Owner

Contractor

Project

Title

METHOD STATEMENT FOR STEEL PIPING INSTALLATION

Contractor Document Number: Rev. No. Pages

A 1 of 9
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METHOD STATEMENT FOR Rev. No.
STEEL PIPING INSTALLATION A
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Revision Record

Rev. Prepared Reviewed Checked Approved

Date Purpose
No. by by by by
A DDMMYYYY Issued For Approval XXX XXX XXX XXX

TABLE OF CONTENTS
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METHOD STATEMENT FOR Rev. No.
STEEL PIPING INSTALLATION A
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1. GENERAL............................................................................................ 4

2. PURPOSE............................................................................................ 4

3. WORK SCOPE.................................................................................... 4

4. REFERENCES..................................................................................... 4

5. RESPONSIBILITY................................................................................ 5

6. WORK SEQUENCE............................................................................. 5

7. INSPECTION & TEST PLAN................................................................ 8

8. TOOLS & EQUIPMENT....................................................................... 8

9. SAFETY............................................................................................... 8
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METHOD STATEMENT FOR Rev. No.
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1. GENERAL

The proposed project consists of one (1) combined cycle power block (2+2+1), comprising
of two (2) gas turbine and generators (GTGs), two (2) fired heat recovery steam generators
(HRSGs) & one (1) steam turbine and generator (STG), and Balance of Plant (BOP)
equipment.

The Power Plant will be equipped with GT capable of firing on natural gas. The exhaust gas
from the GT is fed to a HRSG, which is designed as a horizontal triple pressure, natural
circulation HRSG with re-heater. The HRSG will be supplied with supplemental firing for
meeting the load demand.

The ST will be a reheat condensing turbine. The exhaust steam is condensed in a water-
cooled condenser with mechanical draft wet cooling tower using river water from the River.

The GT, ST and Generator will be of a multi shaft configuration, with a separate Generator
for GT’s and ST.

2. PURPOSE

This method of statement gives the requirements as a guideline for

F a b r i c a t i o n a n d Field Installation of BOP (Balance Of Plan) Pressure Piping.
This procedure is to be used by the Contractor as a basis for identifying the
requirements of Project Works. All works shall be done in accordance with
manufactures handling manuals and recommendations. To establish a procedure to
ensure a safe and quality installation with systematic approach to all related work
implemented in accordance with the technical specification requirement of the contract
and applicable code & standard.

3. WORK SCOPE
The scope of work covered in this Method Statement is as follows;

3.1 Perform fabrication, erection, and field installation of steel piping as indicated the
related drawing and specification.
3.2 Checking elevation, leveling and alignment, where required
3.3 Any field touch up painting of pipe, and support
4. REFERENCES
All the Work must be performed according to the following as listed and the most relevant
codes & standards with good practices.

4.1 Welding Control Procedures (-XXX-XX-XXXX)

4.2 Health Safety and Environment (HSE) Plan (XXX-XX-XXXX)
4.3 Code and Standard

ASME B 31.1 – Power Piping

ASME Sec. IX – Welding and Brazing

Qualifications
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ASME B16.5 – Pipe Flanges & Flanged Fittings

5. RESPONSIBILITIES
5.1 Joint Operation QA/QC Manager is responsible for the implementation of all required
control activities and shall ensure that the procedure is established related with this
particular job.

5.2 Joint Operation QA/QC Engineer shall execute all required quality activities such as
inspection and test in coordination with the Owner’s representative to obtain necessary
approval, and responsible for preparing all necessary check list and documents
required for carrying activities.

5.3 Piping Engineer shall ensure that the job is performed according to the latest
revision drawings and inform any problems, mismatches discovered at field to the
Piping Manager. Piping engineer is responsible for incorporating all safety
procedures, work permit requirements and all related quality control procedures.
Piping engineer shall coordinate the whole job of all other related departments
towards the end of the activity.

5.4 HSE Engineer with his team shall ensure that the work will be implemented properly
and
effectively enough to maintain safety requirement on site and train persons as
necessary.

