Method Statement No: A008-MS-PIP-014 Issue: A5

Al RushaidConstruction Co., Ltd.

AL RUSHAID CONSTRUCTION CO. LTD.

Method Statement

Project – JUPC ETHYLENE PLANT PROJECT

Document Title:

Method Statement for Installation of Piping Around Equipment

APPROVED FOR CPL BY:

Reviewed by Approved by
Rev. No.
DISCIPLINE SAFETY QA / QC FEM CM

A5
ARCC/EE/ ISSUE STATUS

A5 Incorporates UNITED ANDMojica 15-Oct-03 EVC/FPS MT Magno

Comments
Incorporates UNITED
A4 ANDMojica 05-Oct-03 EVC/FPS MT Magno
and CPL comments
Revise as per CPL
A3 ANDMojica 8-Sept-03 EVC/FPS 8-Sept-03 MT Magno 8-Sept-03
comments
A2 Incorporates UNITED & RCP / EVC 30-Aug-03 FP Sawal 30-Aug-03 MT Magno 30-Aug-03
CPL comments
A1 Incorporates CPL RCP / EVC 21-June-03 FP Sawal 21-June-03 MT Magno 23-June-03
comments
A0 Issued for Approval RCP / EVC 09-June-03 FP Sawal 09-June-03 MT Magno 11-June-03
Issue
Issue or Revision Description Origin By Date Checked By Date Approved By Date
Rev.
Method Statement for Installation of Piping Around Equipment Page 1 of 13
 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

TABLE OF CONTENTS

Page

1 PURPOSE 3

2 SCOPE 3

3 REFERENCE DOCUMENTS 3

4 MANPOWER 4

5 EQUIPMENT 4

6 METHODS AND PROCEDURES 5

7 QUALITY CONTROL 12

8 SAFETY PRECAUTIONS 12

9 ATTACHMENT 12

Notes:
1.0 The latest revised documents shall always be used.
2.0 Any conflict between this method statement and the CPL procedure, the CPL procedure shall
be followed.

Method Statement for Installation of Piping Around Equipment Page 2 of 13

 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

1.0 PURPOSE

This method statement shall serve as guidelines for installation of piping around
equipment for United Ethylene Plant Project.

2.0 SCOPE

This method statement will cover installation of piping around static and rotating
equipment.

3.0 REFERENCE DOCUMENTS

3.1 Project Specifications and Standards

 P02-S01 Piping Materials Specifications – Part I, Group 1
 P02-S14 Piping Materials Specifications – Part I, Group 2
 P03-S01 Piping Materials Specifications – Part II
 P04-S01 Piping Materials Specifications – Part III
 00-P-0017 Specification for Cleaning Requirements of Piping Systems
 00-P-0036 Specification for Field Fabrication and Erection
 00-P-0034 Acceptance Criteria - Flange Face
 00-W-0001 General Welding/NDE Specification for Pressure Retaining
Components
 00-W-0003 General Welding / NDE Specification for Piping, Shop/Field
Fabrication (00-W-0003)
 00-G-0013 Installation of Machinery and Criteria for Installation Design
 10-Z-0004 Specification for Shop Preparation of Equipment and
Materials for Shipment
 10-Z-2010 Field Inspection and Test Procedure

3.2 Industry Codes and Standards

 ASME B31.3 Process Piping (American Society of Mechanical
Engineers)
 ASME B31.1 Power Piping (American Society of Mechanical
Engineers)
 PFI STD. ES-3 PFI Fabrication Tolerances

3.3 MS, ITP and Other Applicable Procedures

 A008-MS-MECH-015 MS for Preservation of Sub-assembly and
Equipment
 A008-MS-PIP-005 MS for Piping Installation of Compressors K-
1200, K-1500 and K-1600
 A008-ITP-MR-001 ITP for Materials Receiving Inspection
 A008-ITP-P001 ITP for Installation of Piping
 A008-ITP-P004 ITP for Piping Installation of Compressors K-
1200, K-1500 and K-1600
Method Statement for Installation of Piping Around Equipment Page 3 of 13
 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

