SOHAR REFINERY IMPROVEMENT PROJECT

Method Statement for Under Ground Metallic

Piping Installation

Document No : BEC - OFD0137 -MS-003,REV 0

BEC Project Number : OFD0137
DPJV Contract Number : 120476 / JI-02022
Package Number : 2 & 6

21-12-2014

Issue for approval

Rev.

Date

Description

Bahwan Engineering Co LLC, PO Box 703, PC 112, Sultanate of Oman

Tel: +968 24597510, Fax: +968 24597511 www.bahwanengineering.com

V.K.R

Prepared

S.J

G.V.A

Reviewed

Approved

DPJV

Method statement for

Under Ground Metallic Piping
Installation

Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

INDEX
1. OBJECTIVE

2. SCOPE

3. ABBREVATIONS

4. SPECIFICATIONS

5. CODES

6. ROLESANDRESPONSIBILITIES

7. MANPOWER

8. EQUIPMENTANDTOOLS

9. SEQUENCEOFACTIVITIES

10. SCOPEOFWORK

11. SAFETYPRECAUTIONS

ATTACHMENT
12.

Page No: 2 OF 11

Project No: OFD0137

Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

Method statement for

Under Ground Metallic Piping
Installation

Project No: OFD0137

1. OBJECTIVE
Thisdocumentis intended to briefly describe sequence of events duringunderGround
metallic Piping Installation, confirms the risk assessment & to cover so far as is reasonably
practicable,thehealth,safety&welfareofouremployeesandotherswhomaybeaffectedduring
theUGPipingfielderection/welding/pressuretestingoftheworkscope.
2. SCOPE
ThismethodstatementisapplicableforUnderGroundmetallicpipingInstallation(Package
Number2&6)atSoharRefineryImprovementProject(SRIP).
3. ABBREVIATIONS
AFC
:ApprovedforConstruction.
AWS
:AmericanWeldingSociety
ASME
:AmericansocietyofMechanicalengineers
ANSI :AmericanNationalStandardsInstitution
Company :SoharRefineryImprovementProject(SRIP)
Contractor
:DaelimPetrofacJointVenture
SubContractor
:BahwanEngineeringCo.LLC(BEC)
ISO :InternationalStandardsOrganization
ITP :Inspection&testplan
NCR :Nonconformancereport
P&ID
:Piping&Instrumentationdiagram
PPE :PersonnelProtectiveEquipment
RA :RiskAssessment
4. SPECIFICATIONS
:GeneralrepairprocedureforPiping

SpecificationforPipingmaterial:S0005360003
PipingMaterialClassification:S0005360003139
ProjectspecificLineclass:S0005360003138

GeneralSpecificationforExternalCoatingofUndergroundSteelPipeS00013A0102
Rev.R1C2
Weldingcontrolandconsumablecontrolprocedure.

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Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

Method statement for

Under Ground Metallic Piping
Installation

Project No: OFD0137

MethodStatementforPressureTestingofU/GPiping.
MethodstatementforNDT
Heattreatmentprocedure.

5.CODES
ASMESect.IX

:Welding&BrazingQualifications

ASMESect.V

:NonDestructiveExamination

ASMEB31.1

:PowerPiping

ASMEB31.3

:ProcessPiping

ASMEB16.5

:PipeFlanges&PipeFittings

ASMEB16.47

:LargeDiameterSteelFlanges

ASMEB16.25

:ButtWeldingEnds

ASMEB1.20.1

:PipeThreads,GeneralPurpose

AWSD1.1

:StructuralWeldingCodesteel

6. ROLES&RESPONSIBILITIES
ConstructionManager

ShallReporttoSiteManager

Shall be overall responsible for control and monitoring of all Piping Installation
activities.

Shall have overall responsibility to ensure safety at site for the working group and
environment.

Shall be responsible for the execution ofworkin accordance with project HSE and
Qualityrequirements

QA/QCManager

ReporttoSiteManager.

Responsibilitiesforqualitycontrolofthepiping,welding,installation&testing

ResponsibleforpreparingITP,Inspection&testprocedures.

ShallreviewInspectionreports,testcertificates&prepareTQfortechnicalinformation.

Shallberesponsibleformonitoringmaterialpreservation,Installation&alignmentin
accordancewiththeSpecifications.
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Method statement for

Under Ground Metallic Piping
Installation

Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

Project No: OFD0137

Shallensurethattherequirements&specificationsstipulatedinthismethodstatement
areappliedandmaintainedthroughouttheprojectconstructionperiod

Shallensurethatallrelevantproceduresforundergroundpipinghavebeenapprovedby
DPJVpriortoworkcommencing.

PipingEngineer

ShallreporttoConstructionManager

Shall ensure that welding & epoxy coating activities are ongoing as per project
specificationrequirementsandasperthelatestdrawings.

