KINGSVILLE @ KALLANG WAY

METHOD STATEMENT
FOR GAS SYSTEM

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METHOD STATEMENT FOR:

CONTENTS:

1. INTRODUCTION
2. SCOPE OF WORKS
3. MATERIAL
4. PIPE INSTALLTION & TESTING

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METHOD STATEMENT FOR:

1. Introduction

This method statement explains about the installation and testing of Gas pipe
works.

2. Scope of work

The scope of works for gas pipe installation above ground &underground are as
follows;
 Obtain relevant permits from Main Contractor’s Safety Department

 Mobilization of Machineries/Equipment

 Installation of Town Gas System in compliance with the latest relevant

code of practices SS 608 installed in Gas Pipe

 Testing and Commissioning of System

 Demobilization of Machineries/Equipment’s

3. Material

3.1.1 Material for pipes and fittings:

(a) Pipes and fittings –

 API PIPE & FITTING -Gas pipe seamless steel pipes
complying with API 5L Grade B schedule40.
 PE PIPE& FITTING - complying with BS EN 1555
 GI PIPE & FITTING - Gas pipe complying with BS EN 10255
& Fitting complying with BS EN 10242

(b) Ball valves –All brass ball valves complying with BS EN 331.

(c) Gate valves –All gate valves complying with BS EN 13774.

3.1.2 Types of joints for pipes and fittings:

(a) Pipes and fittings – (i) API pipes and fittings - Welded joints.
(ii) GI pipes and fittings – Threaded joints.
(iii) PE pipes and fittings –Electro Fusion joints.

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(b) Ball valves – Threaded joints.

(c) Gate valves- flanged joints

3.1.3 Type of joints (Transition joint) for change of materials.

(a) Threaded joints – Pipes 80mm and below.

(b) Flanged joints – Pipes 100mm and above.

4. Pipes Installation Work:

4.1.1Pipe laying (Underground):

(a) Underground gas mains shall be installed with a minimum cover of 1

meter unless specified otherwise, where an underground structure or
service prevents the installation of the main with the minimum cover, it
may be installed with less cover if it is provided with additional
protection to withstand anticipated external loads or damages.

(b) The pipe shall be laid with a fall gradient of 10mm in 2 m to the main, if
the Relative levels will allow. Where this is not practicable, a syphon
should Be provided for the removal of condensate from the lowest point
of the Pipe, the pipe having a fall to this point from both directions.

(d) A service valve (SV) shall be installed in a position preferably outside,

Either buried or exposed but as near as practicable to the building.

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(e) A surface box and ductile cover to BS 5834 shall be placed over the
siphon Standpipe and service valve.

(f) After the pipe had been laid, electronic markers have to be attached to all
tees, bends and at 30 meters apart along the pipeline; these markers are
for future locating of the pipeline.

(g) A layer of quarry dust has to be backfill up to 300mm above the pipe,
follow by a strip of approved PVC protection strip.

(h) The PE pipe shall end with a stud flange to connect to the API pipe.

4.1.2 Pigging of pipes:

(a) All pipes laid will have to be pigged to remove debris in the pipes.

(b) One end of the pipe will be inserted with a pig and blanked off;
compressed air will be introduced to push the pig through the pipes.

(c)The other end of the pipes will have to be left opened to allow debris
and the pig to exit from it.

4.1.3 Under Ground Pressure Testing Of Pipes:

(a) The testing medium shall be air.

(b) A pressure gauge range from 0 to 200 kpa should be used.

(c) The air pressure in the pipes shall be raised to the test pressure of 140kpa

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(d) The pressure shall not be any fall in the test, After period of not less than
10 minutes

(e) The pressure test shall be left for duration of 24 hrs.

(f) If there is no fall in pressure as registered on the pressure gauge at the

end of 24 hrs. The system is considered satisfactory.

(g) Witness by Consultant /RE/RTO for the tested piping before releasing air
pressure.

