Beruflich Dokumente
Kultur Dokumente
PIPING
Tag/Item number(s):N/A
18-09-08
AR
MKM
19-08-08
AR
MKM
OA
02-08-08
AR
Rev.
Date
By
SKS
IFL
SKS
ICC
MKM
SKS
IIR
Chkd
Appr.
Status
Contractor name:
VSA CONSORTIUM
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F15032-AJE-0-0000-CMT-MST-7414
VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
TABLE OF CONTENTS
1.0
SCOPE .......................................................................................................................................... 4
2.0
PURPOSE ..................................................................................................................................... 4
3.0
REFERENCES .............................................................................................................................. 4
4.0
DEFINITIONS ................................................................................................................................ 5
5.0
ORGANIZATION CHART.............................................................................................................. 6
6.0
RESPONSIBILITES....................................................................................................................... 7
6.1
6.2
Workshop Manager........................................................................................................................ 7
6.3
Piping Engineer.............................................................................................................................. 7
6.4
6.5
6.6
QC Engineer ................................................................................................................................. 7
6.7
QC Inspector.................................................................................................................................. 7
6.8
6.9
7.0
7.1
General .......................................................................................................................................... 8
7.2
Preparation ................................................................................................................................... 9
7.2.1
7.2.2
7.3
7.4
Tolerances ................................................................................................................................... 10
7.4.1
7.5
Length .................................................................................................................................. 10
7.5.2
7.6
7.7
8.0
WELDING .................................................................................................................................... 12
8.1
General ........................................................................................................................................ 12
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VSA CONSORTIUM
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VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
8.2
Production Welding...................................................................................................................... 12
9.0
10.0
11.0
11.1
11.2
11.3
12.0
13.0
14.0
15.0
ATTACHMENTS.......................................................................................................................... 17
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VSA CONSORTIUM
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F15032-AJE-0-0000-CMT-MST-7414
VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
1.0
SCOPE
This document defines the methods to be adopted for issue of material, pre-fabrication ,
welding, NDT, painting ,Inspection ,documentation and delivery of spool to site when fabrication
done at Doha workshop.
2.0
PURPOSE
Purpose of this document is to give methods and guidelines for proper execution of material
control, Pre fabrication, welding and delivery when piping spool are fabricated at an off site
facility away from site Fabrication shop
This document gives the method of documentation to be followed for the activities undertaken
at shop and appending the same to the mainstream documentation of the project.
And further purpose of this Method Statement is the following:
Intends to define the responsibilities of the project personnel involved at different levels for
execution of the activity.
Shows correct procedure of identification and selection of material and right method for material
traceability maintenance through out the fabrication stages.
Gives proper method for performance of every activity
Precautions and controls to be adopted to complete an activity according to the requirements.
Quality control requirements in an activity
Safety and risk assessment of the activity and mitigations actions
Identifies Key performance areas to mitigate flaws, if any
3.0
REFERENCES
F15032-AJE-0-0000-CMT-PLA-0001_O
(T-4.120.342)
F15032-SSA-0-0000-PMT-PLA-0001_O
(T-4.116.980)
F15032-SSA-0-0000-HSE-PLA-0001
(T-4.116.982)
F15032-SSA-0-0000-PMT-PLA-0005
(T-4.132.019)
F15032-AJE-0-0000-CMT-MST-1889
(T-4.143.074)
Testing of Piping
F15032-AJE-0-0000-CMT-MST-1902
(T-4.143.087)
ASME B31.3
Process Piping
F15032-AJE-0-0000-QCS-SPC-3475
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VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
(T-4.255-798)
4.0
F15032-AJE-0-0000-CMT-MST- 1897
(T-4.143.082)
DEP31.38.01.31
F15032-AJE-0-0000-CMT-MST-1883
(T-4.132.095)
T-13.377.441
DEP 30.10.60.18
DEP 31.38.01.29
Pipe supports
T-13.377.453
DEFINITIONS
PROJECT
COMPANY
CONTRACTOR
VSA Consortium
DOC
ETP
IC
Implementation Contractor
PMC
VSA Consortium
QC
SMAW
GTAW
HSSE
RFC
DWR
ITP
Quality Control
Shielded metal Arc welding
Gas Tungsten Arc Welding
Health, Safety, Security and Environment
Released For Construction
Daily Welding Report
Inspection and Test Plan
OFF-SITE SHOP
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VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
5.0
ORGANIZATION CHART
QC MANAGER
WORKSHOP MANAGER
ENGG.MANAGER
HSSE
QC ENGINEER
PIPING ENGINEER
QC INSPECTOR
DATA ENTRY
OPERATOR
STOREKEEPER
CONSUMABALE
CONTROLLER
WELDING SUPERVISOR
PIPING SUPERVISOR
WELDER
HELPER
PIPING FOREMAN
FABRICATOR /
FITTER
/ HELPER
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VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
6.0
RESPONSIBILITES
6.1
Engineering Dept.
