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The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation METHOD OF STATEMENT FOR PIPING FABRICATION AND PIPING

METHOD OF STATEMENT FOR PIPING FABRICATION AND PIPING INSTALLATION WORK

Installation METHOD OF STATEMENT FOR PIPING FABRICATION AND PIPING INSTALLATION WORK KOBELCO SANKYU JOINT VENTURE Page
Installation METHOD OF STATEMENT FOR PIPING FABRICATION AND PIPING INSTALLATION WORK KOBELCO SANKYU JOINT VENTURE Page

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation 1. PURPOSE 2. SCOPE 3. REFERENCES 4. DEFINITIONS

1. PURPOSE

2. SCOPE

3. REFERENCES

4. DEFINITIONS

5. RESPONSIBILITIES

CONTENTS

6. PROCEDURES – METHOD OF WORKS – INSTRUCTIONS

6.1

RECEIPT & STORAGE OF PIPE RAW MATERIALS

6.2

PIPING FABRICATION

6.3

CUTTING AND BEVELING

6.4

FIT-UP WORK

6.5

WELDING

6.6

ASSEMBLY AND INSTALLATION

7. INSPECTION, EXAMTION AND TESTING

8. IDENTIFICATION

9. TOOLS & EQUIPMENT

10. SAFETY CONDITION AND ENVIROMENT

8. I DENTIFICATION 9. TOOLS & EQUIPMENT 10. SAFETY CONDITION AND ENVIROMENT KOBELCO SANKYU JOINT VENTURE
8. I DENTIFICATION 9. TOOLS & EQUIPMENT 10. SAFETY CONDITION AND ENVIROMENT KOBELCO SANKYU JOINT VENTURE

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation 1. PURPOSE o The purpose of this generic

1.

PURPOSE

o The purpose of this generic method statement is to define the procedure for fabrication and installation of stainless steel piping in UBCF system for improving An Duong water treatment plant in Hai Phong city

2.

SCOPE

Scope of this method statement covers the following activities.

o

Material handling and unloading

o

Fabrication

o

Welding and welding visual check

o

Installation

o

Inspection

3

.

REFERENCES

3.1 PROJECT DRAWINGS

Project drawings consist of followings:

o

Applicable Piping drawings for WTP ( UBCF system ) .

o

Piping Layout drawings.

o

Others.

3.2 PROJECT SPECIFICATION

Project specification consist of followings:

o

Piping Specification

o

Approved WPS and MOS for welder’s qualification

o

Other related specifications in tender document.

3.3 PROJECT QUALITY PLAN (PQP)

Project quality consist of followings:

o Project Quality plan for SUS piping

3.4 CODES AND STANDARDS

Project codes and standard consist of followings:

ISO 559

JIS 2311 Steel but welding pipe fitting for Ordinary piping

AWWA C200 Steel Water Pipe 150 mm and lager

Steel tubes for water and sewerage

 AWWA C200 Steel Water Pipe 150 mm and lager Steel tubes for water and sewerage
 AWWA C200 Steel Water Pipe 150 mm and lager Steel tubes for water and sewerage

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation 4. DEFINITIONS The followings abbreviation are used in

4. DEFINITIONS

The followings abbreviation are used in this document

o

PM

Project Manager

o

SM

Site Manager

o

CM

Construction Manager

o

ITP

Inspection and Test Plan

o

QC

Quality Control

o

QCI

Quality Control Inspector

o

PQP

Project Quality Plan

o

PPE

Personal Protection Equipment

o

HSE PLAN

Health Safety & Environment Plan

5. RESPONSIBILITIES

o

It is overall responsibility of PM/SM to organize resources to perform construction activities as per project specification, in compliance with quality, schedule & safety requirements.

o

It is the responsibility of CM that construction activities are executed according to the relevant project specifications, in compliance with quality, schedule & safety requirements.

o

DE will ensure that all the works are performed safely as per latest Approved for Construction (IFC) drawings & specifications.

o

The relevant DE and Supervisor will ensure that all the piping work is conducted in accordance with this method statement and project specifications

o

The QCI will ensure that all work is executed according to PQP and that requirements of quality dossier are full filled.

o

Safety and construction supervision will be carried out under responsibility of Client wherever required.