 A008-ITP-S-005 ITP for Erection & Instln of Misc. Strl. Items

 A008-ITP-S-006 ITP for Erection Pipe Stanchion, Operating Pltf &
Equipment Structure
 Welding Procedure Specifications

3.4 Latest revision of the following IFC documents shall be used

 Isometric Drawings
 Piping General Arrangement Drawings Around Equipment
 Piping and Instrument Diagram (P & ID)
 Pipe Support Drawings

4.0 MANPOWER

Piping Superintendent will control the over-all activity for piping erection and installation
works. Basic manpower under him will basically include, but not limited to:
 Piping Supervisors
 Piping Foreman
 Piping Leadman
 Pipefitters
 Welders
 Crane Operators
 Manlift Operators
 Riggers
 Helpers / Firewatchers

5.0 EQUIPMENT

Tools and equipment shall be made available to support continuous work. Tools and
equipment shall include but not limited to as follows:

5.1 Tools and Jigs

a) Ball hammers; 2,5,10 lbs. i) Bevel gage
b) Pipe wrenches/combination j) Steel square
c) Socket wrenches k) Straight edge
d) Hammer / spud wrenches l) A-frames
e) Torpedo/protractor’s level m) Gap /feeler gauge
f) Grinders: Angle grinders, n) Hi-Lo gauge
Pencil grinder, Baby grinders o) Chainblocks
g) Impact wrenches p) Pipe clamps
h) Manual Pipe Threaders

5.2 Equipment
a) Mobile crane (telescopic type)
b) Welding machine
c) Air compressors
Method Statement for Installation of Piping Around Equipment Page 4 of 13
 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

d) Boom truck
e) Manlifts
f) Genset

6.0 METHODS AND PROCEDURES

6.1 Receipt and Preservation of Piping Materials

6.1.1 Delivered spools, random length, pipe supports and other materials for
erection shall be inspected upon receipt from CPL and piping fabricators as
per A008-ITP-MR001 to verify following:
6.1.1.1 Piping materials meet acceptance criteria as per Spec No. P02-S01,
P02-S14, P03-S01 and P04-S01.
6.1.1.2 Alloy materials must have the proper markings as per Spec. No. 00-
P-0036 Sect. 6.1 para. 6.1.2. Related documents attesting PMI of the
alloy materials should also be available.
6.1.1.3 Pipe support materials delivered from ARCC Subcontractor are
coated according to Sect. 6.5 OF P01-E06.
6.1.1.4 Spool pieces have correct line number.
6.1.1.5 Piping materials are shipped according to the requirements of Spec.
No. 00-Z-004 Sect. 6.4.1, 6.4.2 and 6.4.3.

6.1.2 Review spool fabrication package and checked requirements for erection
including NDT, painting, heat treatment, cleaning, PMI documentation &
marking, etc.

6.1.3 Check material quantities against ISO Bill of Materials.

6.1.4 Preservation of piping materials where needed shall be done following Item
5.4.12 of A008-MS-MECH-015.

6.2 Preparatory Works

6.2.1 Prior to piping erection works, ensure scaffoldings are sufficiently installed
for access of workers during fit-up, and fullwelding/bolting of pipe joints.
Install lifelines as needed.

6.2.2 Get ready and prepare manpower, tools, equipment and other logistics for
installation.

6.2.3 Secure a Work Transfer Sheet/Package from equipment installation group.

Work Transfer Package shall includes:
 Survey Data Report indicating Northings, Eastings and Elevation of
Nozzles Centerlines
 Equipment General Assembly Drawing(s)
Piping shall not be connected to equipment until turn over by equipment
group.

