SOHAR REFINERY IMPROVEMENT PROJECT

SRIP

Method Statement for Above Ground Piping

Installation
Document No: BEC-OFD0137-MS-007-REV. 0
BEC Project Number - OFD0137
DPJV Contract Number 120476 / JI-02022
Package
Number 2 & 6

5/01/2015

Issued for approval

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

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

V.R.N

S.J

G.V.A

Sohar Refinery Improvement Project SRIP

Above Ground Piping Installation

Doc Ref : BEC- OFD0137-MS-007 Rev-0

Rev
.

Date

Description

Project No: OFD0137

Originat
or

INDEX

1. OBJECTIVE
2. SCOPE
3. ABBREVIATIONS
4. SPECIFICATIONS
5. CODES
6. ROLESANDRESPONSIBILITIES
7. MANPOWER
8. EQUIPMENTANDTOOLS
9. SEQUENCEOFACTIVITIES
10. SCOPEOFWORK
11. SAFETYPRECAUTIONS
12. ATTACHMENTS

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Checker

Approve
r

DPJV

Sohar Refinery Improvement Project SRIP

Above Ground Piping Installation

Doc Ref : BEC- OFD0137-MS-007 Rev-0

Project No: OFD0137

1. OBJECTIVE
Thisdocumentis intended to briefly describe sequence of events duringAboveGround
PipingInstallation,confirmstheriskassessment&tocoversofarasisreasonablypracticable,the
health,safety&welfareofouremployeesandotherswhomaybeaffectedduringtheAGPiping
erection/testingofpackagenumber(2&6)theworkscope.
2. SCOPE
ThismethodstatementisapplicableforAboveGroundpipingInstallationforpackagenumber(2
&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
TRA :RiskAssessment
4. SPECIFICATIONS

ProjectQualityPlan
:GeneralrepairprocedureforPiping
WelderandweldingoperatorQualificationprocedure
MeasuringandTestEquipmentcontrolprocedure
Weldingqualitycontrolprocedure

PipingMaterialSpecification
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Project No: OFD0137

PipeMarkingSpecification
Specificationforinternalcleaningofpiping
Materials&FabricationRequirementsforcarbonsteel.
Welding,NDE,PreventionofBrittleFractureofPiping
SpecificationforFabricationHandling&InstallationofProcessandUtilityPiping
TechnicalSpecificationforPipingSystemSpecificationforGeneralPiping
GeneralPipingProcessandUtilityDesignFieldPressureTesting

Specificationforbolttorqueing/TensioningforFlangedConnection
SpecificationforthetraceabilityofshopandfieldPipingMaterials
SpecificationforpreservationandExportPacking
WeldingConsumableControlProcedure
NDEControlProcedure
HeatTreatmentandHardnessControlProcedure
MethodStatementforPressureTestingofA/GPiping.
PMIProcedure

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
Construction Manager

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.

Shallhaveoverallresponsibilityforthequalityoffabricateditemsifmodifiedatsite.

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

QA/QC Manager

ReporttoSiteManager.
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Project No: OFD0137

Responsibilities for quality control of the piping fabrication, welding, installation &
testing

ResponsibleforpreparingITP,Inspection&testprocedures.

ShallreviewInspectionreports,testcertificates&prepareTQfortechnicalinformation.

Shallberesponsibleformonitoringmaterialpreservation,Installation&alignmentin
accordancewiththeSpecifications.

Shallensurethattherequirements&specificationsstipulatedinthismethodstatement
areappliedandmaintainedthroughouttheprojectconstructionperiod

Shallensurethatallrelevantproceduresforabovegroundpipinghavebeenapprovedby
COMPANYpriortoworkcommencing.

Piping Engineer

ShallreporttoConstructionManager

Shallensurethatfabrication,welding&Paintingactivitiesareongoingasperproject
specificationrequirementsandasperthelatestdrawings.

Preparetechnicaldeviation,concessionrequest,as&whenrequired.

ShallberesponsibleforexecutionofworkincompliancetotheprojectHSEandQuality
requirements

Piping Supervisor/Foreman

ShallreporttoPipingEngineer

ShallensurethatpersonnelworkingareHSEinductedandarecomplyingwithProject
HSERequirements.