4.2 Pipe laying (Above Ground):

Main activities
 Materials inspection by RTO and representative from Main Contractor to be
cleared before it is allowed to be used for installation.
 Marking out of Pipe Routing on Wall and Soffit in accordance to the
Approved Shop Drawings.
 Installation of Pipe: Galvanised Iron (GI) Pipe and American Petroleum
Institute (API) Pipe.
 Hot Work – Cutting of API Pipe and Welding of API Joint.
 100% radiography examination (X-ray) for API pipe routing in accordance
to API 1104 Standard.
 Air Pressure Testing for Gas Pipe Routings.
 Painting and Labelling works.
 Jacketing of API Gas Pipe Routings within false ceiling spaces.

4.2.1 Method Statement for Installation of API Pipe

 API Pipes within false ceiling spaces (e.g. lift lobbies, false ceiling) shall
be boxed-up with sheet metal sleeve, as known as Jacketing in the industry.
 Ball valve shall be installed at each dropper point at kitchen.
 Check the position of pipe routing layout from approved drawing.
 Use the pipes and fittings that are approved by the Authority and
Consultants as per submitted approved samples.
 Preparation of all needful tools and materials.
 Using a marker, mark the route of the pipe on the slab soffit as per
approved drawing.
 Using a drill and drill bit of 10mm, drill the ceiling to a depth of 40mm of
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the marked position. Always hang up the electrical cables to prevent others
from tripping on the wire.
 Mount the wall plug into the ceiling.
 Tightened a galvanized iron threaded/stud rod to the wall plug and to one
end of the rod.
 Tightened the other end of the rod to the bracket.
 For every two to three meters of API pipe routing, install a bracket.
 After all the brackets are installed, ensure the pipelines are straight for
smooth installation of API pipe.
 Measure the API pipe and cut according to the required dimensions.
 Install the API pipe to fit onto the brackets

4.2.2 Hot Work: Cutting And Welding Work: (Description of Activities)

a) General
 Check all pipes and fitting to be used for free from defects, dents or
deformities and straight. Remove pipes and fitting with defects and
replace with acceptable materials.
 Remove foreign matter or dirt from inside of the pipe and fitting before
fit up.
 For longer work breaks, place suitable stoppers to prevent debris, earth or
water from entering pipe open ends.
 Argon welding set shall be stored and handled as per manufacturer’s
instructions.

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 There will be three types of welding method to be used for this project,
namely: 1) Fillet Welds, 2) Groove Joint Design and 3) Welding
Sequence as shown below as Figure 1:

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b) Pipe to Pipe Fit Up: To be done at ground level before bringing up by

means of Mobile Elevating Work Platforms (MEWP): E.g. Scissor Lift,
Boom Lift for High Level Installation
 Lay the two pipes on top of the pipe stand or adjustable support, with each
pipe each pipe ends aligned near each other using adjustable bolt stopper as
show on Figure 2 below.
 Level one length of pipe using spirit level for the parallelism.
 Weld the joints together leaving only a small welding gap for continuation
of welding when sections are hang at high level. In normal practice, argon
welding of 2.4mm diameter size, removed of its covering and bent in the
middle at an angle of 30 degrees is inserted between the two pipes to obtain
a perfect welding gap. It is recommended to weld adjustable bolt stoppers
(small piece of plate about 12mm thick with an m-16 hexagon bolt and nut
welded at one end as shown in Figure 2) for perfect and easy alignment.
 Remove the adjustable bolt stoppers after fit up and grind flush all tack
welded points making sure that there is no over grinding of the base metal.
 Place the spirit level over both pipes as shown on Figure 2 and maneuvre
until both pipes are levelled. Adjusting the pipe support can easily do this.
Ensure that there is no high-low situation or misalignment between the two
outside surfaces.
 Tack weld at the top bottom.
 Rotate the pipes 90 degree.
 Repeat the same procedure.