Preparetechnicaldeviation,concessionrequest,as&whenrequired.

ShallberesponsibleforexecutionofworkincompliancetotheprojectHSEandQuality
requirements

PipingSupervisor/Foreman

ShallreporttoPipingEngineer

ShallensurethatpersonnelworkingareHSEinductedandarecomplyingwithProject
HSERequirements.

ShallconductHSEtoolboxtalktoallconcernedpersonnelpriortostartofwork

ControlExecutionofPipinginstallation,storage,trackingofthematerialreceivedatsite.

CoordinatewithQA/QCInspectorwhileperformingInspectionaspertheITP.

Shall ensure all dimensional & structural control is as per approved drawing
requirements.

QCInspector

ShallreporttoQCEngineerPiping/Welding

Shallmonitor&InspectQA/QCactivitiesagainstapprovedITP,Projectspecification,
drawings.

ShallliaisewithClientInspectionPersonnelduringinspection.

PrepareandmaintainInspectiondocuments.

Shallinspecttheincomingmaterialsasperdesigngeneralspecificationandpurchase
orderrequirements.

ShallmonitortheWPS/Weldersqualificationstatus.
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Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

Method statement for

Under Ground Metallic Piping
Installation

Project No: OFD0137

Shallensurethatallinstrumentsaredulycalibratedandcertified

WeldingForeman

Shallbereportingtopipingengineer

Shallensurethatonlyqualifiedweldersaredeployedonjob.

ShallberesponsiblefortheissueandcontrolofweldingconsumablerelevanttoWPS.

ShallensurethatallpersonnelworkinginweldingareHSEInductedandfamiliarwith
projectHSE&Qualityrequirements

Shallconducttoolboxtalkpriortostartofwork&ensurecompliancewithWPS

Materialcontroller

ShallreporttoMaterialManager

Shallensurethatallmaterialsarestored&segregatedaspermaterialspecification&
size/schedulewise.

Shallensurethatallboughtoutprojectmaterialsareinspected&certifiedbyconcern
authority.

Shallensurethatallmaterials/spoolsareissuedforinstallationinaccordancewithMIR.

SafetyOfficer

ShallreporttoHSEManager

Ensure valid work permit for all activities performed during installation and permit
conditionarecomplied.

Ensurescaffoldingsaretaggedanddulysignedbyscaffoldinginspector

Ensurethatemployeesinvolvedinthescaffoldingworkaretrained/qualified

EnsurethatproperPPEsarebeingusedbyemployeesduringwork.

Conducttoolboxtalkinordertoexplainpossiblehazards,associatedrisks&control
measures

IdentifyspecifichazardsandassistconstructionSupervisiontoensuresafeprogressof
workactivity.

Controlunauthorizedentrytoworkareabyproperbarricading&displayingwarning
signboardsandindicators.
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Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

Method statement for

Under Ground Metallic Piping
Installation

Project No: OFD0137

CoordinatewithcontractorsiteHSEstaffforeffectivecontrolofactivityatsite.

7. MANPOWER

SiteManager

ConstructionManager

QCManager

PipingEngineer

PipingSupervisor/Foreman

Pipefabricator/Fitter

Welders

Riggers

QCInspector

Materialcontroller

HSEOfficer

CraneOperator

Forkliftoperators

Helpers

8. EQUIPMENT&TOOLS

Trailer

Crane

Forklift

Spanners/TorqueWrench

WeldingMachines

AlignmentInspectiontools

Liftingtools&tackles

HolidayMachine
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Method statement for

Under Ground Metallic Piping
Installation

Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

TestManifold

Pressuregauges/Recorder

Spiritlevel,Measuringtape

CuttingSet

GrindingMachine

Project No: OFD0137

9. SEQUENCEOFACTIVITIES

Transportation,Loading&unloadingofmaterials

Surfacepreparationandhighsolidepoxycoating

PipeInstallationandfieldwelding

NDTofWeldingJoints

Holidayinspectionforcoating

Linecheckingandpunchclearance

Hydrotesting

Holidayinspectionforfieldweldcoatingarea

Reinstatement

Backfilling

10. SCOPEOFWORK
10.1.1

Transportation,Loading&unloadingofmaterials

MaterialcontrollershallrequestforthespoolaspertheprogramprovidedbyFieldEngineering&

planningdepartment.

MaterialsissuevouchershallbepreparedandissuedtoProjectstorestowithdrawErection
items

Spools requirement based on the front availability & Priorities shall be provided to spool
coordinatorbyFieldpipingengineerfortracking&issueofspool.

Materials received shall be segregated with respect to the type of materials (Carbon
steel/Galvanizedsteel/Stainlesssteel)andkeptseparatelyaccordingtothecolorcode.
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Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

Method statement for

Under Ground Metallic Piping
Installation

Project No: OFD0137

Preservationandstorageofpipingspools,supportanderectionmaterialsshallbeensuredin
accordancewithprojectspecification.