ShallconductHSEtoolboxtalktoallconcernedpersonnelpriortostartofwork

ControlExecutionofPipinginstallation,storage,trackingofthematerialreceivedatsite.

CoordinatewithQA/QCInspectorwhileperformingInspectionaspertheITP.

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

QC Inspector

ShallreporttoQCEngineerPiping/Welding
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Project No: OFD0137

Shallmonitor&InspectQA/QCactivitiesagainstapprovedITP,Projectspecification,
drawings.

ShallliaisewithClientInspectionPersonnelduringinspection.

PrepareandmaintainInspectiondocuments.

Shallinspecttheincomingmaterialsasperdesigngeneralspecificationandpurchase
orderrequirements.

ShallmonitortheWPS/Weldersqualificationstatus.

Shallensurethatallinstrumentsaredulycalibratedandcertified

Welding Foreman

Shallbereportingtopipingengineer

Shallensurethatonlyqualifiedweldersaredeployedonjob.

ShallberesponsiblefortheissueandcontrolofweldingconsumablerelevanttoWPS.

ShallensurethatallpersonnelworkinginweldingareHSEInductedandfamiliarwith
projectHSE&Qualityrequirements

Shallconducttoolboxtalkpriortostartofwork&ensurecompliancewithWPS

Material controller

ShallreporttoMaterialManager

Shallensurethatallmaterialsarestored&segregatedaspermaterialspecification&
size/schedulewise.

Shallensurethatallboughtoutprojectmaterialsareinspected&certifiedbyconcern
authority.

Shallensurethatallmaterials/spoolsareissuedforinstallationinaccordancewithMIR.

Safety Officer

ShallreporttoHSEManager

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

Ensurescaffoldingsaretaggedanddulysignedbyscaffoldinginspector

Ensurethatemployeesinvolvedinthescaffoldingworkaretrained/qualified
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Project No: OFD0137

EnsurethatproperPPEsarebeingusedbyemployeesduringwork.

Conducttoolboxtalkinordertoexplainpossiblehazards,associatedrisks&control
measures

IdentifyspecifichazardsandassistconstructionSupervisiontoensuresafeprogressof
workactivity.

Controlunauthorizedentrytoworkareabyproperbarricading&displayingwarning
signboardsandindicators.

CoordinatewithDPJVHSEstaffforeffectivecontrolofactivityatsite.

7. MANPOWER

SiteManager

ConstructionManager

QCManager

PipingEngineer

PipingSupervisor/Foreman

Pipefabricator/Fitter

Welders

Riggers

QCInspector

Materialcontroller

HSEOfficer

CraneOperator

Manlift/Forkliftoperators

8. EQUIPMENT&TOOLS

Trailer

Crane
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Forklift&Manlift/ManBasket

Spanners/TorqueWrench

WeldingMachines

Highfrequencyunit

AlignmentInspectiontools

Liftingtools&tackles

TestManifold

Pressuregauges/Recorder

Spiritlevel,Measuringtape

CuttingSet

GrindingMachine

9. SEQUENCEOFACTIVITIES

Transportation,Loading&unloadingofmaterials

Installationofpipespools&fieldwelding

PipeSupportfabrication&Installation

NDTofWeldingJoints

Installationofvalves&fittings

Hydrotest/Pneumatictest

Punchlisting&Reinstatement

Precommissioningactivities

Finalclearance&Handover

10. SCOPEOFWORK
10.1

Transportation, Loading & unloading of materials

MaterialcontrollershallrequestforthespoolaspertheprogramprovidedbyFieldEngineering&

planningdepartment.

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Project No: OFD0137

MaterialsissuevouchershallbepreparedandissuedtoProjectstorestowithdrawErection
items

Spool/Supportsrequirementbasedonthefrontavailability&Prioritiesshallbeprovidedto
spoolcoordinatorbyFieldpipingengineerfortracking&issueofspool.

Materialsreceivedshallbesegregatedwithrespecttothetypeofmaterials(CS/SS/LTCS/AS/
Nickelalloys)andkeptseparatelyaccordingtothecolorcode

Materialsreceivedforpipesupportsshallbeinaccordancetothestandardsupportspecification

Preservationandstorageofpipingspools,supportanderectionmaterialsshallbeensuredin
accordancewithprojectspecification.

