METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

INDEX
1.INTRODUCTION
2.DEFINITION
3.APPLICABLE DOCUMENTS
4.SCOPE OF WORK
5.PROCEDURE
6.MATERIALS RECEIVING & STORAGE
7.PRE FABRICATION
8.PIPING ERECTION
9.MECHANICAL CLEARANCE AND PRESSURE TEST
10.INSPECTION AND QUALITY RECORDS
11.SAFETY PROCEDURE
12.ATTACHEMENT:SAMPLE OF WELD MAP

1)Introduction
The purpose of this method statement is to ensure that the methods and
proceduresshall be carried out for the fabrication, erection and testing of
piping work as per theTechnical / Contractual specifications of Dar Al
Handasah.
2)DefinitionsProject:Massa Extension Project MakkahConsultant:Dar Al
HandasahContractor:Advanced Vision Co.
3)Applicable Documents
3.1Codes & Standards
ASMEB 31.3 ANSIB 16.25 ASME SEC II Part C ASME SEC IX ASME SEC V AWS
D 1.1
3.2 R ef. Project Specifications
4.Scope
The scope of this method statement is limited to Pre-fabrication, Erection and
Testing procedures followed for Carbon Steel and Stainless Steel piping.
5.Procedure
The Engineering drawings and documents received from Consultant shall be
clearlyunderstood to find out the service, material specification, size, thickness,
NDTrequirements, PWHT requirements, pipe routings quantity etc. line wise and
areawise.Ensure that the documents received bear the stamp Issued for
Construction and areof latest revision.Make sure that all the Quality Control and Pre
Construction formalities, approvals,and preparations are done sufficiently in
advance to start the construction activity as per the schedule.
6.Materials Receiving and Storage
1)
Material Requisition form prepared by supervisor shall be forwarded to thematerial
controller who shall collect the piping materials as per the pipingspecifications and
drawings from Consultant, respecting the material issue procedure of Consultant.
2)Handling and transportation of piping materials shall be done with utmostcare to
avoid any damage.
3)Separate area shall be assigned for the storage of Carbon Steel and StainlessSteel
piping materials. Pipes shall be stored in open area resting on woodensleepers and
small pipe fittings, bolts, nuts, and gaskets shall be stored inshelved containers.
Storage & issue procedure of piping materials shall be intime with the requirements
of Consultant.4)Documents shall be maintained by the material controller till the
end of the project.
7.Pre Fabrication7.1Replacement
1)Determine the safe location on the Rejected Fittings to start the cuttingand
remove the cut items to scrap area by safely procedure.2)Select the proper cut
method either flame cut or cut machine.
7.2Cutting and Beveling
1)Pre-fabrication of Carbon Steel and Stainless Steel Pipes shall bedone in separate
fabrication ways.
2)Proceed with cutting of pipes, edge preparation, joint alignment,and fit-ups as per
the WPS.
3)The edge cleaning and beveling shall be done using abrasivegrinding disc/
beveling machines.
4)Line Number, Spool Numbers, and Joint Numbers are to be clearlyidentified and
marked on the spools with the welder identification for each joint.
7.3Fit Up and Tack Welding
1)Fit-up assembly shall be carried out by using locally prepared couplers.All the
required pipe holding work benches, assembling brackets, U bolts etc. would be
made in house to suit the pipe sizes.2)For butt welds a uniform root opening as
specified below shall bemaintained.1.5 mm for pipe diameters < 50 mm1.5 / 2.5
mm for pipe diameters 50 mm to 250 mm.2.5 / 3.5 mm for pipe diameters > 250
mm3)For all socket weld joints the pipe end shall be free from cutting burrs.
Aclearance of 1.6 mm shall be provided between the end of pipe and bottom of
socket.4)Internal misalignment shall be limited to1.6 mm for pipe diameter 24 and
below.3.2 mm for pipe diameter 26 and above.5)The pipes shall be tack welded in
three equidistant positions. Tack Weldshall be done as per approved WPS by a
qualified welder.
7.4Welding
1)Welding procedures and welders shall be qualified as per ProjectSpecifications and
relevant codes, prior to start of the welding.2)Ensure that the edges are free from
dirt, rust, oil, grease, paint etc.
3)Welding shall be done as per approved WPS for the particular piping. Preheating
and welding consumable shall be checked before starting of welding.
4)Each weld layer shall be cleaned before starting to weld next layer. Thecleaned
area shall be free from slags. Any visual defects like cracks, pores, spatters weld
shall be removed by grinding before the next layer isapplied. The ends of weld layer
shall be removed by grinding at tack points of each weld. Any possible weld excess
layer will be removed bygrinding.
5)For the fabrication & welding of Stainless Steel pipes, only Stainless Steeltools &
consumables (Wire Brush Chipping, Hammer, and Abrasivedisc) shall be
used.6)Appearance of finished weld shall be as even as possible and free
fromspatter, under cutting, cracks, excess reinforcement etc.
7.5Non Destructive Examination
1)The extent of NDT will be in accordance with Project General Specificationfor
different piping systems. The acceptance criteria shall be in accordancewith ASME B
31.3.2)If PWHT is applicable for any piping system, NDT shall be carried out after
completion of PWHT.3)Welding record shall be maintained with proper identification
of joint,welder etc. for all joints.4)NDT shall be carried out as per approved
procedure and the results shall berecorded properly
8.Piping Erection
1)The Pre-Fabricated spools shall be identified by spool and line numbers before and
after priming.2)Care shall be taken while handling and stacking of spools to prevent
any possible damage.3)Open ends of spools shall be covered by caps after thorough
cleaning.4)Erection of spools shall be carried out area by area as per piping
layoutdrawing and Isometric drawings.5)Scaffolding and temporary platforms shall
be arranged to carry out fit up andwelding of field joints at elevated positions.6)Pre-
fabricated spools shall be shifted to site carefully as per daily erection plan.7)Before
erection of spools ensure for inside cleaning of the spools and their items.8)Erect
the spools in position using crane or other lifting devices as per
thedrawings.9)Supports to be welded on to the pipe (shoes or saddles) shall be
done beforeerection.10)Check the pipe supports details in the piping layout
drawings andIsometric drawing for location and type of supports.11)Install the pre-
fabricated supports as per drawings.12)Joints shall be aligned and complete the fit-
up / welding as per applicableWPS.13)NDT and other inspection shall be completed
for the field joints andrecorded properly.
9.Mechanical Clearance, Inspection & Pressure Testing

