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EPIC CONTRACTOR
REVISION HISTORY
Title :
Project Co. :
EPC 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
1.0 PURPOSE
The purpose of this method statement is to provide a standard for the fabrication of steel piping
constructed by HANWHA in YANBU II POWER & WATER Project. 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 YANBU II POWER & WATER project. Pipe 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:
1) Preparation, revision and the implementation of this method statement.
2) Establishment and execution of fabrication and erection schedule and sequence
3) Control of construction documents and drawings
4) Overall site safety management
5) Ensures that all fabrication and erection tasks are done as per specification.
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
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.
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
Min.150㎜
Rope DAM 2
Purge Hose
Sketch B
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.