It shall be the responsibility of the Engineering Dept to prepare and issue (Through Document
Control dept) detailed fabrication drawings. Spool drawings and isometrics shall be issued
complete with Weld joint/Flange joint numbering and with RFC status stamp. Engineering shall
issue a Request For Fabrication for the Spools which are to be fabricated at offsite shop with
the Material Take Off .
6.2
Workshop Manager
Work shop manager is responsible for the implementation of this procedure for Prefabrication
of spools at Work shop
6.3
Piping Engineer
Shall be responsible for the over all control of fabrication, welding, surface preparation and
painting of the spools fabricated at shop
6.4
6.5
Welding supervisor/Forman
Supervision of welding activities like, issue of correct consumables, storage and handling of
consumables, maintenance of, baking, holding, issuing, records of consumables, execution of
welding according to correct WPS, preparation of DWR, shall be the responsibilities of the
welding Supervisor. Safety and House keeping of the work area are also supervisors
responsibility. Welding Supervisor reports to Piping Engineer, but shall work in close
coordination with QC dept. in matters of Consumable control and Welder/Procedure
Qualifications activities.
6.6
QC Engineer
QC Engineer or, QC inspector designated by him, shall be responsible the Quality of the work
at shop. Assure proper implementation of the project procedures on Quality Control and FSI is
the responsibility of QC Engineer. QC Engineer/Inspector, in close coordination with store,
shall ensure that the consumable control procedure is followed in receipt, inspection, issue ,
control and processing of consumable.
6.7
QC Inspector
QC inspector shall be responsible to verify the correct implementation of the project
specifications in the execution of Fabrication and welding .Witnessing of tests, preparation of
records according to ITP, shall also be the responsibility of the QC Inspector. QC Inspector
shall check the correct implementation of consumable control procedure. QC shall ensure that
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
the fabrication and welding data are entered and updated in the system at Fab. shop and
appended to the SOC system regularly by the data entry operator.
6.8
6.9
Consumable Controller
Consumable issued from GTL shall be received and stored at the consumable store separately
by the consumable controller. All GTL consumable shall be labelled with a GTL sticker .
Consumable controller in co ordination with the QC inspector and Welding supervisor shall
implement the consumable receipt, treatment and issue according to the method statement for
Welding consumable control.
7.0
SHOP FABRICATION
7.1
General
Piping shall be fabricated based on the latest revision RFC (Released for Construction)
drawing. The RFC drawing shall be complete with, weld numbered isometric /spool drawing,
weld map, Bill of materials, support location, support detail and any additional information
necessary.
In addition to weld joint numbering, the flange joints also shall be numbered.
While numbering flange joints, disturbed and undisturbed flange joints (as differentiated in
Spec: T-13.377.453) shall be identified with distinct notation. (Key Performance Area Q11)
A controlled copy of the concerned drawing shall be available with the
Supervisor/Forman/Fabricator while fabrication of piping. (Key Performance Area Q11)
Fabrication of different material like Stainless Steel, Carbon steel and Low alloy steel shall be
done at separate areas . Separate tools shall be used for stainless steel fabrication. Wire
Brush, grinding wheels Earth clamps used shall be of SS material when working on SS piping.
All fabrication tables and pipe stands shall have sufficient isolation between SS pipe and CS
table with suitable non contaminating material, like wood.