1)Identify the test loops for the completed line system wise.
2)Upon obtaining mechanical clearance, Hydrotest shall be carried out as per
project specification.3)Arrange for Hydrotest Pump, Calibrated Pressure Gauges,
Test medium(Water) etc.4)Blind flanges shall be installed on all required locations
and items which arenot to be included in pressure testing, shall be isolated.5)Water
shall be filled and vented properly before pressurising.6)Line shall be pressurized to
the required pressure of that piping class andhold the pressure till the inspection is
completed.7)Pressure Test shall be witnessed by contractor representative.8)On
satisfactory completion of test, pressure shall be released and line is todrained off
completely.9)Reinstate the line with all the permanent items and remove all the
blinds.
10)Inspection and Quality Records
Inspection, Testing and Recording shall be in accordance with the
approvedInspection & Test Plan.
11.Safety Procedure
Prefabrication and Erection of Piping and Pipe Supports.
Equipment and tools
1) Portable cranes, column cranes.2) Scaffoldings
3) Small items (lifting jacks, slings, chain block, D-shackles, etc.)4) Oxygen
Acetylene Cutting, Portable Power Tools, and Welding units.
Safety Measures
Protective Clothing1) Helmet2) Gloves3) Safety shoes4) Full Body Safety Harness5)
Face shields
Accident Prevention Safety Procedures
1) Area shall be barricaded adequately with warning barriers prior to any lift.2) All
Equipment shall be checked for good conditions before commencing the work.3)
Unauthorized persons shall be excluded from the area.4) When lifting, the personnel
shall not remain in the lifting equipment work area.5) Adequate caution boards and
warning signs shall be provided.6)Only trained and authorized personnel shall
operate the hydraulic lift.7)Observance of the lifting equipment capacity.8)Electrical
installations and equipment shall conform to standards.9)Application, maintainence,
storage of electric, and oxygen cutting welding unitsshall conform to applicable
standards.10)Do not stand under suspended loads.11)On Completion of job, the
area shall be cleared of any materials and kept cleanand tidy.12)Hazard analysis for
hazardous operation shall be carried out prior to commencingthe works.