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c) 45 Degree Elbow to Pipe Fit Up: To be done at ground level before

bringing up by means of Mobile Elevating Work Platforms (MEWP): E.g.
Scissor Lift, Boom Lift for High Level Installation
 Lay one (1) pipe on top of the adjustable pipe support.
 Level the pipe using spirit level.
 Place the 45-degree elbow to the end of the pipe leaving a small welding
gap, similar to item 4.3.3 for pipe to pipe fit up.
 Place 45-degree spirit level on the face of the elbow until bubble is
centered and ensures that there is no high-low situation or misalignment
between the two outside surfaces.
 Tack welds in place both the pipe and the elbow.

d) 90 Degree Elbow to Pipe Fit Up: To be done at ground level before

bringing up by means of Mobile Elevating Work Platforms (MEWP): E.g.
Scissor Lift, Boom Lift for High Level Installation
 Lay one (1) pipe on top of the adjustable pipe supports.
 Level the pipe using spirit level.
 Place the 90-degree elbow to end of the pipe leaving a small welding gap
the same as item 4.3.3 for pipe to pipe fit up.
 Place a spirit level on the face of the elbow and maneuver the elbow until it
is levelled and ensure that there is no high-low situation or misalignment
between the two outside surfaces.
 Tack weld in place both the pipe and elbow.

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e) Tee to Pipe Fit-Up: To be done at ground level before bringing up by

means of Mobile Elevating Work Platforms (MEWP): E.g. Scissor Lift,
Boom Lift for High Level Installation
 Lay one (1) pipe on top of the adjustable pipe supports.
 Level the pipe using spirit level.
 Place the tee of the end of the pipe leaving a small welding gap the same as
item 4.3.3 for pipe to pipe fit up.
 Place a spirit level on the face of the tee and maneuver the tee until it is
levelled and ensure that there is no high-low situation or misalignment
between the two outside surfaces.
 Tack weld in place both the pipe and tee.

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f) Flange to Pipe Fit-Up: To be done at ground level before bringing up by

means of Mobile Elevating Work Platforms (MEWP): E.g. Scissor Lift,
Boom Lift for High Level Installation
 Lay one (1) pipe on top of the adjustable pipe supports.
 Level the pipe using spirit level.
 Place the flange of the end of the pipe leaving a small welding gap the
same as item 4.3.3 for pipe to pipe fit up (In case a weld neck type of
flange is used). If a slip-on type of flange is to be used, insert the pipe to
the flange bore up to 5mm depth from the flange face to give enough space
for a fillet weld.
 Place a spirit level on the face of the tee and maneuver the tee until it is
levelled and ensure that there is no high-low situation or misalignment
between the two outside surfaces.
 Tack weld in place both the pipe and flange.

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4.2.3 X-Ray Test:

a) Testing Equipment:
Team Accessories:
o Survey Meter.
o Barricade Signed Boards (>4).
o Barricade tape/rope (>100ft), (Yellow & Black)
o Warning lights (>4).
o Whistle.
Radiation Equipment:
o Gamma Projector
o Winding cable, Extension tube & Guide tube
o Collimator (if necessary)
o Magnet stand.
o Radiographic Films.
o Masking Tape.
o Lead letters / numbers.
o Penetrometer (IQI).
o Measuring Tape.
o Timer.
o Torch-light.
o I/Cs, Passes, License.
o Markers / crayons.
o Radiation safety procedure.
METHODOLOGY:
1 Radiography site supervision will be done before commencement of
Radiography at Site.
2 Prior to the approval Radiography area shall be barricaded based on the Safe
distance, as per National Environmental Agency Singapore – Regulation. Also
Radiation warning signboards & lights displayed around the area to make
aware the public & others to not enter into the corridor area.
3 Before the commencement of radiography, RT Team will inform to the
Maincon safety department.
4 The surface of the base metal and weld to be examined shall be free from weld
spatters, weld ripples or weld surface irregularities etc. to such a degree that the
resulting radiographic image due to any irregularities could not mask or be
Confused with the image of any discontinuities.
5 Radiography test is carried out in accordance with MN-TP-006.
6 Gamma ray Source of lr-192 with the source size of 3.089mm diagonal, loaded
in a remote control type isotope container shall be used for Radiography
Testing.
7 The weld or part to be radiographed shall be divided into segments to suit the
film size with the overlap of 1" to cover the entire weldment. The divided
segments shall be marked with permanent marker for identification. Lead