Galvanised materials shall not be used to support pipe so as to avoid zinc contact with pipe
material.
Shops shall be kept clean to maintain a healthy and safe working environment.
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
7.2
Preparation
7.2.1
7.2.2
For low-alloy steel, after flame cutting a minimum of 2 mm of material shall be removed
from the cut surface by grinding.
For stainless steel, flame cutting shall not be used but plasma or water cutting may be
used. The surface shall be ground to bright metal after plasma cutting.
Weld bevels for butt welds of pipes and fittings shall be in accordance with ASME B16.25.
Shop-bevelling of field welds is not required if a make-up length (extra length for field cutting to
size) is provided. In these cases, bevels shall be prepared after cutting the relevant pipe spool
to the required length. Cutting oil shall be removed.
Pipes for socket weld joints shall be cut square and burrs removed.
7.3
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
Care shall be taken to avoid damage to the root face of the joint during tacking the joint and
again while removing the bridges during welding.
Also the below mentioned norms shall be followed;
Non welded fit-up clamps shall be used for alignment of all pipes.
The minimum distance between the edges of two pressure-containing welds shall be twice the
wall thickness of the thicker pressure part. The same requirement applies to the distance
between non-pressure attachment welds and a pressure-containing weld in order to allow nondestructive inspection of the pressure-containing weld. Longitudinal welds in two adjacent pipes
should be 180 apart, but in any case shall be separated by at least twice the wall thickness of
the thicker pipe. (In the case of an additional pup piece, minimum length shall be the pipe
diameter but not less than twelve inches unless otherwise specified in the drawing)
If the pipe contains a longitudinal weld, this weld shall not be located at the bottom of the pipe
after installation; it should be located at least 45 from the bottom of the pipe.
In order to avoid excessive shrinkage stresses during weld solidification, a gap shall be left
between the end of the pipe and the stop of the socket-welding component in accordance with
ASME B16.11. Failure to include this gap can lead to premature piping failures.
Pipes that are required to be free of scale shall be suitably cleaned before the welding shop
accepts them for further handling.
Refer to DEP 31.38.01.11-Gen. for flange misalignment acceptance criteria and also
requirements for cold and hot bending. (in case fabrication of bends called for)
7.4
Tolerances
The following dimensional tolerances shall apply:
7.4.1
Length
For Length
distance of any two
parallel or crossing
centre lines
Centre to flange face
Flange face to flange
face
7.5
< 1.5 m
1.5 m
1.5 mm
3 mm
Joint Identification
After completion of fit up, the joint number shall be hard stamped at two locations about 180
degrees apart and with in 50 mm from the joint .The fitter/fabricator doing the fit up shall sign off
the joint with paint marker.
The following nomenclature is used for identification of weld joints.
7.5.1
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
SOW
SSW
SCW
SPW
SLW
7.5.2
7.6
7.7
Inspection of Fit up
QC inspector shall make surveillance inspections to see that the fabrication is going on
according to the project requirements in, but not limited to;
pre-heat,
Qualification of personnel,
consumable control
and weather conditions
QC Inspector shall confirm that the fit up and visual check of the reported joints completed and
accepted , while reviewing Daily Welding Report(DWR).
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
8.0
WELDING
8.1
General
Before starting any welding work, Welding procedure Specification (WPS) shall be prepared,
qualified and approved by the company. Latest revisions of the WPS in The Welding Book
Piping (T-4.255.798) shall be used for the welding of any piping work connected to C8 ETP
,Shell GTL project Qatar
8.2
All the welders working in the Project shall be qualified on the WPS he is working, thickness
and position of the weld joint he is working on.
All the welders shall be given unique welder numbers specific for the GTL project.
The Gas Tungsten Arc Welding (GTAW) process shall be employed for root welds of all
pipes, and for welds of pipes, branch fittings and flanges DN80 and below. Above DN80
filling and capping layers may be performed with SMAW or other approved processes. For
process limitations Refer DEP30.10.60.18 Art 2.2.6
All GTAW machines shall be equipped with arc starting devices (high frequency, lift arc).
Two-sided welding should be applied whenever possible.