6. PROCEDURES METHOD OF WORKS INSTRUCTIONS

6.1 RECEIPT & STORAGE OF PIPE RAW MATERIALS

o

The piping raw material receiving and unloading shall be offloaded in designated lay down yard.

o

During offloading, pipes shall not be dropped off the transport. A crane and suitable certified slings shall be used. Nylon slings with hook will be used to handle SS and coated piping & fittings.

o

The pipes shall be placed on wooden bar or concrete blocks with wooden packing in between.

shall be placed on wooden bar or concrete blocks with wooden packing in between. KOBELCO SANKYU
shall be placed on wooden bar or concrete blocks with wooden packing in between. KOBELCO SANKYU

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation o The piping end covers shall be kept

o

The piping end covers shall be kept in place to prevent foreign particle entry into the pipes.

o

All materials shall come with color-coding as per size, material & schedule.

o

The piping material shall be segregated accordingly to facilitate location of the items. Alloy. SS, low Temperature CS, CS and Galvanized pipe & fittings to be stored separately.

6.2 PIPING FABRICATION

o

Material will be shifted from lay down area to work shop at site as per relevant piping drawings

o

Carbon steel, low temperature carbon steel, NACE and stainless steel pipe fabrication work will be done in separate areas. Tools & equipment compatible with the material in fabrication shall be used.

o

The piping material is to be used in appropriate and economical way. All cuttings should be collected separately as per material code and place in order to make best use of these.

o

Pipes for socket weld joints shall be cut square

6.3. CUTTING AND BEVELING

6.3.1 GENERAL

o

The pipes shall be cut as per dimensions mentioned in the drawings and all pipe length shall be marked. Material traceability shall be maintained as per relevant agreed.

o

Based on spool break down of piping drawings, pipe lengths shall be cut 150mm extra length for pipe will be provided in spools for field adjustment. The pipe ends for 2 inch & above shall be beveled as per approved WPS for the piping class.

o

The cutting and beveling of pipes shall be done by mechanical means cold cutting machine/ flame cutting or plasma/ arc cutting, cutting shall be acceptable provided that the edges are smooth.

o

The fit up of pipe ends, fittings & weld neck flanges shall be done to obtain uniform root opening. The criterion given in related WPS shall be followed.

o

The joint should be free of grease, oil, scales, rust or other foreign material.

o

The primer paint coat on pipe & fitting ends shall be removed prior to bevel end preparation.

coat on pipe & fitting ends shall be removed prior to bevel end preparation. KOBELCO SANKYU
coat on pipe & fitting ends shall be removed prior to bevel end preparation. KOBELCO SANKYU

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation o The pipes shall be tack welded by

o

The pipes shall be tack welded by a qualified welder. If the pipes are of different thickness, the larger thickness will be tapered in compliance with standard to match the smaller thickness.

o

The adjacent section of longitudinally welded pipes that are to be joined by butt welds shall have longitudinal weld seams positioned such that they are at least 30 degrees apart from horizontal center line. The fabricator will also not locate longitudinal weld seams on top or bottom of the pipe so that branch connections are not located on the seam.

o

Reinforcement pads shall be fabricated only if required in the drawings. The material for reinforcement pad shall be same as that for the pipe unless otherwise authorized by main contractor. The size & thickness of pad will be as specified in the.

o

The Flanges indicated on piping drawings to be supplied loose shall be tack welded with the pipe. Full welding shall be made after site checking.

the pipe. Full welding shall be made after site checking. FABRICATION AREA DESCRIPTION 6.4 FIT-UP WORK

