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METHOD STATEMENT FOR Page 1 of 17
CROSS COUNTRY PIPELINE INTALLATION
METHOD STATEMENT
FOR
CROSS COUNTRY PIPELINE INTALLATION
INDEX
1. PURPOSE
2. SCOPE
3. REFERENCES
4. DEFINITIONS
5. RESPONSIBILITIES
6. PROCEDURE
8. SAFETY INSTRUCTIONS
9. ATTACHMENTS
1. PURPOSE
DESCON ENGINEERING LIMITED MS//MECH/16
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METHOD STATEMENT FOR Page 3 of 17
CROSS COUNTRY PIPELINE INTALLATION
2. SCOPE
Survey
Right of way
Trenching
Stringing
Welding
Inspection
Holiday test
Lowering in
Field Bending
Crossings
Cleaning
Hydro testing
3. REFERENCES
Others.
Approved WPS.
Project Drawings
Project Specifications
4. DEFINITIONS
CL Client
PM Project Manager
SM Site Manager
CM Construction Manager
DE Discipline Engineer
ROW Right Of Way
ITP Inspection and Test Plan
QC Quality Control
QCI Quality Control Inspector
PQP Project Quality Plan
PPE Personal Protection Equipment
HSE PLAN Health Safety & Environment Plan.
DESCON ENGINEERING LIMITED MS//MECH/16
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METHOD STATEMENT FOR Page 5 of 17
CROSS COUNTRY PIPELINE INTALLATION
5. RESPONSIBILITIES
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.
DE will ensure that all the works are performed safely as per latest Approved For
Construction (AFC) drawings & specifications.
The relevant DE and Supervisor will ensure that all the piping work is conducted
in accordance with this method statement and project specification.
The QC Inspector will ensure that all work is executed according to PQP and that
requirements of quality dossier are full filled.
6. PROCEDURES / METHODOLOGY.
A suitable crane and Nylon slings shall be used for off loading of piping.
The Nylon slings will be used for handling of the pipes to avoid / minimizes the
external coating damaged.
During loading or unloading pipes shall not be dropped onto or off the transporting
vehicle.
The material received shall be checked for quantity and quality items.
The piping materials shall be segregated as per size to facilitate the location and
ease of handling.
DESCON ENGINEERING LIMITED MS//MECH/16
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METHOD STATEMENT FOR Page 6 of 17
CROSS COUNTRY PIPELINE INTALLATION
It is understood that Client shall obtain necessary right of way from the
concerned Agencies / Authorities and there shall be no reason of
dispute with the landowners, which can become cause of any delay.
However, Descon shall keep a liaison with these Agencies / Authorities
for smooth working on the project.
Four to five survey teams shall be deployed for carrying out the survey.
It is planned to submit for Clients’ approval a ROW survey carried out in
first 10 days enabling the ROW crew to start work.
Make the width of ROW from the survey stones and start cutting and
leveling of ROW as per sectional drawings.
6.4 TRENCHING:
The soil will be placed a minimum 0.4m from the edge of the ditch.
The trench walls and bottom shall be made free of any sharp edges and
elements that may cause damage to pipe coating.
The excavated materials suitable for back filling shall be placed along
side the trench at a sufficient distance, 1m away to avoid any
unnecessary load on trench walls and it does not obstruct pipeline
stringing and welding works.
The explosive shall be charged just before the start of blasting works.
Stringing may proceed after the ROW clearing and grading is complete
and will be in accordance with the specifications.
Place wooden skids / dirt berms approximate 02 meter away and along
the side of the trench.
The pipes shall be strung along side excavated trench and marked for
identification.
The trailer bed and their side supports shall have a suitable protective
material to avoid chances of scratches, scars or brusis to the pipe
coating.
The pipe will be off loaded in accordance with the stringing schedule.
This is to ensure that, pipes of the correct wall thickness are placed in
correct sequence of use.
The WPS shall be prepared in accordance with API Standard 1104 latest
edition for field welding of pipeline / as per the project specifications
and shall be submitted for client’s approval. The tests shall be
conducted for the final acceptance of welding procedure, welding
consumables, welding current and other parameters. The incharge
quality control shall maintain a record of all WPS.