Production Welding
A copy of the approved WPS shall be available with the welding supervisor/Forman during
execution of welding work. Copies of the WPS shall be displayed at suitable area in the work
place for the reference of welders and welding operators.
The first ten production welds of all welders shall be radiographed in addition to the percentage
requirements according to the line class
Welding of carbon steel, ITCS, stainless steels and other corrosion resistant alloy materials
shall be carried out in separate workshops to avoid mix-up and/or contamination of materials
and welding consumables.
Joint fit up cleared by Welding Supervisor/or QC Inspector only shall be taken up for welding.
Pipes shall be supported in such a way that the joint being welded is not stressed/loaded and
so not distorted.
The root pass welding should start immediately after acceptance of the fit-up. No welding shall
be carried out when the parts to be welded are wet. No welding shall be performed unless the
welder and the work are properly protected from wind.
Arc strikes shall be situated in the fusion path. When interruption in welding takes place, a
proper restart procedure shall be used, ensuring full fusion with the previously deposited weld
metal.
Irrespective of the base material, root runs shall be made without interruption other than for
changing electrodes or to allow the welder to reposition himself. Welds shall not be allowed to
cool until at least half the wall thickness has been welded.
Thorough inter-run cleaning and slag removal shall be carried out.
Back-chipping, or gouging and grinding, shall be carried out thoroughly to sound metal before
deposition of subsequent layers
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
After completion of root run in Austenitic stainless steel material, welding supervisor/foreman
shall perform Alloy verification with a permanent magnet and result shall be updated in the
DWR. This activity shall be a witness point for QC inspector in the ITP
The QC inspector shall confirm that the welders are qualified and that the correct welding
consumables, as shown on the WPS are used - this applies in particular to stainless steel and
high alloy welding.
On completion of all welding activity of the day, Welding Forman/Supervisor shall make a Daily
Welding Report (DWR) for all completed spools and submit to the QC Dept. for verification
and updating in the system.
9.0
10.0
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VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
11.0
11.1
11.2
11.3
7), 8)
MATERIAL
SERVICE
RADIO
UT
Carbon &
Carbon
Manganese
Steels,
including 0.3 &
0.5
Molybdenum
Steels
Process
Hydrogen, Very
5)
Toxic Substances ,
LPG Temp < 0 C
All
Ratings
Process Hydrogen
+ Sulphur
Compounds, LPG
Temp > 0 C,
Caustic & Sulphuric
Acid
150,
300, 600
10 %
Process All
Services & Utilities
(other than A or B)
150,
300, 600
Random
100 %
Contractor name:
VSA CONSORTIUM
2), 3), 7)
4)
MAG PART
DP
HARDNESS
PMI
1)
N/A
6)
1)
N/A
6)
1)
N/A
9), 10)
6)
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
MATERIAL
SERVICE
7), 8)
ASME
RATING
CLASS
RADIO
UT
> 600
100 %
100 %
MAG PART
DP
HARDNESS
PMI
2), 7)
1)
N/A
9), 10)
6)
2), 7)
100 %
N/A
N/A
1), 3)
N/A
6)
N/A
1), 3)
N/A
6)
Process All
Services & Utilities
All Services
All
Ratings
Low Pressure
Service, T < 400 C,
(Except Hydrogen &
Very Toxic
5)
Substances )
150, 300
10 %
Hydrogen, Very
5)
Toxic Substances ,
Low Temperature &
All Services other
than F
All
Ratings
100 %
Nickel &
Nickel Alloys,
including 5 %
& 9 % Nickel
Steels
All Services
All
Ratings
100 %
N/A
1), 3)
N/A
6)
Dissimilar
Metal
Weldments
All Services
All
Ratings
100 %
100 %
100 %
6)
Low
Chromium
Molybdenum
Steels (Ferritic
Alloys)
Austenitic
Stainless
Steels
7)
100 %
9), 11)
6)
NOTES:
1)
All branch welds with through weld thicknesses > 25 mm shall be crack detected.
2)
Ultrasonic examination may be applied if the configuration precludes radiography and the pipe Diameter > DN 100
and the nominal wall thickness > 10 mm.