Pipespoolshouldbekeptclearfromtheground.Beforetransportationoffabricatedspoolsat
site,necessaryclearance(SpoolID,DimensionandNDE)shallbeobtainedfromContractor
QA/QCdivision.

DuringTransportationoffabricatedspool,muchattentionshallbetakentoavoiddamagetopipe
orpainting.

Theendcapsshallbekeptinplaceduringtransportandstorageinordertopreventdust,dirtand
foreignmatterfromenteringthepipe.

10.2

Installation & Field welding

Priortostartinstallation,handovernotefromStructuralshallbeobtained.

Correctelevation,coordinationandalignmentshallbeverifiedbeforestartuptheinstallation,
fitupandweldingactivitiesasperapprovedISODrawings.

Welding Supervisor shall assign qualified welders for all welding activities

Approved welding procedure shall be followed for all welding activities

during fit up & field welding

Heat number to be transferred on the pipe prior to cut the piping spool.

After fit-up of the piping spool, joint number to be incorporated on pipe as

per specification.

Piping spool shall be properly identify with spool no, drawing/ISO no.

Belt slings shall be used for lifting pipes & spools in order to avoid damages
to painted pipes / spools
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Correct orientation, dimensions shall be confirmed during fit up with respect

to ISO drawing

Pre heating of pipes /fittings shall be performed prior to tack/full welding as

per the approved WPS

Purging shall be done for SS & AS Materials during welding as per approved
WPS.

Thermal expansion clearance shall be provided between pipe edge and inner
face of the fitting for welding socket joints as per project requirement

Propercuttingtechniquesshallbefollowedforedgepreparationduringfitupandgascutting
shallnotbedoneforSS(SA312TP304L/316L/321)&AS(2Cr,5Cr,9Cr1Mo)Materials.

Separatetoolsandtackleslikewirebrushes,grindingwheels,chippinghammersetc.shallbe
usedforstainlesssteelpipingwork.
SmallboreweldingshallbedonebyGTAWprocessonly.

Necessaryscaffoldingplatformarrangementsshallbeprovidedtoensuresafeaccessforfitup/
welding

Properbarricadesshallbeprovidedallaroundtheworklocationwhileworkingontoptier.

Allpipes/spoolsshallbecleanedandensurethatitisfreefromanyforeignmaterialsinsidethe
pipes.

Allopenendsofpipingspoolsshallbeblankedproperlytoprevententryofforeignmaterials
anddamagetobevelends,duringentireconstructionperiod

Productionshallbeperformedinaccordancewithapprovedprocedure.

FituptackingshallbecarriedoutbyusingqualifiedweldersaccordingtoapprovedWPS.

After fit-up of the piping spool, joint number to be incorporated on pipe as

per specification.

WeldersshallbetestedandqualificationswillbeendorsedbyDPJVQA/QCdivisionpriorto
commencementofproductionwelding.

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

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10.4

Project No: OFD0137

Uponinstallationofpiping,thepipejointsshallbepreparedtotherequireddimensionsas
specifiedintheapprovedisometricdrawings.Weldedgeshallbepreparedasperapplicable
approvedWPS.Pipingcomponentsshallbecleanedfrominsideandconductvisualinspection
priortofitupassembly.
NDT of Welding Joints
All NDT activities shall be carried out by client approved and qualified NDT
technicians

DPJV approved NDT procedure shall be followed for Inspection and

evaluation of the result

Only calibrated instruments with third party certification shall be used for
Inspection

All consumables used at the time of inspection shall be approved by DPJV

Visual inspection of welded joints shall be completed prior to NDT

implement.

All inspection reports shall be maintained properly as per ISO requirement

Radiation safety procedure shall be followed for conducting radiography.

PWHT to be completed prior to commence of RT/MT/PT, if PWHT is

applicable.

All repairs shall be conducted with client recommendation and RFI shall be
raised for the same

10.5 PWHT of Welding Joints

ClientapprovedPWHTProcedureshallbefollowedforPWHTofweldingjoints

Temperature recorders shall calibrated by third party inspector

Only Client approved thermocouples shall be used and shall be color coded
for identification

Band width of heating coil and insulation width shall be as per PWHT
procedure.
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All openings shall be closed to avoid heat loss due to air circulating through
pipe.