FABRICATION AREA DESCRIPTION

6.4 FIT-UP WORK

6.4.1 Groove

Pipe ends and fittings shall be properly beveled

Beveled surfaces shall be thoroughly cleaned

fittings shall be properly beveled  Beveled surfaces shall be thoroughly cleaned KOBELCO SANKYU JOINT VENTURE
fittings shall be properly beveled  Beveled surfaces shall be thoroughly cleaned KOBELCO SANKYU JOINT VENTURE

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation 6.4.2 Type of welding: Diameter(mm ) 15A to
Method of Statement for Piping Fabrication and Installation 6.4.2 Type of welding: Diameter(mm ) 15A to

6.4.2 Type of welding:

Diameter(mm )

15A to 125A

150A to 500A

Thickness of pipe

Up to 3mm

3mm or more

Manual Type

Welding

I Welding Surface

V Welding Surface

6.4.3 Welding procedure:

Weld layer

Process

Filler metal

Travel speed

 

1 GTAW

ER-308L

2.0

 
 

2 GTAW

ER-308L

3.2

 
 

3 GTAW

ER-308L

3.2

 
 

4 GTAW

ER-308L

3.2

 

6.4.4 Alignment and Trimming

Root gap for butt-weld shall be in accordance with the WPS.

In the case of butt welding pipe and/or fitting having unequal wall thickness, of which the difference is more than 3 mm in outer surface and/or I .5 mm in inner surface, the end of the thicker pipe shall be trimmed by grinding as per the Fig. (a), (b) and (c) shown below.

pipe shall be trimmed by grinding as per the Fig. (a), (b) and (c) shown below.
pipe shall be trimmed by grinding as per the Fig. (a), (b) and (c) shown below.

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation  When a pipe having a longitudinal weld
Method of Statement for Piping Fabrication and Installation  When a pipe having a longitudinal weld
Method of Statement for Piping Fabrication and Installation  When a pipe having a longitudinal weld

When a pipe having a longitudinal weld seam is used in a horizontal line, the pipe shall be laid so that the longitudinal weld seam is not on bottom or top of the pipe. Allocation and relation among circumferential, longitudinal and other (branch, support, etc.) welds are shown in the Fig. 3.4.4 (a), (b) or (c).

Circumferential joint

the Fig. 3.4.4 (a), (b) or (c).  Circumferential joint Note: L1 shall be minimum five

Note: L1 shall be minimum five times the pipe thickness or over.

Branch pipe and weld line on run pipe

five times the pipe thickness or over.  Branch pipe and weld line on run pipe
five times the pipe thickness or over.  Branch pipe and weld line on run pipe

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation  Butt joint welding of pipes shall be
Method of Statement for Piping Fabrication and Installation  Butt joint welding of pipes shall be

Butt joint welding of pipes shall be performed as follows:

o

Welding shall be performed in accordance with WPS.

o

Circumferential butt welding shall be performed without the use of a backing ring unless specified in WPS.

o

Before welding of the root, both ends of the root tack weld bead shall be prepared with a grinder as shown in the following illustration in order to make complete fusion.

the following illustration in order to make complete fusion.  Fillet welding of pipe to slip-on

Fillet welding of pipe to slip-on and socket weld flanges shall be performed as shown in following

socket weld flanges shall be performed as shown in following  SOCKET JOINT o The pipe

SOCKET JOINT

o The pipe for welded sockets joint shall be ground to remove burrs due to cutting. A gap between end of pipe & bottom of socket will be maintained as per Project Specifications.

end of pipe & bottom of socket will be maintained as per Project Specifications. KOBELCO SANKYU
end of pipe & bottom of socket will be maintained as per Project Specifications. KOBELCO SANKYU

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation  THREADED JOINT o In case of threaded

THREADED JOINT

o In case of threaded pipes (for utilities piping only) screw threads shall be concentric with axis of pipes with no burrs or stripping. The threading dies shall be sharp & properly designated for the piping material.