3)
In the case of fillet, socket or reinforcement attached welds; radiography shall be replaced by magnetic particle
inspection or dye penetrant inspection.
4)
The indicated minimum percentage of welds to be radiographed over the completed circumference shall cover all
welders at least once every week.
5)
Hydrogen service and Very Toxic substances are defined in (1.3.2).of DEP 31.38.01.31
6)
Positive Metal Identification (PMI) shall be carried out on all ferritic alloy steel welds and component parts, including
0.3 and 0.5 Mo steels, if any of Steps 1 through Steps 5 in (3.5 of DEP 31.38.01.31) is not followed completely.
7)
All nozzle/branch connections, including small nipples, shall be radiographed unless waived by the Principal.
8)
An Image Quality Indicator (IQI) with sensitivity better than 2 % shall be achieved by means of source side
location of the IQI. Where access only allows the use of film side IQI, the technique shall be proved by
means of a representative sample with IQI set source side and film side.
9)
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
10) Hardness reading may be required depending on the tensile strength of the material involved.
12.0
13.0
14.0
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
15.0
ATTACHMENTS
Contractor name:
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
REV. N: OA
DEPARTMENT : HSSE
DATE :
JSA APPROVED BY :
DEPARTMENT :
DATE :
CLIENTS APPROVAL :
CLIENT :
DATE :
WHERE REQUIRED)
General job requirements/common PPE
Stop work, switch off equipment,
Supervisor directs personnel to
nearest and safest Muster point
considering wind direction.
A) HSE Induction,
B) Hard Hat,
C) Hearing Protection
Contractor name:
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
No.
1
Job Steps
Pre-task
briefing
(TSTI) and
inspection
Cutting &
bevelling
Hazards
Prob.
Control Measures
Prob.
L.C.
Ensure that the pre task briefing is given out in a language understood
by the work force, have it translated. Ask question regarding the briefing
to get feed back from the staff, this ensures full comprehension.
Issue any required PPE and replace PPE that has signs of defect. PPE
must include both hearing protection as well as dust inhalation
protection.
Contractor name:
VSA CONSORTIUM
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Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
Check guard of the grinder is in place & cords are in good condition.
Ensure earthing. Use ear plugs/ muffs in the vicinity of Air Compressor.
No.
3
Job Steps
Fit-Up and
Assembly of
Piping
Components
Hazards
Prob.
Fall of material,
Tripping hazard
Control Measures
Ensure proper support to pipes to prevent fall of it.
Prob.
L.C.
Pre heating
Use other PPEs like safety shoes, safety glass, helmet, hand gloves.
Take hot work permit. Keep fire extinguisher ready to use.
Remove combustibles & flammables from work area.
Check all cords are in good condition.
Ensure earthing.
Wear required PPEs. (Hand gloves, safety glasses, Face shield,
Helmet, safety shoes, masks)
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PCWBS: NA
Contractor Doc No:
Orig. Org.:
F15032-AJE-0-0000-CMT-MST-7414
VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
For working at height: Provide safe access, use full body harness.
Fuel refilling shall not be done at work site.
Welding
Prob.
L.C.
No.
Job Steps
Hazards
Prob.
Contractor name:
VSA CONSORTIUM
Control Measures
For working at height: Provide safe access, use full body harness.
Wear required PPEs. (Hand gloves, safety glasses, Face shield,
Helmet, safety shoes, masks)
Unit: 0-0000
Sheet: 21 of 23
PCWBS: NA
Contractor Doc No:
Orig. Org.:
F15032-AJE-0-0000-CMT-MST-7414
VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
Contractor name:
VSA CONSORTIUM
Unit: 0-0000
Sheet: 22 of 23
PCWBS: NA
Contractor Doc No:
Orig. Org.:
F15032-AJE-0-0000-CMT-MST-7414
VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A
Contractor name:
VSA CONSORTIUM
Unit: 0-0000
Sheet: 23 of 23
PCWBS: NA
Contractor Doc No:
Orig. Org.:
F15032-AJE-0-0000-CMT-MST-7414
VSA
Project Doc No:
T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping
T-4.301.770
Rev.:A