Number of thermocouples used and their position shall be as per PWHT

procedure

Thermocouples shall be attached to pipe by capacitor discharge welding

method or by client recommendation

Recorder chart must be signed by client & sub-contractor QC Inspectors prior

to the start of PWHT and Joint & temperature details provided shall be
verified.

10.6 Bolting & Tightening

All bolting materials shall confirm to ISO drawing

Only latest revision drawings with AFC Stamping shall be used for
Installation.

Follow client approved bolt tightening/torqueing procedure.

Diagonally opposite bolts shall be tightened for a uniform tightness of the

flange joints

Ensure that permanent gaskets have installed prior to bolt tightening

Only Calibrated torque wrenches shall be used for bolt torqueing and
company approved torqueing procedure shall be followed

10.7 Pressure Test

Prior to pressure testing of the system, line shall be Mechanical & NDT
cleared as per project specification/standard.

All pressure gauges used for pressure test shall be calibrated once in every
six month & pressure-temperature recorders shall be calibrated once in
every six month by a third party or laboratory.

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A minimum of two calibrated Pressure gauges shall be used and once at

lowest point and one at highest point of the pressurized system. It will be
placed in such a way that dial reading is visible and readable.

Test packages shall be prepared and reviewed prior to pressure test, all the
relevant drawings, forms & certificates shall be attached

Test blinds used shall have sufficient thickness to withstand test pressure.

Test manifold shall be pressure tested as per project specification and

certified by a DPJV

Water shall be filled from the possible lower portion of the piping system to
release air from inside.

All welding joints shall be visually exposed at the time of test.

All NDT and Visual inspection of welded joints shall be completed prior to
pressure test.

Ensure the correct orientation and flow direction of valves and instruments
prior to test.

Items which may damage during test or obstruct the flow including flow
meters, orifice plates, control valves, check valves, strainers, steam
trapsetc., shall be removed or its internals shall be removed whichever is
appropriate.

Holding time of the test pressure shall be as per standard.

Items /internal parts removed shall be re-instated after test.

After complete hydrostatic test, the piping shall be carried out drain
immediately with compressed air.

All the vents to be opened before draining to prevent the formation of

vacuum on the system.

All test vents & drains shall be seal welded after pressure test & dewatering, as applicable.
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11. SAFETYPRECAUTIONS

All applicable requirements mentioned in the Project HSE Plan and specific
RA shall be implemented at the construction site.

Tool box talks shall be conducted daily for safety and environmental matters
related to construction activities at site.

Only those lifting equipment and tools which are of suitable capacity, in
good condition, certified, inspected and color coded shall be used for all
lifting activities.

Trained and competent bank men or riggers shall be appointed for the heavy
lift operations.

Adequate signaling system shall be implemented to control the lifting

activities.

Personnel movement under the suspended loads shall be avoided. All the
lifting activities shall be carried out under the strict supervision of
experienced foreman / charge hands.

Suitable fire extinguishers shall be provided in all equipments, where

required.

Permit to work shall be obtained from CONTRACTOR/COMPANY for the works

in the area of existing structures and/or confined spaces, as per the project
site regulations.

Sign boards & hard barricades shall be placed around erection area except
where active work requires opening of such devices and then only such
portion of the barricade needed for work access will be removed.

No lifting operations shall be carried out in the heavy wind and bad weather
conditions.

Night operations shall be carried out only with the prior permissions from
HSE and CONTRACTOR.
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Project No: OFD0137

Personnel working at heights shall wear suitable PPE and body harness. All
those personnel shall attend and inducted by HSE for working at heights.

Prior to pipe insertion / erection of pipe spools in various levels of pipe rack,
Construction Supervisor & Rigging supervisor must make a joint survey of
the insertion / erection area and ensure the riggers involved are having safe
access to the work location and ensure 100% tie of at all time.

Keep some scaffolders readily available or modify / dismantle the

obstructions before lifting pipes for insertion.

No one shall be allowed to go under the suspended loads, barricade safety

signs & watcher shall be provided when erection work done at congested or
high elevated area.

12. ATTACHMENTS
JHA/RA

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