Method Statement for Installation of Piping Around Equipment Page 5 of 13

 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

6.2.4 Secure and check availability of following IFC documents:

 Isometric Drawings
 Piping General Arrangement Drawings Around Equipment
 Piping and Instrument Diagram (P & ID)
 Pipe Support Drawings
 Equipment Lists
 Valve Lists

6.2.5 Check the area or location of the piping for possible obstruction before
erection.

6.3 Erection/Fit-up of Permanent Pipe Supports

6.3.1 Pipe supports and hangers shall be installed prior to connection of pipe
spools to equipment nozzles. In case where permanent supports are not
available, then temporary support shall be provided to avoid piping strain
applied to the equipment.

6.3.2 Installation of pipe supports shall be done using small capacity cranes
and/or chain blocks where applicable. Only nylon slings shall be used in
lifting supports to location.

6.3.3 For field-welded supports:

 Tack-weld supports, then check elevation, levelness
and plumbness. Proceed to full welding following approved WPS.
 After full welding conduct NDE as required in AWS
D1.1. Refer to Sect.5.3 of P01-E06.
 Document inspections in accordance with A008-ITP-
S006

6.3.4 For bolted supports:

 Fit-up, insert bolt, then proceed to preliminary
tightening of nuts.
 Check elevation, levelness, squareness and
plumbness.
 Proceed to final tightening on nuts to bring them to “snug-tight”
condition.
 Document inspections in accordance with A008-ITP-
S005

6.4 Piping Installation /Erection

6.4.1 After withdrawal of pipe spools from laydown yard and prior to erection,
conduct air blowing of pipe spools to ensure piping cleanliness as
required in Sect. 5.2 of P01-E27. Orifice flanges welded at site should be
internally flush after welding. Conduct flange face inspection on pipe &
equipment side.

Method Statement for Installation of Piping Around Equipment Page 6 of 13

 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

6.4.2 Erection of pipe spools shall start from equipment nozzles where spool
flanges are fitted to equipment nozzle flanges.

6.4.3 Set-up pipe spool thru reference point such as Northing and Easting.

6.4.4 Check bottom of pipe (BOP) elevation.

6.4.5 For welded spools:

6.4.5.1 Fit-up spools using appropriate pipe clamps, check the gaps using
gap gauge.

6.4.5.2 Check for squareness and levelness using appropriate level and
steel square. Check plumbness (vertical pipes) using plumb bob.

6.4.5.3 Tack -weld directly on the bevel of pipes after checking. Tack
welding shall be done on four quadrants.

6.4.5.4 Prior to full welding of pipes, QC inspector shall conduct

inspection to document work compliance. Following are items to
be verified:

 Bevel angle, root opening, and tack weld

A5
shall be in accordance with the approved Welding Procedure
Specification, Spec. No. 00-W-0001 Sect. 2.5.2/ ASME B31.3
Chapter V Sect. 328.4.2 & 328.4.3/ ASME B31.1 Chapter V
Sect. 127.3(a), (c) & (d).
A5
 Socket Gap shall be in accordance with
Spec. No. 00-P-0036 Sect. 10.6/ ASME B31.1 Chapter V
Sect.127.3 Para (e)/ ASME B31.3 Chapter V Sect. 328.5 Para.
328.5.2.
A5
 All surfaces to be welded shall be clean
and free from paint, oil, dirt, scale and foreign material
detrimental to welding as specified in Spec. No. 00-W-0001
Sect. 2.5.3 para. 2.5.3.1 & 2.5.3.4/ ASME B31.3 Sect.
328.4.1/ ASME B31.1 Sect. 127.3(b).

A5  Defects such as cracks, inadequate

penetration of temporary weld and/or tack welds shall be
removed, as specified on ASME B31.1 Chapter V Sect. 127.4
Para. 127.4.11/ ASME B31.3 Chapter V Sect. 127.4.

A5  The welding consumables to be used are in

accordance with the approved WPS, ASME B31.1 Chapter V

Method Statement for Installation of Piping Around Equipment Page 7 of 13

 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

Sect. 127.2 Para 127.2.1/ ASME B31.3 Chapter V Sect. 328.3

Para 328.3.1/ Spec. No. 00-W-0001 Sect. 2.4.1 & 2.4.2.