6.5 WELDING.

6.5.1 General

All welding work will be according to approved WPS and standard as tender document and only qualified welders shall be employed.

The welding work piece will be shielded against high winds and rain. If the wind speed exceeding 10 m/sec and 3 m/sec for SMAW & GTAW respectively then welding work will stopping

The weld surface shall be cleaned with SUS wire brush or grinding prior to welding operations to give a surface free from rust, scale or mill coating.

Between each layer of welding any cracks, pores or welding spatters shall be removed by grinding the surface before application of next layer.

The appearance of finished welds shall conform to ASME B31.3 code & WPS and shall exclude any under cuts, spatters, and cracks.

All branch connections shall be joined to headers with full penetration welding. The bore side shall be ground smooth, free from cracks.

For flange to pipe connections if welding shrinkages can lead to misalignment, two similar flanges shall be joined by inserting a temporary gasket and then welded.

The distance between centerlines of adjacent girth butt welds and staggering of longitudinally welded pipe for making butt weld shall be carried out ccording to project specification.

Welding shall be performed to ensure complete fusion of the weld deposit and the base metal in order to obtain homogeneous bound over the entire cross section area of the weld.

Welding current and polarities shall comply with the approved WPS. And or instruction given by the manufactures of the filler metal.

Number of layers shall never be less two layer.

The welding seam of welder are not meet quality regularly when visually inspected by main contractor and consultant. The welder will be rejected or qualification again

main contractor and consultant. The welder will be rejected or qualification again KOBELCO SANKYU JOINT VENTURE
main contractor and consultant. The welder will be rejected or qualification again KOBELCO SANKYU JOINT VENTURE

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation 6.5.2 Pre-treatment of base metal Adhering substances such

6.5.2 Pre-treatment of base metal

Adhering substances such as oil, paint, dust, water, etc, shall be completely removed before welding. A piece of cloth with organic solvent like thinner or gasoline, a stainless steel wire brush and/or sand paper may be used to remove any adhering substances.

6.5.3 Pre-treatment of base metal

Tack welding

6.5.3 Pre-treatment of base metal  Tack welding  Pure Argon (AR) gas shall be used

Pure Argon (AR) gas shall be used during the welding

 Pure Argon (AR) gas shall be used during the welding 6 .5.4 Tack welds o

6.5.4 Tack welds

o

Tack welds on pipe fit-up shall be minimum eight (8 ) points with pipes alignment

o

carefully checked. Minimum heat shall be applied on executing tack welds. Internal shielding not necessary on tack welding

applied on executing tack welds. Internal shielding not necessary on tack welding KOBELCO SANKYU JOINT VENTURE
applied on executing tack welds. Internal shielding not necessary on tack welding KOBELCO SANKYU JOINT VENTURE

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation 6.6 ASSEMBLY AND INSTALLATION 6.6 .1 General o

6.6 ASSEMBLY AND INSTALLATION

6.6 .1 General

o

Before assembling of piping, actual tolerance causing from foundation, steel structure, equipment installation work shall be considered for the piping assembling work.

o

Excessive stress shall not be allowed to the nozzles of rotating machine when the flange of fabricated component is connected, such work shall be carried out in the presence of person in charge of the mechanical work. And openings such as flanged joints of a pump, compressor, etc. shall be kept covered with thin metal plate or other solid blinds with a handle to prevent dust and/or foreign material from entering into the machine.

o

If the hot work (welding or cutting …) to be performed in the vicinity of instrument control or power cable duct, an adequate protective cover shall be provided in advance so as not to damage the cables.

o

When work is carried out in the vicinity of piping made of, or lined with special materials such as plastics, rubber, glass, etc., care shall be taken so as not to damage them.

o

Valves shall be assembled in clean condition, they shall not be opened during piping erection except that welding and heat treatment of a welded valve joint shall be carried out with valve opened.

o

If cutting, making of holes to the assembled piping and such kind of work is carried out at assembled place due to the reason of modification, improvement, etc., cut piece and foreign materials shall be removed from inside of piping and it shall be confirmed that the inside of piping is cleaned.

o

Valves having flow direction shall be installed to conform the flow direction in accordance with piping drawings. Care shall be taken to the valves in case valve flow direction is reversed against the flow direction of pipe line.

o

It is prohibited to use small size piping, pumps, instrument etc. as scaffolding or working stage.