A) Own Photograph
B) Welder’s name
C) Company name
D) Qualification symbol
The pipe ends shall be factories beveled to satisfy API 1104. The ends
shall be checked for their geometry, mechanically cleaned, reset on the
sandbags / wooden skids and shall be made ready for welding crew.
Cleaning shall be performed on the inside and outside of the pipe and
at least up to ten cm from the edge. In case any end is damaged
beyond the permissible limits set in the Project Specification/Applicable
Code it shall be brought to the notice of the Job Inspector and a suitable
remedial action shall be taken.
The line shall be swabbed and cleaning means. Subsequently the pipe
ends shall be covered using polyethylene sheet and tape or any other
economical means.
The crew shall have its own dedicated crane and necessary tools to
continue the job independently to provide lead to the welding crew.
Pipe diameter and thickness will be verified at each pipe end and any
deviation shall be brought to the notice of field inspector for corrective
action if needed.
Following codes and standards shall be used for welding and welding
related requirements:
The pipe shall be visually checked from inside for any foreign material.
In case it carries any foreign material it shall be swabbed again before
engaging the two ends by external line up clamp.
The two sections shall be aligned together using nylon belts and line-up
clamp. On achieving the proper gap as given in WPS the root bead will
be run by a pair of qualified welders as per parameters established
during the execution of the WPS.
Another pair of welders shall carry out hot pass and hot fill pass while
the third pair of welders shall complete filling / capping. Thorough
cleaning of the root pass shall be done before start of the subsequent
passes by using power brush and / or disc grinder. The hot pass shall be
applied quickly before the stinger bead gets cool. Minimum and
maximum interpass temperature shall be checked during welding.
DESCON ENGINEERING LIMITED MS//MECH/16
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METHOD STATEMENT FOR Page 10 of 17
CROSS COUNTRY PIPELINE INTALLATION
No arc strike shall be permitted outside the bevel area. Any accidental
arc strike shall be ground out and then subject to MPI or DPT test in
accordance with ASME SE-138 / 165 respectively.
Any weld not completed on the day due to any reason shall be well
supported and protected against dew and dust.
Each weld shall have a unique number. Welder shall write their
identification number with crayon on each weld. A record shall be
maintained to control the quality of the welders and also to work on the
modification / repair of any joint.
The weld acceptance standard of API 1104 shall apply to the visual and
non-destructive inspections.
The welding inspectors shall have visual check of the weld joints to
ensure procedure and specification compliance.
The weld shall be cleaned and the sleeve shall be installed as per the
sleeve manufacturer’s recommendations and project specifications.
Holiday test shall be carried out after the installation is complete.
Before lower in the pipe the trench shall be inspected for its
dimensions, centerline and soil condition along its walls and at its
DESCON ENGINEERING LIMITED MS//MECH/16
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METHOD STATEMENT FOR Page 11 of 17
CROSS COUNTRY PIPELINE INTALLATION
bottom as per ITP. The bottom of the trench shall not have elements,
which can cause damage to the pipe and its coating. In case the soil
condition is such that such fragments cannot be avoided then sand
padding shall be provided to protect the pipe.
Standing water shall be pumped out from the trench wherever possible prior to
lowering the pipe into the ditch.
Care shall be taken to ensure that the pipe is in the center of the trench
and that the coating or joint wraps are not damage.
6.15 TIE-INS
All Tie-ins shall be undertaken by a dedicated crew (s) fully equipped for
this operation.
Tie-in shall be carried out where sections of pipeline laid in the trench
join and at road, canal, railway crossings and other major crossings.
For tie-ins the pipe shall be cut so as to permit a good alignment of two
strings and a good weld. The lap of pipe strings at tie-ins shall be at
least 1~2 meters. The weld seams of the adjoining pipes shall offset by
30% of the diameter or 76mm which ever is greater. If this is not
possible then a spool piece of not less than 1.2 meters in length shall
be inserted. The minimum pup length shall be one (1) meter. The tie-ins
shall be made at the minimum temperature of the day but not less than
10C0.
Bell Holes shall be made in the trench to perform the weld. The bell hole
shall be of following minimum dimensions
Width 90 cm between the outside of the pipe and the bell hole wall on
either side of the pipe.
