Method Statement forPre-Fabrication and Erection of Piping

CONTRACTOR :ADVANCED VISION CO.PROJECT NAME: MASAA EXTENSION PROJECTCONSULTANT :DAR

AL HANDASAHSITE : AL HARAM-MAKKAH-KSA

0Issued for Approval

REV.DATEDESCRIPTIONPRPDTPIAPPD

Advanced Vision Co Ltd..

Massa Extention Project

Al Haram- Makkah- KSA

METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

INDEX

1.INTRODUCTION2.DEFINITION3.APPLICABLE DOCUMENTS4.SCOPE OF WORK 5.PROCEDURE6.MATERIAL

S RECEIVING & STORAGE7.PRE – FABRICATION8.PIPING ERECTION9.MECHANICAL CLEARANCE AND
PRESSURE TEST10.INSPECTION AND QUALITY RECORDS11.SAFETY
PROCEDURE12.ATTACHEMENT:SAMPLE OF WELD MAP

Advanced Vision Co Ltd..

Massa Extention Project

Al Haram- Makkah- KSA

METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

1)Introduction
The purpose of this method statement is to ensure that the methods and proceduresshall be carried out
for the fabrication, erection and testing of piping work as per theTechnical / Contractual specifications
of Dar Al Handasah.

2)DefinitionsProject:Massa Extension Project –

MakkahConsultant:Dar Al HandasahContractor:Advanced Vision Co.3)Applicable Documents3.1Codes &
Standards

ASMEB 31.3ANSIB 16.25ASMESEC II Part CASMESEC IXASMESEC VAWSD 1.1

3.2Ref. Project Specifications

Advanced Vision Co Ltd..

Massa Extention Project

Al Haram- Makkah- KSA

METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

4.Scope

The scope of this method statement is limited to Pre-fabrication, Erection and Testing procedures
followed for Carbon Steel and Stainless Steel piping.

5.Procedure

The Engineering drawings and documents received from Consultant shall be

clearlyunderstood to find out the service, material specification, size, thickness, NDTrequirements,
PWHT requirements, pipe routings quantity etc. line wise and areawise.Ensure that the
documents received bear the stamp “Issued for Construction” and areof latest revision.Make sure that
all the Quality Control and Pre – Construction formalities, approvals,and preparations are done
sufficiently in advance to start the construction activity as per the schedule.

6.Materials Receiving and Storage

1)

Material Requisition form prepared by supervisor shall be forwarded to thematerial controller who shall
collect the piping materials as per the
pipingspecifications and drawings from Consultant, respecting the material issue procedure of
Consultant.

Advanced Vision Co Ltd..

Massa Extention Project

Al Haram- Makkah- KSA

METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

2)Handling and transportation of piping materials shall be done with utmostcare to avoid any damage.

3)

Separate area shall be assigned for the storage of Carbon Steel and StainlessSteel piping materials. Pipes
shall be stored in open area resting on woodensleepers and small pipe fittings, bolts, nuts, and gaskets
shall be stored inshelved containers. Storage & issue procedure of piping materials shall be intime with
the requirements of Consultant.4)Documents shall be maintained by the material controller till the end
of the project.

7.Pre – Fabrication7.1Replacement

1)

Determine the safe location on the Rejected Fittings to start the cuttingand remove the cut items to
scrap area by safely procedure.2)Select the proper cut method either flame cut or cut machine.

7.2Cutting and Beveling

1)

Pre-fabrication of Carbon Steel and Stainless Steel Pipes shall bedone in separate fabrication ways.

2)

Proceed with cutting of pipes, edge preparation, joint alignment,and fit-ups as per the WPS.

3)

The edge cleaning and beveling shall be done using abrasivegrinding disc/ beveling machines.
Advanced Vision Co Ltd..

Massa Extention Project

Al Haram- Makkah- KSA

METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

4)Line Number, Spool Numbers, and Joint Numbers are to be clearlyidentified and marked on the spools
with the welder identification for each joint.

7.3Fit – Up and Tack Welding

1)Fit-up assembly shall be carried out by using locally prepared couplers.All the required pipe holding
work benches, assembling brackets, ‘U’ bolts etc. would be made in house to suit the pipe
sizes.2)For butt welds a uniform root opening as specified below shall bemaintained.1.5 mm for pipe
diameters < 50 mm1.5 / 2.5 mm for pipe diameters 50 mm to 250 mm.2.5 / 3.5 mm for pipe diameters >
250 mm3)For all socket weld joints the pipe end shall be free from cutting burrs. Aclearance of 1.6 mm
shall be provided between the end of pipe and bottom of socket.4)Internal misalignment shall be limited
to1.6 mm for pipe diameter 24” and below.3.2 mm for pipe diameter 26” and above.5)The pipes shall be
tack welded in three equidistant positions. Tack Weldshall be done as per approved WPS by a qualified
welder.

7.4Welding

1)Welding procedures and welders shall be qualified as per ProjectSpecifications and relevant codes,
prior to start of the welding.2)Ensure that the edges are free from dirt, rust, oil, grease, paint etc.