A. The following requirement shall be observed for piping support.

o

Pipe supports shall be fabricated and installed in accordance support drawings

o

As a rule, the location of pipe-supports shall be in accordance with the piping arrangement drawing and support drawing.

o

The pre-setting pieces of the pipe hanger shall be removed after completion of leak test of the pipe line. However, pipe lines which will be insulated, it shall be removed after completion of the insulation work.

o

A shoe support shall be attached to the pipe in accordance with the drawings. It is not permitted to tack-weld a shoe support to the pipe rack, where the shoe support is not to be permanently fixed to the pipe rack.

pipe rack, where the shoe support is not to be permanently fixed to the pipe rack.
pipe rack, where the shoe support is not to be permanently fixed to the pipe rack.

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation B. Flanged Joint o Any damage to the

B. Flanged Joint

o

Any damage to the gasket seating surface which would prevent gasket seating shall be repaired, or the flange shall be replaced.

o

Flanged joints shall be bolted up, after checking the alignment of the flange centers and the parallel ness of flange faces, to ensure that the contact faces bear uniformly on the gasket. Bolting-up shall ensure that bolt tension is spread uniformly around the flange.

o

Particular care shall be exercised to ensure that all bolt, nut and gasket are correctly installed in accordance with the requirements of piping specification for piping material.

o

When assembling flange connections, paste shall be applied to the gasket and bolts. These prevent seizure of nuts and adherence of gaskets. Reference of pastes and their applications shall be in standard and drawing.

C. Threaded Joint

o

The standard to be applied to all threads shall be ANSI/ASME Bl.20.l Pipe Threads (NPT).

o

Lubricant shall be removed completely from the thread and inside of pipe after threading.

o

In a threaded joint between pipe and flange, the length of thread on the pipe shall be such that the end of the pipe is short of the gasket surface on the flange by 1.5 to 3.0 mm when screwed-in.

o

Thread shall be jointed with full coupling between straight pipes, and piping shall have union joints in consideration with repairing at leak test.

o

Threaded joints shall be sealed with tape or threading compound, unless there is restriction from process requirement

o

Seal welding of threaded parts, if specified, shall be performed after the part is screwed-in completely without using paste or oil and fully cleaned, decreased and dried out. Reinforcement of the seal weld bead shall cover completely the remaining thread and must be at least 2-layers weld using a suitable size of electrode.

D. Mechanical Joint

o

Mechanical Joint other than flanged joint and threaded joint shall be in accordance with manufacturer's Instruction or drawing.

o

Care shall be taken to avoid distorting the sheet when incorporating such joint into piping assemblies by welding.

E. Valve Installation

o

Where carried out ever valves are to be installed, the installation/orientation of valve handles and

flow direction shall be according to the piping layout.

o

All valves to be installed will be cross checked according to the number to ensure that the proper valves are installed in the proper location.

the number to ensure that the proper valves are installed in the proper location. KOBELCO SANKYU
the number to ensure that the proper valves are installed in the proper location. KOBELCO SANKYU

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation o Valves shall be installed in the closed

o

Valves shall be installed in the closed position except for ball valves and plug valves.

o

New gaskets will be installed between the valve flange and pipe flange. Final tightening of all nuts shall be done once proper alignment is achieved.

o

Bolting of flanges will be done in a cross pattern.

o

All bolts, gaskets and valves shall be properly stored to avoid contamination with the environment. Valve ends will be sealed until installation and gaskets and bolts shall be kept clean of any debris such as sand.