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numbers 0-1, 1-2, etc., or letters A-B, B-C, ... etc., shall be placed on the
marked area to indicate the segment in the film.
8 Project No., Line No., Drawing No. etc. as per the requirement of client
prepared in a lead strip shall be placed 3mm away from along the sides of the
weld. To determine the sensitivity of radiograph a wire type penetro-meter (IQI)
shall be placed across on the source side of the weld. When IQI placed on the
film side a lead letter F shall be paste on the IQI. IQI shall be selected
according to the specification requirement.
9 Type I or Type II film sandwiched with lead screens and loaded in a cassette
(film holder) shall be placed (should cover the area of interest, lead markers
and penetrometer) on the weld segment prepared for radiography testing.
10 To minimize the Geometric Un-sharpness Source-to-film distance shall be as
far as possible as recommended in the specification.
12 Exposure time Calculation shall be based on the part thickness, Source-to-film
distance and curie strength used.
13 Source shall be kept "ON" for particular exposure time by driving the source
from a remote control type source container. After completion of the exposure
source shall be drive back to the source container.
14 Now the exposed film is ready for processing (film shall be handled with great
care
When loading the film and processing the film).
The exposed films shall be processed in accordance with the conditions
recommended by the film and chemical manufacturer to obtain the selected
film quality. Particular attention shall be paid to temperature development time
and washing time to obtain a radiograph, which shall be free from defects due
to processing or other causes that would interfere with interpretation.
TRANSPORTATION OF RADIATION SOURCE:
Transportation of Radioactive material (Projector) to the Site:
o The inspector shall carry the projector and related instruments by hand trolley to
the location required.

o Projector should be carried in this way due to relative high radiation level, which
high radiation exists at the surface of projector. At no time should the projector
be carried or held against the body or carried at shoulder level.
o Caution shall be exercised such that projector is not dropped in any way while
moving it, particularly when carrying it up ladder, working at height.
o The route to be taken from the storage pit to the exposure site will be checked by
the radiographer carrying the projector.

o Should accidents occur during the transportation of the projector such as

dropped or struck by falling object, the applicable emergency procedure shall be
initiated at once and immediately notify Radiation Safety Officer.

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Transportation By Motor Vehicle:

o Transportation shall be by company or company authorized vehicle only.

o Distinguishable radiation signs as described in the Government of Singapore

o This placard shall be displayed on the left and right side of the vehicle.
o L6 license holder is required to monitor the transporting of radioactive material.

o The projector shall be secured during transport in a lead lined box located in the
rear of the vehicle positioned at all times in such a way that a maximum distance
between the driver and his assistant and the source is maintained.
o At no time shall non-radiation worker be carried in the same vehicle when
transporting radioactive materials.

o The vehicle will be surveyed on its outside surfaces to ensure that radiation
levels in excess 0f 2.0 mRem/hour are not present.

o Should radiation levels exceed the stipulated maximum value, the vehicle shall
be posted on each side with additional radiation sign which shall state:
“CAUTION: RADIATION AREA – DO NOT REMAIN UNNECESSARY
NEAR THIS VEHICLE”.

o The minimum equipment and accessories to be placed in the vehicle prior to

departure are as follows:

 9.1 Radiation survey instruments.

 9.2 100 feet of rope complete with pennants.
 9.3 Enough number of “DANGER – RADIATION AREA” warning
signboards.
 9.4 The projector plus all related equipment and accessories.

Transportation of Radioactive sources on Site work:

The following rules for transporting of radioactive sources on work sites are:
Sources must be transported in approved containers, designated and placard
radiation transport vehicles (as specified by regulatory requirements for
dangerous goods vehicles).