6.4.5.5 Full welding of pipe joints shall be done by qualified welders

following approved WPS, which are qualified in accordance with
ASME Code Sec. IX and Spec. No. 00-W-0001 Sect. 2.2.
Welder’s qualification shall be verified in accordance with Spec.
No. 00-W-0001 Sect. 2.3.

6.4.5.5.1 During the welding process the in-process inspection will

be done verifying the following items;
 The required pre-heating / inter-pass
A5
temperature requirements is done as per approved WPS
and Spec. No. 00-P-0036 Sect. 9.1.3/ ASME B31.1
Chapter V Sect. 131/ ASME B31.3 Sect. 330.
A5  Purging requirement, as applicable, is being
maintained as per approved WPS/ ASME B31.1 Para.
136.4.2/ ASME B31.3 Para. 344.2 and Spec. No. 00-W-
0001 Sect. 2.5.8 para. 2.5.8.2 (b). 6.4.5.6. When welding
is completed visual inspection will be done to check the
A5 following items, as applicable;
 The root pass in accordance with ASME
B31.3 Table 341.3.2/ ASME B31.1 127.3 (c) & (d) and
Spec. No. 00-P-0036 Sect. 10.8.

 Arc strikes in areas in areas not covered by

the finished weld is ground as per Spec. No. 00-W-0001
Sect. 2.5.5 para. 2.5.5.4.

 Temporary materials used are already

removed as per Spec. No. 00-W-0001 Section 2.5.5
para. 2.5.5.3.

 Check for surface porosities, underbead,

undercut, etc.

A5  Internal flush/grinding of orifice flanges

weld joint was done.

6.4.5.6 Cleanliness of pipe shall be maintained as per Spec. No. 00-W-

0001 Sect. 2.7.1 para. 2.7.1.2. The weld spatter, slag, flux, and
other foreign materials are removed.

6.4.5.7 The welder’s ID, weld no., and line no. will be marked with metal
marker on the pipe next to the weld. Refer to P13-C02 Para. 6.1.

A5
6.4.5.8 The completed weld will be subjected to the required NDE as per
Spec. No. 00-W-0003 Sect. 2.4 and ASME 31.1 Chapter VI Sect.
Method Statement for Installation of Piping Around Equipment Page 8 of 13
 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

136.4 Para. 136.4.3 to Para. 136.6/ ASME 31.3 Chapter VI Sect.

344 Para. 344.3 to Para. 344.6. Ferrite testing shall be as per
Spec.No.00-W-001 Sect. 11.4.1.

A5 6.4.5.9 Seal Welds shall be as per ASME B31.1 Chapter V Sect. 127.4
Para. 127.4.5 and 135.5.2/ ASME B31.3 Chapter V Sect. 335.3
Para. 335.3.2
A5
6.4.5.10 Post Weld Heat Treatment (as required) as per Spec. No. 00-W-
0001 Sect.2.5.7, Spec. No. 00-W-0003 Sect. 2.3.2 and ASME
B31.1 Chapter V Sect. 132/ ASME B31.3 Chapter V Sect. 331.

6.4.5.11 Document inspections in accordance with A008-ITP-P001.

6.4.6 For flange-connected spools:

6.4.6.1 Check flange faces of spools if it’s free from damage and serrations.
Refer to Table 1 of Spec. 00-P-0034 for the acceptance criteria.

A5 6.4.6.2 Check type, materials of gaskets as specified in the ISO BM. Also
check bolt length and protruding threads. Temporary gaskets to be
used for pressuretest shall be dabbed with a spot of fluorescent red
paint in 4 spots (90 degrees equidistant). End points of temporary
bolts and nuts used for pressuretest shall be dabbed with a spot of
red fluorescent paint. Refer to Specs. No. 00-P-0033 Sect. 7.7.3
Para. d/ ASME B31.1 Chapter V Sect. 135.3 Para. 135.3.2/ ASME
B31.3 Chapter V Sect. 335.2 Para. 335.2.4 as applicable.

