping Line Class
SAES-L-109 Saudi Aramco Selection of Flanges, Stud Bolts and Gaskets
SAES-L-110 Saudi Aramco Limitations on Pipe Joints and Components
SAES-L-150 Saudi Aramco Pressure Testing of Plant Piping and
SAES-L-310 Saudi Aramco Pipelines
Design of Plant Piping
SAES-L-350 Saudi Aramco Construction of Plant Piping.
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API 598 API Valve Inspection and Testing

ASME B31.3 ASME Process Piping
ASME Section IX ASME Welding and Brazing Qualifications
SAES-W-011 Saudi Aramco Welding requirements for On-Plot Piping.
01-SAMSS-010 Saudi Aramco Fabricated Steel Piping.
01-SAMSS-048 Saudi Aramco Valve Inspection and Testing Requirements.
Disposal of Waste water from
SAEP-327 Saudi Aramco Cleaning, Flushing, and Dewatering
Pipelines and
Vessels
SAEP-351 Saudi Aramco Bolted Flange Joints Assembly
SATIP-L-350-02 Saudi Aramco Saudi Aramco Typical Inspection Plan
GI-0002.100 Saudi Aramco Work Permit System
GI-0002.102 Saudi Aramco Pressure Testing Safely
GI-0002.711 Saudi Aramco Fire and Safety Watch

12.0 APPENDICES

CD-363071 Sht.001 rev. 01B -TIE IN ISOMETRIC DRAWING

NA-641518 Sht.001 Rev. 09A1 - P&ID
ATTACHMENT 2 - Limits mark P&ID
ATTACHMENT 3 - Welder JCC
SATR-L-2001 - Flange Joint Tightening Inspection Report
SATR-W-2006 - Fit-Up Report
SATR-W-2007 - Welding Report
SATR-W-2008 - Welding Summary
JSA - Job Safety Analysis
SIS - Safety Instruction Sheet.

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