Advanced Vision Co Ltd..

Massa Extention Project

Al Haram- Makkah- KSA

METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

3)Welding shall be done as per approved WPS for the particular piping.
Preheating and welding consumable shall be checked before starting of welding.

4)

Each weld layer shall be cleaned before starting to weld next layer. Thecleaned area shall be free from
slags. Any visual defects like cracks, pores, spatters weld shall be removed by grinding before the next
layer isapplied. The ends of weld layer shall be removed by grinding at tack points of each weld.
Any possible weld excess layer will be removed bygrinding.

5)

For the fabrication & welding of Stainless Steel pipes, only Stainless
Steeltools & consumables (Wire Brush Chipping, Hammer, and Abrasivedisc) shall be
used.6)Appearance of finished weld shall be as even as possible and free fromspatter, under cutting,
cracks, excess reinforcement etc.

7.5Non Destructive Examination

1)The extent of NDT will be in accordance with Project General Specificationfor different piping systems.
The acceptance criteria shall be in accordancewith ASME B 31.3.2)If PWHT is applicable for any piping
system, NDT shall be carried out after completion of PWHT.3)Welding record
shall be maintained with proper identification of joint,welder etc. for all joints.4)NDT shall be carried out
as per approved procedure and the results shall berecorded properly.

Advanced Vision Co Ltd..

Massa Extention Project

Al Haram- Makkah- KSA

METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

8.Piping Erection
1)The Pre-Fabricated spools shall be identified by spool and line numbers before and after
priming.2)Care shall be taken while handling and stacking of spools to prevent any possible
damage.3)Open ends of spools shall be covered by caps after thorough cleaning.4)Erection of spools
shall be carried out area by area as per piping layoutdrawing and Isometric drawings.5)Scaffolding and
temporary platforms shall be arranged to carry out fit up andwelding of field joints at elevated
positions.6)Pre-fabricated spools shall be shifted to site carefully as per daily erection plan.7)Before
erection of spools ensure for inside cleaning of the spools and their items.8)Erect the spools in position
using crane or other lifting devices as per thedrawings.9)Supports to be welded on to the pipe (shoes or
saddles) shall be done
beforeerection.10)Check the pipe supports details in the piping layout drawings andIsometric drawing
for location and type of supports.11)Install the pre-fabricated supports as per drawings.12)Joints shall
be aligned and complete the fit-up / welding as per applicableWPS.13)NDT and other inspection shall be
completed for the field joints andrecorded properly.

9.Mechanical Clearance, Inspection & Pressure Testing

Advanced Vision Co Ltd..

Massa Extention Project

Al Haram- Makkah- KSA

METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

1)Identify the test loops for the completed line system wise.

2)

Upon obtaining mechanical clearance, Hydrotest shall be carried out as per project
specification.3)Arrange for Hydrotest Pump, Calibrated Pressure Gauges, Test medium(Water)
etc.4)Blind flanges shall be installed on all required locations and items which arenot to be included in
pressure testing, shall be isolated.5)Water shall be filled and vented properly before pressurising.6)Line
shall be pressurized to the required pressure of that piping class andhold the pressure till the inspection
is completed.7)Pressure Test shall be witnessed by contractor representative.8)On
satisfactory completion of test, pressure shall be released and line is todrained off
completely.9)Reinstate the line with all the permanent items and remove all the blinds.

10)Inspection and Quality Records

Inspection, Testing and Recording shall be in accordance with the approvedInspection & Test Plan.

11.Safety Procedure

Prefabrication and Erection of Piping and Pipe Supports.

Equipment and tools

1) Portable cranes, column cranes.2) Scaffoldings

Advanced Vision Co Ltd..

Massa Extention Project

Al Haram- Makkah- KSA

METHOD STATEMENT FOR

Replacement, PRE-FABRICATION AND ERECTION OF PIPING

3) Small items (lifting jacks, slings, chain block, D-

shackles, etc.)4) Oxygen Acetylene Cutting, Portable Power Tools, and Welding units.

Safety Measures

Protective Clothing1) Helmet2) Gloves3) Safety shoes4) Full Body Safety Harness5) Face shields

Accident Prevention Safety Procedures

1) Area shall be barricaded adequately with warning barriers prior to any lift.2) All Equipment shall be ch
ecked for good conditions before commencing the work.3) Unauthorized persons shall be excluded from
the area.4) When lifting, the personnel shall not remain in the lifting equipment work area.5) Adequate
caution boards and warning signs shall be provided.6)Only trained and authorized personnel shall
operate the hydraulic lift.7)Observance of the lifting equipment capacity.8)Electrical installations
and equipment shall conform to standards.9)Application, maintainence, storage of electric, and oxygen
cutting welding unitsshall conform to applicable standards.10)Do not stand under suspended
loads.11)On Completion of job, the area shall be cleared of any materials and kept cleanand
tidy.12)Hazard analysis for hazardous operation shall be carried out prior to commencingthe works.