F. Scaffolding Work

kept clean of any debris such as sand. F. Scaffolding Work o Scaffolding if required shall

o Scaffolding if required shall be erected by qualified personnel in a safe and suitable manner.

if required shall be erected by qualified personnel in a safe and suitable manner. KOBELCO SANKYU
if required shall be erected by qualified personnel in a safe and suitable manner. KOBELCO SANKYU

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation o Scaffolding above 2 m in height shall

o

Scaffolding above 2 m in height shall be inspected by a scaffolding inspector and a scaffold-tag shall be

signed and provided on the scaffolding near the ladder. No one shall use the scaffolding without the

staff-tag being approved.

o

Scaffolding material to be used shall be in good conditions, brass hammer shall be used to assemble

and tighten the scaffolding locks.

7.INSPECTION, EXAMTION AND TESTRNG

In-Process Inspection

(1) Prior to Commencement of Work

 

Examination and Testing

Acceptance Criterion

(a)

Material check

To satisfy the requirement of Engineering Specification

( b) Welding Procedure Specification

To satisfy the requirement of Welding Specification

(c)

Welder's performance

Welder's performance qualification certificate.

qualification

(d)

Electrode and welding

Material certificate (material name, brand). To satisfy a applicable codes and standards.

consumable

(2) Prior to Welding

 

Examination and Testing

Acceptance Criterion

(a)

End

Shape and dimension

To satisfy the requirements of Par. 3.4 of this specification.

preparation

Cleanliness

To be free from paint, oil, rust, scale or other foreign material.

(b)

Tack weld

Root opening (Gap)

To be within the tolerance specified in WPS.

 

Alignment (Mismatch)

Misalignment is not more than 1.5 mm for internal surface and 3.0 mm for outer surface.

(c)

Preheating

Preheating temperature

To keep the Preheating temperature within the tolerance specified in Table 3.5.2. and WPS.

(d)

Electrode

Drying temperature

To be in accordance with manufacturer's standard.

 

Drying time

- ditto -

(3

) During fabrication and assembling

Examination and Testing

 

Acceptance Criterion

Dimension checking and inspection

see photo 7.3 as below

 
Criterion Dimension checking and inspection see photo 7.3 as below   KOBELCO SANKYU JOINT VENTURE Page
Criterion Dimension checking and inspection see photo 7.3 as below   KOBELCO SANKYU JOINT VENTURE Page

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation o Flattening ratio and reduction of thickness acceptance

o Flattening ratio and reduction of thickness acceptance criteria, which shall be decided in accordance with practical conditions, shall not be applied for steam trace piping.

End preparation for weld shall not
End preparation
for weld shall not

Description photo 7.3

for steam trace piping. End preparation for weld shall not Description photo 7.3 KOBELCO SANKYU JOINT
for steam trace piping. End preparation for weld shall not Description photo 7.3 KOBELCO SANKYU JOINT

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation (4) After Welding Examination and Testing Acceptance

(4) After Welding

Examination and Testing

Acceptance Criterion

 

Crack

 

None

(a) Visual examination of welding

Under cut Girth weld and Branch connection

Less than 0.3 mm. But for low temperature service and high temperature service materials, under cut is not permitted.

Overlap (Cold lap)

Less than I .0 mm

Throat thickness of fillet weld

Over 0.91

(Hatful Coupling)

Over 1.01 (SO/SW Flange) t:

thinner i e thickness

Weld reinforcement or internal weld protrusion (Root Penetration)

Thickness

WallMax. (mm) 6.4 or under

1.6 over 6.4upto 12.7 3.2

 

over 12.7 up to 25.4 4.0 over 25.4

 

4.8

Weld scars from jigs and arc strikes

Visual check and no defect. Liquid penetrant examination as per following part (b) for high temperature and low temperature service.