DuringTransportationofhigh/fusionbondedepoxycoatedpipe,muchattentionshallbetaken
toavoiddamagetopipeorcoating.

Theendcapsshallbekeptinplaceduringtransportandstorageinordertopreventdust,dirtand
foreignmatterfromenteringthepipe.

10.1.2 Surfacepreparation&Highsolidepoxycoating

AllbarecarbonsteelpipeshallbesurfacepreparationinaccordancewithSSPCSP3orSA2
(ISO85011)
Forstainlesssteelpiping,surfacepreparationshallbesweepblasting/chlorinefreeabrasives.
TheapplicationofthetapeprimerandwrappingshallbeinaccordancewithS00013A0102
Rev.R1C2(Externalcoatingofundergroundsteelpipe)andapprovedmethodstatement.

10.1.3 Installation&Fieldwelding

Priortostartpipeinstallation,handovertrenchingnotefromcivilshallbeobtained.

Correctelevation,coordinationandalignmentshallbeverifiedbeforestartuptheinstallation,
fitupandweldingactivitiesasperapprovedISODrawings.

Properbarricadesshallbeprovidedallaroundthetrenchlocationwhileworking.

Beltslingsshallbeusedforliftingpipes&spoolsinordertoavoiddamagestocoatedpipes.

Allpipes/spoolsshallbecleanedandensurethatitisfreefromanyforeignmaterialsinsidethe
pipes.

Allopenendsofpipingspoolsshallbeblankedproperlytoprevententryofforeignmaterials
anddamagetobevelends,duringentireconstructionperiod.

FituptackingshallbecarriedoutbyusingqualifiedweldersaccordingtoapprovedWPS.

Afterfitupofthepipingspool,jointnumbertobeincorporatedonpipeasperapproveddrawing.

WeldersshallbetestedandqualificationswillbeendorsedbyDPJVQA/QCdivisionpriorto
commencementofproductionwelding.

Noweldingshallbedoneiftherewillbeanimpactofrain,snow,sleetorhighwindinthe
workingarea.However,weldingworkshallbedoneprovidedthatsuitableprotectionisinstalled
andapprovedbycontractor.

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Method statement for

Under Ground Metallic Piping
Installation

Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

Project No: OFD0137

Uponinstallationofpiping,thepipejointsshallbepreparedtotherequireddimensionsas
specifiedintheapprovedisometricdrawings.Weldedgeshallbepreparedasperapplicable
approvedWPS.

Separatetoolsandtackleslikewirebrushes,grindingwheels,chippinghammersetc.shallbe
usedforstainlesssteelpipingwork.

Thermalexpansionclearanceshallbeprovidedbetweenpipeedgeandinnerfaceofthefitting
forweldingsocketjointsasperprojectrequirement

Careshallbetakentopreventdistortionofpipewhilecuttingthebranchholesandweldingthe
branchconnection.Temporarystrongbackswherenecessary;maybeprovidedpriortowelding
the branch connection. Other suitable measures such as holding the pipe in
camber/concretewallpriortoweldingmayalsobeconsidered.

10.1.4 Bolting&Tightening

AllboltingmaterialsshallconfirmtoISOdrawing

OnlylatestrevisiondrawingswithAFCStampingshallbeusedforInstallation.

Followclientapprovedbolttightening/torqueingprocedure

Diagonallyoppositeboltsshallbetightenedforauniformtightnessoftheflangejoints

Ensurethatpermanentgasketshaveinstalledpriortobolttightening

Allpermanentflangejointswhichareinlinetotestcircuitshallbefittedwith
permanentgasketwithcorrectsizeofboltsandnutsandbolttighteningtobe
completed.

OnlyCalibratedtorquewrenchesshallbeusedforbolttorqueingandcompanyapproved
torqueingprocedureshallbefollowed.

10.1.5 NDTofWeldingJoints

AllNDTactivitiesshallbecarriedoutbyclientapprovedandqualifiedNDTtechnicians

Percentage of NDT requirement (RT/M.P.I/L.P.T) defines from ASME B 31.3 or project

specificpipingclass.

ClientapprovedNDTprocedureshallbefollowedforInspectionandevaluationoftheresult
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Method statement for

Under Ground Metallic Piping
Installation

Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

OnlycalibratedinstrumentshallbeusedforInspection.

Allconsumablesusedatthetimeofinspectionshallbeapprovedbyclient

VisualinspectionofweldedjointsshallbecompletedpriortoNDTimplement.

AllinspectionreportsshallbemaintainedproperlyasperISOrequirement

Radiationsafetyprocedureshallbefollowedforconductingradiography.

PWHTtobecompletedpriortocommenceofRT/MT/PT,ifPWHTapplicable.

