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METHOD STATEMENT
FOR
THREADED PIPING
Doc No: GSE/MS/AGP-002 REV 1
PREPARED By
GULF SPIC
ENGINEERING L. L. C
REVIEWED By
APPROVED By
SIEMENS/ETA
MMD/DEWA
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CONTENTS
Sl No
DESCRIPTION
PAGE No
DEFINITIONS
INTRODUCTIONS
SCOPE OF WORK
REFERENCE
RESPONSIBILITIES
4.1
PIPING ENGINEER
4.2
MATERIAL CONTROLLER
4.3
QC ENGINEER
4.4
SAFETY ENGINEER
HSE CONTROL
WORK SCHEDULE
EXECUTION PLAN
7.1
7.2
7.3
HYDROTEST
13
7.4
14
7.5
MANPOWER
15
8.
15
9.
DOCUMENTS ATTACHEMENT
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I.
DEFINITIONS
GSE
ETA
SIEMENS/ETA-
SIEMENS/ETA CONSORTIUM
DEWA
QA
QUALITY ASSURANCE
QC
QUALITY CONTROL
AG
ABOVE GROUND
HSE
ASME
WPS
PQR
NDE
NON-DESTRUCTIVE EXAMINATION
PWHT
SS
STAINLESS STEEL
CS
CARBON STEEL
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1.0
INTRODUCTION
This method statement is intended to outline the method and sequence of work
execution which will be followed for FABRICATION, ERECTION & TESTING of
aboveground piping of AL-AWEER GAS TURBINE POWER STATION H PHASE III.
2.0
SCOPE OF WORK
The activities includes but not limited to receiving of pipes and fittings from
ETA/SIEMENS, transporting to site, installation of piping, fabrication & threading,
and leak test as per project specifications for the following piping systems
3.0
REFERENCE DOCUMENTS
ASME B 31.1
ASME B 31.3
DEWA PROJECT SPECIFICATION G5.1, G5.5 & G5.6
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4.0
RESPONSIBILITIES
SITE ORGANISATION CHART AS FOLLOWS
SITE
MANAGER
PIPING
ENGINEER
4.1
QA/QC
ENGINEER
MATERIAL
CONTROLLE
R
SAFETY
ENGINEER
PIPING ENGINEER
He shall be responsible for carrying out all the activities associated with AG
piping works including prefabrication
MATERIAL CONTROLLER
Material controller is responsible for collecting materials from warehouse
designated lay down area and shifting the same to the fabrication area and
shifting fabricated spools from the fabrication area to the erection site.
4.3
QC ENGINEER
He is responsible for preparation of WPS / PQR, welder performance
qualification, selection and control of welding consumables & NDE requirements.
He will be in-charge for verification & documentation of all relevant drawings
and reports; material, welding and welder traceability on job and all stage
inspection as per approved ITP. QUALITY ASSURANCE is ensured at all levels of
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SAFETY ENGINEER
Ensure all tools & tackles, heavy equipments and machinery do comply
with the safety requirements of the project.
5.0
6.0
WORK SCHEDULE
From the master schedule, related sections of piping works shall be extracted
and be used as the timeframe. Work sequence shall be followed while executing
the different activities involved.
7.0
EXECUTION PLAN
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7.1
7.1.1
7.1.2
Material controller ensures only accepted materials are issued to the concerned
Piping Engineer.
7.1.3
Piping Engineer shall identify the list of material as per the approved drawings.
He prepares a material requisition and submits to stores via MATERIAL ISSUE
VOUCHER for drawing the materials.
7.1.4
7.1.5
7.2
7.2.1
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7.2.2
The piping engineer on referring the P&ID and ISO drawings will identify the
scope for pre-fabrication & doubling of pipes. ETA shall also decide on the
scope for pre-fabrication.
7.2.3
The priorities for pre-fabrication of pipes, spools will be identified based on the
overall project schedule. ETA shall also advice on the priorities of the piping
systems to be made ready for erection.
7.2.4
7.2.5
Welding of the pipes will be carried out as per the approved WPS by qualified
welders. The joint design will be ensured for compliance with WPS checking the
edge preparation, root gap, bevel angle, land etc. Preheat of weld joint will be
done at applicable areas which will be identified based on project
specifications/codes & standards.