6.4.6.3 Conduct air blowing prior to lifting of spools to ensure conformance

to piping cleanliness requirements.

6.4.6.4 Using nylon sling, lift and set-up pipe spool thru reference point
such as Northing, Easting, columns, or beams.

6.4.6.5 Check bottom of pipe (BOP) elevation.

6.4.6.6 Install gasket to check distance. Use temporary gasket same as

original gasket thickness.

6.4.6.7 Fit-up flanges using appropriate flange alignment tools and/or flange
bolts. Check alignment as follows:

6.4.6.7.1 Rotating Equipment

6.4.6.7.1.1 Pipe strain measurement shall be measured while all

piping connections are being made to the
equipment/machinery.

Method Statement for Installation of Piping Around Equipment Page 9 of 13

 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

6.4.6.7.1.2 Install alignment bracket on the coupling hub or

shaft.

6.4.6.7.1.3 Mount dial indicator on the coupling hub to measure

vertical and horizontal movement on the opposite
machine as the pipe flange bolts are being tightened
using torque wrench.

6.4.6.7.1.4 Bolting of pipe flanges to rotating equipment flanges

shall be done with the largest flanges bolted-up first.
Bolting up shall be done continuously without
disturbing the location of the dial indicators.

6.4.6.7.1.5 Pipe flange bolts shall be lined up with rotating

A5
equipment nozzle boltholes within 1mm in 200mm
(1/16”) maximum offset from center of bolt holes as
required in ASME B31.1 Chapter V Sect. 135.3 Para.
135.3.1/ ASME B31.3 Chapter V Sec. 335 Assembly
and Erection, Par.335.1.1 as applicable.

6.4.6.7.1.6 Rotating equipment and piping flanges shall be

parallel to less than 10 micrometers per centimeter of
pipe flange outer diameter up to maximum of
750micrometers. Piping flange outer diameter less
than 25 centimeters, flange shall be parallel to 250
micrometers or less. For raised face flange feeler
gauge readings shall be taken at the raised face. Refer
to project Spec.00-G-0018, par.4.5.5.

6.4.6.7.1.7 Flange face separation shall be within the gasket

spacing plus or minus +_1.5 mm as required in project
Spec.00-G-0018, par.4.5.5. Document readings using
QCF-196C Piping Alignment Data Sheet for Rotating
Equipment.

6.4.6.7.1.8 Proceed to initial tightening of flange bolts to bring

them to snug-tight condition using hand wrench.
Tightening of bolts shall be done in diametrically
opposite direction for even compression of the
gaskets and produce uniform bolt loads as required in
Spec. No. 00-P-0036 Sect. 10.3.2.

6.4.6.7.1.9 Maximum shaft movement in the vertical and

horizontal direction after the flange is tightened shall
be 50 micrometers (0.002 in.) or less.

Method Statement for Installation of Piping Around Equipment Page 10 of 13

 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

6.4.6.7.1.10 If shaft movement is more than 50 micrometers,

loosened piping flanges from the equipment and
correction shall be made on to piping or supports.

6.4.6.7.1.11 Proceed with above steps until the required shaft

movement is attained and hand bolting finalized.

6.4.6.7.2 Static Equipment

6.4.6.7.2.1 Rotation of flanges shall be maximum of 1/16” (2.0

mm) as shown in Figure 1 of PFI Standard ES-3 on
attachment D.

6.4.6.7.2.2 Alignment of Facing or ends shall deviate by more

than 3/64” per foot (1.0mm per 25cm) of any
diameter Figure 1 of PFI Standard ES-3.

6.4.6.7.2.3 For over NPS 3” flange separation should not exceed

the gasket thickness plus 1.6mm required in Specs.
No. 00-P-0036 Section 8 para. 8.4.

6.4.6.7.3 Flange to Flange Spools

6.4.6.7.3.1 Rotation of flanges shall be maximum of 1/16” as

shown in Figure 1 of PFI Standard ES-3.

