Professional Documents
Culture Documents
Method Statement Damaged Spool Replacent
Method Statement Damaged Spool Replacent
FABRICATION
Project Co. :
ROO
EPC Contractor:
TAAM ENG. CO.
Contract PO No.: METHOD STATEMENT FOR
Date of Issue: 04/02/2018
Doc No. : DAMAGED SPOOL
REPLACEMENT & FABRICATION Page 2 of 12
Rev No. :
REVISION HISTORY
EPIC 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
Contract PO No.: METHOD STATEMENT FOR
Date of Issue: 04/02/2018
Doc No. : DAMAGED SPOOL
REPLACEMENT & FABRICATION Page 4 of 12
Rev No. :
1.0 PURPOSE
The purpose of this method statement is to provide a standard for the Repair of Damaged steel piping
constructed by TAAM ENG. in Rumaila Oil Field 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 Rumaila Oil Field. Damaged steel piping 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:
Contract PO No.: METHOD STATEMENT FOR
Date of Issue: 04/02/2018
Doc No. : DAMAGED SPOOL
REPLACEMENT & FABRICATION Page 5 of 12
Rev No. :
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
steel materials will be stored in separate areas on the timber lined floor of the stock area and will be
moved by the use of web slings or by hand into clean timber / rubber lined trestles / work benches. There
shall be no direct contact between carbon steel and stainless steel material under any circumstances.
Tools for use on stainless steel, carbon steel materials will be kept in separate tool boxes under the
control of the material controller and foreman. All tools such as wire brushes, cutting tools for facing
machines will be identified by color codes for carbon steel, and stainless steel materials.
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
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.
Contract PO No.: METHOD STATEMENT FOR
Date of Issue: 04/02/2018
Doc No. : DAMAGED SPOOL
REPLACEMENT & FABRICATION Page 8 of 12
Rev No. :
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
d) Branch reinforcement pads or each segment thereof shall be provided with a minimum 3.0 mm drilled
and tapped whole prior to fitting to the pipe, so ensuring leak detection, venting and testing facilities.
Whenever possible, pad should be made in one piece before fitting onto pipe.
8) In case of stainless steel marking shall be done with weather proof chalk (chloride free crayon), low
chloride marking pen (less than 30 PPM) or engraving.
9) The method will be used for the permanent marking for welder identification, in lieu of marking the weld,
appropriate records shall be filed as per approved inspection procedure.
10) After spool installation, testing and final reinstatement of stainless steels, all markings shall be removed
using an appropriate solvent.
11) Welding material control. This shall be controlled by welding material control procedure
12) Qualification of welders and welding operators.
a) Qualification of welders and welding operators shall be performed in accordance with qualification and
control procedure of welders and welding operators. All welding procedures, welders & reference to be
used shall be qualified in accordance with ASME B 31.3 paragraph 328.2
b) Performance qualifications will be carried out for all welders and welding operators in accordance with the
requirement.
c) All welders should always keep their identification cards at all times with their name and number plus a
photograph, signed by TAAM ENG. surveyor.
d) The qualification limits and ranges for WPS / PQR and welders will to be based on ASME B 31.3
e) The acceptability of the test weld shall be judged as follows. Visual inspection by inspector; Root bead
and surface of weld. Burn thru during application of hot passes and subsequent passes, after visual
acceptance, is cause for immediate disqualification Radiographic examination or bend test in accordance
with ASME B 31.3.
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) Repair welding shall be performed in accordance with piping weld repair procedure and Inspection for
welds shall be examined in accordance with ITP
2) All final examinations shall be performed after any required post weld heat treatment.
3) Root concavity is not permitted. (Too restrictive - follow ASME B 31.3 table 341.3.2, as applicable )
4) Undercut shall be limited the requirement of ASME B 31.3, Table 341.3.2 for industrial piping.
5) The removal of defective areas shall be by machining, grinding, chipping or arc / air gouging followed by
grinding at a depth of 2mm, and The resulting excavation shall be clean, free from scale and have a
contour to permit ease in repair welding, and The repair groove shall be examined, using magnetic
particle inspection to ensure that all defects are removed.
6) NDE and visual inspection for piping should be performed in accordance to ASME B 31.3 and NDE
procedure.
7) All repairs and initial NDE will be completed prior to stress relieving of the pipe spools.
8) The surface of repair welding will be cleaned thoroughly before welding in accordance with applicable
WPS.
9) Prior to repair welding, preheating around the repair area will be as per the approved WPS. Repair
welding shall be performed in accordance with approved piping weld repair procedure and WPS
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.