 A radiation survey is to be performed on the outer surface of the

radioactive source container before the container arrives on project work
sites to ensure the source is properly contained.

 The level of radiation on the outer surface of a properly contained

radioactive source should be less than 0.5µSv / h or 0.05mRem / hr.

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EMERGENCY PROCEDURES:
In the event of an emergency for leaking source or radiation mishap, the
Radiation safety officer or "L6 License holder" shall inform be informed.
Emergency Not Affecting Radiographic Exposure Device:
NOTE: Emergencies in this category are those such as fire, flood, personal
accidents or similar incidents in areas adjacent to the radiographic operations,
but which do not immediately cause danger to the exposure device.
Return the source to its shielded position within the exposure device.

 Disconnect the source extension tube and control cables, insert the
safety plugs, lock the projector and remove it from the danger area.
 If necessary, return the source to the isotope storage pit.

 Once the exposure device has been made secure, the restricted
radiation areas should be made free by removing the rope barriers
and the radiation warning signboard
If radiographic personnel are the only one present at the time of the emergency,
they should immediately notify the radiation safety officer.

4.2.4 Pressure Testing Of Above Ground Pipes:

(a) The testing medium shall be air.

(b) Pipes from underground to riser and riser pipes shall be tested to 70kPa.
Pressure gauge. If there is no fall in pressure as registered on the pressure
gauge at the end of 30 minutes, the system is considered satisfactory. It
should be followed by a second test of pressure 300mm water gauge for
duration of 10 minutes.

(c) Pipes from riser to equipment shall be tested to 300mm water gauge using
a manometer. The air pressure shall be raised to 300mm wg and allowed to
stabilize for 1 minute before recording down the pressure. If there is no fall
in pressure at the end of 10 minutes, the system is considered satisfactory.

(d) For API pipes the testing medium shall be air, pressure at 70KPa for
duration of 30 minutes.

(e) All calibration certificates to be submitted before any testing.

(f) Pressure test procedure:

1. Prepare all necessary equipment and tools for pressure testing.

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2. Prepare inspection form and drawing plan indicating the testing location.
3. All joints to be exposed for inspection during testing.
4. Open pipe ends shall be temporarily capped.
5. One of the pipe ends shall be installed with the testing kit, pressure gauge and
compressor pump.
6. Piping under testing shall be pumped with air to the require test pressure
stated.
7. Check for pressure drop by monitoring the calibrated pressure gauge / u-
gauge as required duration stated.
8. Upon testing satisfactory, witness by RTO for the tested piping before
releasing air pressure.

4.2.5 Jacketing/Box-up works:

a) General
The main activities are:
 Provided jacketing to pipe according to the approved
drawing.
 Arrange required material
 Installation of metal jacketing
 Testing

b) Material for Jacketing/Box-up

 Aluminum sheet
 Rivets
 Fire rated spacer
 Fire stop sealant

c) Types of joints for Jacketing/Box-up

Jacketing joints - Rivet joints
- Close up by sealant

a) Installation of Jacketing/Box-up
 Check the position of pipe routing layout from approved
drawing.
 Use the materials that are approved by the Authority and
Consultants as per submitted approval sample.
 After finished pipe work arranges metal jacketing require size.

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 Fire rated spacers of suitable size and shapes are to be

attached to the pipe with one layer of paper tape to keep them
in place.
 Rolled metal sheet shall be place over the spacer with the
metal overlapping.
 Rivets shall be applied to the joints at equal spacing.
 Elastic Firestop Sealant shall be applying to the gaps of the
joints between each jacketing.

4.2.6 Painting of API Pipes

 Material submission for paints must be approved before painting
of pipe routing.
 All pipes to be painted with primer coat after one day later 1st coat
before installation.
 Colour code for each system has to be strictly followed. (Canary
Yellow BS381C colour number 309).
 Ensure that paint brands and colour codes have prior approval
prior to use.
 Clear inspection with QPS RTO and representative from Main Contractor
before painting of pipes.
 Final coat will be carried out when installation is completed

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