6.4.6.7.3.2 Alignment of Facing or ends shall deviate by more

than 3/64” per foot of any diameter as shown on
Figure 1 of PFI Standard ES-3.

6.4.6.7.3.3 For over NPS 3” flange separation should not exceed

the gasket thickness plus 1.6mm required in Specs.
No. 00-P-0036 Section 8 para. 8.4

6.4.6.8 Bird Mouth

6.4.6.8.1 Birdmouth shall be anticipated and controlled.

6.4.6.8.2 Using work transfer sheet , countercheck the plumbness

and alignment of nozzles and equipment that will have
pipe connection.

6.4.6.8.3 Any excessive out of tolerances shall be brought to the

attention of proponent to make necessary adjustments
while connecting spools are not yet installed.

Method Statement for Installation of Piping Around Equipment Page 11 of 13

 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

6.4.6.8.4 All flanges connected to equipment were only tack

welded while spools are fabricated. Full welding will be
done during fit-up to equipment after making the
necessary adjustments to prevent birdmouth.

A5 6.4.6.9 Tighten the flange bolts to bring them to snug-tight condition

using hand wrench. Tightening of bolts shall be done in
diametrically opposite direction for even compression of the
gaskets and produce uniform bolt loads as required in Spec. No.
00-P-0036 Sect. 10.3.2/ ASME B31.3 Chapter V Sect. 335.2 Para.
335.2.2.

6.4.6.10 Check for squareness, levelness and plumbness.

6.4.6.11 Once accepted, proceed to final tightening using hand bolting

method. The bolt used shall be checked for conformance with
the specifications.

6.4.6.12 Document all inspections in accordance with A008-ITP-P001.

6.5 Pressure Testing

6.5.1 Pressure testing of piping system shall be conducted following A008-MS-

PIP-011. Equipment shall be excluded from pressuretest.

6.5.2 After pressure testing and restoration commence with connection of

suction and discharge pipe flanges to equipment nozzle flanges. Ensure
all supports and hangers are installed to position. This is to avoid stress
or harmful loads from the piping to the equipment.

6.5.3 Final piping connection to equipment will be done after the final
acceptance of pipe works (pressuretested, flushed, cleaned, and
inspected).

7.0 QUALITY CONTROL

7.1 ARCC QC Inspector will be assigned to attend to the quality control and quality
assurance requirement of this work.

7.2 All documents attesting to the acceptability of the work will be produced by
ARCC QC Inspector and submit to CPL/United for review and approval.

8.0 SAFETY PRECAUTIONS

Method Statement for Installation of Piping Around Equipment Page 12 of 13

 Method Statement No: A008-MS-PIP-014 Issue: A5
Al RushaidConstruction Co., Ltd.

8.1 Obtain the approval of the work permit from the concerned CPL/JUPC
Department before starting any work.

8.2 Fire watchers shall be at work area whenever there is hot work.

8.3 All electrical tools shall be checked and color-coded.

8.4 Continuous monitoring and inspection shall be implemented to detect and

correct unsafe practices while performing the work activities.

8.5 Provide warning sign and sufficient barricade on working area and only assigned
personnel will be allowed in the area.

8.6 Welding location shall be enclosed with wind barrier and provided with non-
asbestos fire blanket to prevent spread of any welding sparks.

8.7 Safety Officer shall monitor the work activities to help and to protect all assigned
workers ainst exposure to safety hazards. He shall ensure that Personnel
Protection Equipment (PPE’s) are supplied and used and comply with
CPL/JUPC applicable general instruction and standards.

8.8 Safety harness with double lanyards shall be used all the time when working at
elevated temporary platforms.

8.9 Manlift users shall be trained and certified to operate and use the equipment.

9.0 ATTACHMENTS

Attachment A Job Hazard Analysis

Attachment B Piping Alignment Data Sheet for Rotating Equipment (QCF-

196C)

Attachment C Figure 1 of PFI Standard ES-3

Method Statement for Installation of Piping Around Equipment Page 13 of 13