7.2.6
The fitup of connected fittings with the pipe will be given additional concern to
have a proper orientation as depicted in the ISO drawing for matching with the
connected pipings at site.
7.2.7
7.2.8
NDE for the pre-fabricated pipes will be carried out based on the segregation
made on piping class and Project Specifications. The scope for RT (decided
based on pressure rating as per project technical specifications) will be
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identified at site and the same will be ensured for its compliance (as test
reports).
7.2.9
PWHT for the required pipe weld joints will be identified based on the Project
Specifications G5.6 /applicable codes and standards (ASME B31.1). Before
PWHT, all the required Non-Destructive Examinations will be carried out in the
piping weld joints and the same will be compiled as NDE records.
7.2.10 The stage inspection to be carried out during welding as prescribed in the
approved I&TP will be executed and all the responsible participating parties
will be called during inspection. The following inspection reports will be
maintained and be concurred from ETA after successful completion of
subsequent stages,
RT report
7.2.11 The joint reference will be identified near the weld joint where the details
including weld joint no., welder no., line ISO no. etc., will be transferred by
suitable means (via., permanent paint markers). Such joint references will be
retained till the final pressure test.
7.2.12 The routing of the pipes on steel columns, sleeper bays will be studied by the
piping engineer. This feasibility study will include
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Erection clearance from the preceding contractor for structures & pipe
racks.
Scaffolding requirements.
If any inadequacies exist, the same will be reported to ETA for clarification.
7.2.13 All the pre-fabricated pipes will be covered at the ends by suitable means so as
to ensure debris free inside surface. Before covering the pipes, the removal of
foreign particles will be ensured.
7.2.14 The pre-fabricated pipes will be coated as per the technical specifications
following all the stage inspection process for surface preparation, primer coat
DFT and final coat DFT. The details will be recorded (as inspection reports) and
submitted for clients review.
7.2.15 Coating on weld joints will be carried out only after successful completion of
the pressure test.
7.2.16 Before shifting the pre-fabricated pipes to site, it shall be ensured for its
completeness in all respects (NDE, PWHT, paint coating etc.,). All the prefabricated pipes are identified by their ISO drg no., line no., joint no., welder
no. and will be ensured by supporting documents for conformance of the test
results.
7.2.17 During transit of pre-fabricated pipes to site, proper care (by suitable means
like wrapping with plastic cover sheets, using rubber sheets to avoid contact
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with metal slings while lifting etc.,) will be taken not to damage the coating on
pipe surface.
7.2.18 After shifting the pipes to site, the receiving end inspection will be carried out
for any transit damages (like coating damage etc.,). Presence if any will be
tended before proceeding with the erection.
7.2.19 Dimensional check of the pipes will be carried out at site to identify
trimming/shortcoming requirements. For this a detailed study of the ISO drg
with the layout drg will be carried out by the piping engineer to interpret the
feasibility conditions.
7.2.20 Erection of pipes on structures will be carried out in concurrence with the JOB
SAFETY ANALYSIS (refer attachment 1) to ensure safe working practices. Tools,
tackles and the lifting equipments are ensured for its adequacy and suitability
for the job requirements. Proper concurrences are met and approved prior to
execution. Risk assessment study will be carried out by the Safety Engineer and
will be submitted separately to client for review.
7.2.21 For multi-tier pipe racks, the erection sequence of piping will be followed from
the lower tier to the upper tier. To insert pipes in the lower tier, the columns at
the road cross-over section shall not be installed with interconnecting beams.
This would enable free access for sliding the pipes into the pipe rack with an
extended boom length from the lifting equipments. This pre-requisite shall be
ensured by ETA before the starting of erection activities. Such locations will be
identified by the piping engineer in co-ordination with the ETA engineer prior to
the erection activities (refer attachment 2 for main pipe-rack piping areas
highlighted for crane access requirement).