Lack of fusion Girth weld and Branch connection

 

Nil

Incomplete penetration Girth weld and Branch connection

Lesser <= 0.8 mm or 0.2 t, but not more than 38 mm cumulative length in any 150 mm of weld length depth <= 0.2 t. But for low temperature service and high temperature service materials, incomplete penetration is not permitted.

Surface porosity

 

None

(5) After Completion of Work

 

Examination and Testing

Acceptance Criterion

(a)

Visual check

No extra distortion.

(b)

Hydrostatic and/or pneumatic leak test

According to piping specification and no leak shall be acceptable.

leak test According to piping specification and no leak shall be acceptable. KOBELCO SANKYU JOINT VENTURE
leak test According to piping specification and no leak shall be acceptable. KOBELCO SANKYU JOINT VENTURE

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation ( 6) When an unacceptable defect of welds

(6) When an unacceptable defect of welds is revealed, the following remedial action shall be taken:

o

The repair or replacement shall be carried out, then the new work shall be re-examined in accordance with piping specification.

o

If the repair is again found to be unacceptable, then it shall be carried out once more. Permissible number of welding repairs at the same place shall be a maximum of 2(two). If a further repair is required, then a cut out shall be the sentence. The welder concerned who made repair more than 2 times shall be retrained and requalified.

8. STORAGE

o

The pipe spool complete in all respect shall be stored separately.

o

All spools shall have their identification/piece number clearly designated on each spool.

o

The spool will be cleaned in an inclined position by tapping so that all foreign materials are removed.

o

The spool shall be placed on wooden baton to avoid direct contact with soil.

o

The open ends shall be covered by polyethene sheets or end caps. In case of flanged spools, the same shall be covered by securely tied wooden blanks to avoid foreign material entering the pipes.

o

The spool shall be handled using nylon lifting slings.

o

Alloy / SS to be stored separate form CS.

9. TOOLS & EQUIPMENTS

EXECUTION

o

Hand Tools

o

Cutting, Beveling & Grinding Machines

o

Cranes (Mobile)

o

Plasma machine

o

Gridding machine

o

Welding Machine

o

Hack Saw

o

PPE and Protect equipment

o

Scaffolding

o

Drilling machine

o

Electric panel and wire

o

Other equipment

o Drilling machine o Electric panel and wire o Other equipment KOBELCO SANKYU JOINT VENTURE Page
o Drilling machine o Electric panel and wire o Other equipment KOBELCO SANKYU JOINT VENTURE Page

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam Method of Statement for Piping Fabrication and Installation

Method of Statement for Piping Fabrication and Installation 10.SAFETY CONDITION AND ENVIROMENT o Basically, all

10.SAFETY CONDITION AND ENVIROMENT

o

Basically, all person taking care of work shall be equipped enough PPE such as Helmet, Glove, Glass, Safety belt etc.

o

Arrange the required safety signs, barricades and other related safety precautions highlighted in the risk assessment and permit prior to commencing the works.

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The works shall only commence after the job performer has checked and ensured that all safety

precautions and safety requirements are in place.

o

Ensure employees understand the hazards and control measures related to the critical activities, i.e.

lifting, welding.

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Ensure personnel stay away from lifting zone and do not enter under the suspended loads.

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Qualified First Aider must be on site and identified by a sticker on his helmet.

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Display Emergency Contact number on site.

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Advise the construction crew on HSE aspects and ensure their safety.

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Arrange through Job performer for tool box talk covering risk assessment in language understandable

by workers.

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Cross checking certified material devices and equipment’s are used.

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Do weekly, monthly HSE audit.

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Ensure appropriate safety measures are taken as per the risk assessment and controlled documents.

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Ensure that all staff adhere to the HSE plan and HSE requirements.

o Ensure that all staff adhere to the HSE plan and HSE requirements. KOBELCO SANKYU JOINT
o Ensure that all staff adhere to the HSE plan and HSE requirements. KOBELCO SANKYU JOINT
o Ensure that all staff adhere to the HSE plan and HSE requirements. KOBELCO SANKYU JOINT