Project No: OFD0137

10.1.6 Line checking and Punch clearance.

All piping shall be checked (punched out) to confirm that the final installation
accordance with the latest revision of the relevant P&ID and isometrics.
A thorough line inspection shall be carried out as per Pre Test line check report
All discrepancies shall be recorded on a piping test pack punch list

is in

Prior to hydro test all A punch items shall be completed and cleared by DPJV/ QC by
signing off on the punch list.

10.1.7 PressureTest.

Priortohydrotestingofthesystem,lineshallbeMechanical&NDTclearedasperproject
specification/standard.

Allpressuregaugesusedforpressuretestshallbecalibrated&pressuretemperaturerecorders
shallbecalibrated.

AminimumoftwocalibratedPressuregaugesshallbeusedandonceatlowestpointandoneat
highestpointofthepressurizedsystem.

Testpackagesshallbepreparedandreviewedpriortopressuretest,alltherelevantdrawings,
forms&certificatesshallbeattached

Testblindsusedshallhavesufficientthicknesstowithstandtestpressure.

Testmanifoldshallbepressuretestedandapprovedfromcontractor.

Testingmediumshallbeusepotablewater.

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Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

Method statement for

Under Ground Metallic Piping
Installation

Project No: OFD0137

Watershallbefilledfromthepossiblelowerportionofthepipingsystemtoreleaseairfrom
inside.

AllweldingjointsshallbevisuallyexposedandshallbefreefromHighsolidepoxyorfusion
bondedepoxycoatingatthetimeofhydrotesting.

AllNDTandVisualinspectionofweldedjointsshallbecompletedpriortopressuretest.

Ensurethecorrectorientationandflowdirectionofvalvesandinstrumentspriortotest.

Holdingtimeofthetestpressureshallbeasperstandard.

Items/internalpartsremovedshallbereinstatedaftertest.

Aftercompletehydrostatictest,thepipingshallbecarriedoutdrainimmediately

10.1.8 Holidayinspectionforfieldweldcoatingarea

Aftersuccessfulofpressuretestingallexposedfieldweldlocationshallbecoatingas
perS00013A0102Rev.R1C2(Externalcoatingofundergroundsteelpipe)

Conducttheholidayinspectiononweldlocationarea

10.1.9 Backfilling

11

Aftersuccessfulofpressuretestingandcoatinginspection,trenchingareashallbe
releaseforbackfillingandinformtocivildepartment.

SAFETYPRECAUTIONS

AllapplicablerequirementsmentionedintheProjectHSEPlanandspecificRAshallbe
implementedattheconstructionsite.

Toolboxtalksshallbeconducteddailyforsafetyandenvironmentalmattersrelatedto
constructionactivitiesatsite.

Onlythoseliftingequipmentandtoolswhichareofsuitablecapacity,ingoodcondition,
certified,inspectedandcolorcodedshallbeusedforallliftingactivities.

Trainedandcompetentbanksmenorriggersshallbeappointedfortheheavyliftoperations.

Adequatesignalingsystemshallbeimplementedtocontroltheliftingactivities.

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Sohar Refinery Improvement Project SRIP

Doc Ref : BEC-OFD0137-MS-003 Rev-0

Method statement for

Under Ground Metallic Piping
Installation

Project No: OFD0137

Personnelmovementunderthesuspendedloadsshallbeavoided.Alltheliftingactivitiesshall
becarriedoutunderthestrictsupervisionofexperiencedforeman/chargehands.

Suitablefireextinguishersshallbeprovidedinallequipments,whererequired.

PermittoworkshallbeobtainedfromDPJVfortheworksininsidetrench,aspertheproject
siteregulations.

Signboards&hardbarricadesshallbeplacedaroundpipingerectionareaexceptwhereactive
workrequiresopeningofsuchdevicesandthenonlysuchportionofthebarricadeneededfor
workaccesswillberemoved.

DangersignsshallbeprovidedandwarningsignshallbewritteninEnglishand/orHindiorany
otherlanguageasrequired.

Noliftingoperationsshallbecarriedoutintheheavywindandbadweatherconditions.

NightoperationsshallbecarriedoutonlywiththepriorpermissionsfromHSE/DPJV

PersonnelworkingatinsidetrenchshallwearsuitablePPE.

Priortopipeinsertion/erectionofpipespoolsvariouslevelsintrenching,Construction
Supervisor&Riggingforemanmustmakeajointsurveyoftheinsertion/erectionareaand
ensuretheriggersinvolvedarehavingsafeaccesstotheworklocationandensure100%tieofat
alltime.

Nooneshallbeallowedtogounderthesuspendedloads,barricadesafetysigns&watchershall
beprovidedwhenerectionworkdoneinsidetrenchingarea.

12.ATTACHMENTS
12.1) JOBHAZARDANALYSIS/RISKASSESSMENT

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