7.2.22 Wherever applicable, the erection of upper tier columns and tie beams shall be
on-hold till the completion of erection of lower tier pipings to ensure sufficient
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man & material access for performing site erection activities. The same should
be ensured by ETA prior to starting of the erection activities. Such locations will
be identified by the piping engineer in co-ordination with the ETA engineer
prior to erection activities (refer attachment 3 for pipe-racks in Fuel Oil
Storage Tank - areas highlighted)
7.2.23 The necessary scaffolding platforms shall be ensured by ETA prior to erection to
enable rigging activities and the subsequent joint fitup/welding.
7.2.24 Prior to joint fitup, the provision of permanent supports will be confirmed with
the ISO drawing. Wherever required, temporary supports will be provided to
avoid line distortion while welding. The provision of temporary supports will be
concurred from ETA before further execution.
7.2.25 Permanent supports on pipe racks will be fabricated as two segments with a
field joint. The bottom segment will be fixed on the pipe rack and the top
segment with the pipes. While final alignment of the line, the adjustments in
the slope, orientation and elevation will be made by adjustments, relocating &
trimming at the field joint.
7.2.26 Welding of field joints will be carried out as per approved WPS. For pipes with
connected fittings, the orientation of nozzles, weldolets, half couplings etc.,
will be checked with the connecting piping orientation. The alignment of the
pipe fittings will be given adequate care (via temporary supports wherever
required) to avoid line distortions during welding.
7.2.27 The orientation of drains and vents shall follow the universal rule of highest
point vents and lower point drains.
7.2.28 Wherever SS connected piping and fitting exist, proper care will be taken to
avoid contact corrosion of SS spools with CS materials. As far as possible, only
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belt slings will be used for lifting SS materials. If metal slings be used, then the
contact location will be suitably masked & covered.
7.2.29 Wherever flange connections exists, they will be covered at their faces to avoid
damages at transit (especially at gasket seating faces) by suitable means like
wooden blinds, plastic caps etc.,
7.2.30 The regularization works after the job completion, like removal of fitup cleats,
weld spatters (if any), temporary supports etc., will be carried out and
ensured.
7.2.31 NDE & PWHT for field weld joints will be carried out wherever applicable as per
project technical specifications. Such stage inspections will be backed by NDE
and PWHT test report and submitted for clients review.
7.3
7.3.1
HYDROTEST
Test packs will be identified and prepared and submitted for ETAs approval.
Such test pack segregation will be done based on the topographical
discrepancies, underground to aboveground emerging points (vice-versa) etc.,
7.3.2
A punch list for jobs to be carried out will be prepared by the QC Engineer and
submitted to the ETA. ETA on their discretion will add/delete on the jobs listed.
A walk down inspection of the entire loop will be performed for confirming the
drawing requirements. The activities listed out will be carried out based on the
priority status and the same will be confirmed.
7.3.3
Pipe cleanliness for inside and outside surface will be carried out. For inside
cleaning, card board bursting will be carried out for the entire test loop and
cleanliness will be ensured prior starting of Hydrotest.
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7.3.4
A TEST PACKAGE will be compiled by the QC Engineer which will contain the
following,
HYDROTEST certificate
The test pack will be submitted for clients review and approval before the
starting of HYDROTEST.
7.3.5
7.3.6
Fill water through hoses at the lowest points in the loop. After ensuring priming
in the loop, start pressurizing to the test pressure (1.5 times the design
pressure or as per the project specifications).
7.3.7
Holding time for the test pressure shall be as per ASME B 31.1/project
specifications.
7.3.8
Failure in the test (if any) shall be reverted with draining, repairing and retesting with the above procedure.
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7.3.9
7.3.10 Reinstate the test loops Paint coating at weld joints, isolation of pressuring
equipment, moisture removal by air flushing etc.,
7.4
7.4.1 All required Equipments, Tools and tackles shall be deployed to meet the work
Schedule and satisfactory installation. This equipment is available at GSES Site
store.
7.4.2 All required measurement tools shall be made available to enable correct
installation and inspection of Structures.
7.5
MANPOWER:
Sufficient manpower as required to meet the safe, satisfactory and timely
completion of the job shall be deployed as per enclosed list and these will
consist of but not limited to the following:
8.
Supervisors
Foreman
Skilled workers
Rigging Group
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The job safety analysis for the above ground pipe line erection & testing work is
prepared and enclosed as reference Attachment I documents.
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