DESCON ENGINEERING LIMITED MS//MECH/16
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METHOD STATEMENT FOR Page 12 of 17
CROSS COUNTRY PIPELINE INTALLATION
Field pipe bending shall be done accordance with the project specification.
Bend will be made along the longitudinal axis of the pipe, so that the weld is not
subject to elongation or stress.
All field bends shall be free from buckling or flattening, particular care will be taken
to minimize the ovality.
6.17 BEDDING
Where the trenches have been dug through driveways, roads, dikes,
etc. the compaction shall be done using mechanical means by
adding small layers of materials.
6.18 CROSSINGS
6.19 CLEANING
DESCON ENGINEERING LIMITED MS//MECH/16
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METHOD STATEMENT FOR Page 13 of 17
CROSS COUNTRY PIPELINE INTALLATION
Temporary Pig Launcher & Receiver shall be welded to either end of the
pipeline section under test.
Pipeline cleaning pigs equipped with polymer discs & wire brushes shall
be used for cleaning. During the cleaning process the following
information shall be noted.
Time launched
Time received
Once the debris collected in front of the pig shows decreasing trend &
subsequent cleaning pigging process does not bring much debris, the
clearing process shall be considered complete.
6.20 GAUGING
The Gauging pig shall be fitted with polymer discs & an aluminum
gauge plate. The diameter of plate shall be 95% of minimum ID of the
pipeline section.
The pig shall be passed through the pipeline at controlled speed with
compressed air.
6.21 HYDROTESTING
6.21.1 FLOODING:
The flooding of pipeline shall be carried out by propelling two
pigs in the line using water
Once the first pig is received at the other end pumping shall
continue until the second pig is also received ensuring that the
line is completely full.
6.21.2 PRESSUREIZATION
Temperature stabilization shall begin upon completion of flooding
works.
A) Pipeline pressure
B) Pipeline temperature
C) Soil temperature
D) Ambient temperature
After the foam pigging dry air will be blown through the pipeline
to achieve desired valve of dew point.
Nitrogen gas shall be introduced from one end and air purged out form
the other end by controlled opening of a small valve.
A team from civil work shall be assigned to carry out all civil works
associated with this installation in a sequence determined by the CP
installation team.
Restoration and clean up of the ROW will be in accordance with the project
specification
All waste materials, wooden supports and foreign materials shall be removed and
shifted to a dump and or the appropriate storage location.
Any excess earth shall be spread along the ROW by scraping and or harrowing to
the satisfaction of the client representative.
Access roads, tracks, banks, water courses, fences etc, which have been partially
demolished during the work, shall be restored their original shape and condition.
Special attention will be taken during restoration of the area of the road, canal and
railway crossing.
Pipeline route and aerial markers shall be positioned as stated in the project
specification and drawings.
Hand Tools
Cutting, Beveling & Grinding Machines
Welding Machine
Welding Machine (Diesel)
Cranes
Trailer
Tractor with Trolley
Pipe Layer (Side Boom)
Excavator with Jack Hammer
Loader
Dozer
Motor Grader
Dump Truck
Compressor
Power Generator
Blasting machine
Painting spray machine
DESCON ENGINEERING LIMITED MS//MECH/16
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METHOD STATEMENT FOR Page 17 of 17
CROSS COUNTRY PIPELINE INTALLATION
7.2 TESTING
Holiday Detector
DPT Unit
RT Of Welds
Pressure and Temperature Recorder
Hygrometer
Dry Film Micrometer
Salt Detector
Adhesive Test
Profile Meter
Reference Electrode (Half Cell)
Digital Multimeter
Insulation Resistance Tester (Meger)
7.3 SAFETY
Safety helmet
Safety Shoes
Safety Goggles
Gloves
Welders Helmet
Dust mask (if required)
Fire Extinguishers
Blasting hood.
Long sleeve (if required)
Cover all.
8. SAFETY INSTRUCTIONS
During execution of the job all measure shall be adopted to ensure safe
working.
Client site management system (latest revision) will be implemented.
The workers will be made aware of safety requirements related to this activity
through daily, weekly and monthly toolbox and safety talks.
During transportation of pipes and other fittings, the material shell be properly
supported and tied on the Trailer.
Welding sets should be checked and maintained regularly for wear and tear.
9. ATTACHMENTS
Project Quality Plan.
HSE Plan.