6. WORK SEQUENCES
6.1 General
6.1.1 The work area shall be cleared of any obstacle, dust, cement or inappropriate
tools.

6.1.2 All topographical bench marks shall be marked prior to the commencement of
work.

6.1.3 Extreme care should be taken to prevent any damage during lifting to its
location.

6.1.4 A sequence and work process that includes cleanliness inspections and a
deficiency correction shall be implemented, that maintains cleanliness and that
minimize the need for cleaning activities.

6.1.5 Where conflict exists between this document and drawings and/or specification,
the report will be issued to clarify and resolve it.

6.2 PROCEDURE DURING FABRICATION

6.2.1 Planning
The fabrication plan will be prepared on consideration with project schedule and
aviability of material.
6.2.2 Fabrication Control
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Fabrication spool shall be performed accordance with latest approved ISO

drawing
6.2.3 Transportation, Handling, and Storage of Shop Fabrication Spool
Pipe spool shall be keep clear from the ground. To prevent dust, sand or any
foreign material entering the pipe, an opening on pipe shall be covered. During
transportation of fabricated spool, much attention shall be paid attention to avoid
damage to pipe and painting
6.2.4 Marking Spool Number
All piping spool shall be identified such as line number, spool number, and
welding joint number prior of use. To prevent the incorrect installation spool
during erection, the spool identification shall be carefully checked. After
fabrication tag number shall be provided and stenciled with the drawing number,
line number, spool number and area.

6.3 DURING ERECTION

6.3.1 Pipe Erection
 Pipe shall be adequately temporary supported until final support are installed
 Care shall be taken to avoid any damage to painting of spool surface during
erection
 Care shall be taken to avoid any undue stress
 Valves shall be installed as closed after cleaning, and shall not be opened
during installation of piping system
 The piping components needed handling such as valves shall be
considered to handle easily
 Opening shall be kept covering with ply wood or other blinds to prevent
dust and/or foreign.
 If works using fire are to be performed in the vicinity of instrument
control or power cable duct, an appropriate protection means shall be
provided in advance to prevent the cable from damage
 Any modification or changes in the routing shall be brought to the notice of
Owner with supporting documents and it shall execute as same
manner before pipe / spool erection.
6.3.2 Flange Bolting
 The logical sequence of bolt tightening, even gasket compression shall
be used to ensure as indicated in ASME B16.5.
 Prior to bolting up, flange faces shall be inspected. Flange faces shall be
in “as-new” condition and shall be wiped clean of any debris, excess oil
or grease and dirt. Weld repairs shall not be performed on flange faces or
flanges
 Lubricant may be applied to bolts
6.3.3 Supports
Piping supports shall be performed in accordance with drawing, standards
and specifications. Temporary supports, if required during hydrostatic
testing or for easer installation shall be removed when construction has
been completed.
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6.4 EDGE PREPARATION

6.4.1 Steel pipe shall be cut using gas torch or cutting wheel and beveled by electrical
grinding
6.4.2 Edge preparation to be completed in accordance with approved Welding
Procedure Specification (WPS).
6.4.3 Before beveling, an adjacent area shall be cleaned that surfaces are free from
dirt, oil, rust, paint, oxides, cutting marks, etc. Cleaning tools for carbon and
stainless steel shall be kept separated at all time
6.4.4 The welding inspector shall inspect fusion faces and adjacent surfaces to
ensure that cracks, notches or other defects, which may impair weld quality,
are not present

6.5 PIPE FIT-UP ALIGNMENT

6.5.1 Components to weld shall be aligned, spaced and fitted, as specified within the
limit given in the approved welding procedures
6.5.2 The inside diameters of piping components shall be align with tolerance on
diameter, wall thickness and out of roundness. Alignment shall preserve during
welding
6.5.3 Internal misalignment criteria (pipe to pipe or pipe to fitting) shall be no more
than 2.0mm deviation
6.5.4 Assembly of piping components shall be performed after it is confirmed are in
accordance with drawing.
6.5.5 Supports and clamps shall be used as per specification for the fit up
6.5.6 When bridge tacks are used, the bridging material shall be same with the
piping material
6.5.7 Flanged joints shall be fitted up, after checking for the alignment of the flange
center and parallel

6.6 WELDING
6.6.1 Welding shall be performed in accordance with the approved welding
standards and procedures
6.6.2 Welding shall be tested and qualified by QA/QC department prior to
commencement of welding.
6.6.3 No welding shall be done if there are impacts of any rain, snow, sleet, or high
wind in the working area. However, welding work shall be done provided
that suitable protection is installed
6.6.4 Welding bead shall be carefully laid to avoid undercut, pin hole, slag
inclusion, crater, imperfect penetration, etc.
6.6.5 Welding rod shall be properly selected according to the kind of the steel to be
welded
6.6.6 Grounding wire shall be firmly fastened by screw or clamp to the material to be
welded, at the position as near as possible to the welded part
6.6.7 Spatter, slag, etc. of welded part shall be thoroughly removed
6.6.8 Jigs (bridges or clamps) shall be provided in minimum number necessary for
setting up
6.6.9 Jigs (bridges or clamps) shall be used made of material which quality is the
same as or better than the base material
6.6.10 In a fit-up, select welding rod of appropriate diameter for a tack welding so as
to fit the root opening
6.6.11 Before welding first layer, both ends of tack welding bead shall be
sharpened with grinder in order to allow complete fusion
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6.6.12 Bridges shall be removed after welding. To ensure parent material shall
not be damaged while removing
6.6.13 Repair
Unacceptable discontinuities shall be completely removed by chipping,
gouging, grinding, or other methods (for the type of material being repaired)
to clean. Repairs to correct weld defects shall be made using the same
WPS used for the original weld or other previously authorized WPS. The
repaired area shall be re-examined using the same examination method
and procedure by which the defect was originally detected

7. INSPECTION & TEST PLAN

7.1.1 All inspection activities shall be checked in accordance with the approved ITP.

7.1.2 Any discrepancies or nonconforming conditions detected while performing

inspections required by ITP shall proceed in accordance with “Control of Site
Non-conformances”

7.1.3 The completed inspection records for the installation of rotating equipment will
be maintained as a Quality documents.

7.1.4 All inspection, measuring and test equipment shall be identified with a suitable
number or tag to show the calibration status. The calibration records shall be
easily traceable to the device.
7.1.5 Before witnessing the inspection, test equipment identification tags shall be
checked and verified that the test equipment has been properly kept and
calibrated.

8. TOOLS & EQUIPMENTS

No. Description Remark

1 Crawler & Mobile Crane of appropriate capacity As Required
2 Lifting tools As Required
3 Chain blocks of various capacity As Required
4 Steel Plates for supporting the foundation plates, if necessary As Required
5 Shims of varies thickness 1.0 to 6mm(SUS), 1.0 to 6mm (CS) As Required
6 Hydraulic Jack 10 Tons capacity As Required
7 Arc Electric Welding Machine As Required
8 Oxy Acetylene Set with Cutting outfit As Required
9 Electric Drill Machine As Required
10 Hand tools and Torque wrench plus socket wrench As Required

9. SAFETY
9.1 The safety program as defined the Health, Safety and Environment Plan shall be
implemented on a day to day basis.
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9.2 It is required that site manager and all superintendent clearly communicate HSE
expectations at all project meeting and demonstrate a personal commitment to follow
the HSE policy at all time.

9.3 The unsafe work practice and conditions in the work place shall be immediately
identified and eliminated through the use of analytical techniques such as the risk
assessment.

9.4 Build a team safety mentality where each worker contributes to the effort and each
superintendent is fully aware of the capabilities and limitations of their team.

9.5 All tool and equipment shall be used in accordance with the manufacturer’s
recommendations, required tool guards in place, and maintained in good working
order.

9.6 Where appropriate, all employees shall require to wear eye, ear, head & face, foot
protection outfit.

9.7 Work areas shall be kept clear and unobstructed at all times. Scaffold shall be
developed and modified under the proper supervision.

9.8 All personnel shall wear safety harness / lanyard system if they work at heights where
the fall exposure is more than 6 feet or 2 m.

9.9 All certificates and permits related the particular job shall be kept at site for verification.