Method Statement for Pipe Support Fabrication and Installation 6423dp420!00!0030000_rev01

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TABLE OF CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCE

4.0 ORGANIZATION AND RESPONSIBILITIES

5.0 GENERAL

6.0 WORK PROCEDURE

7.0 HEALTH SAFETY ENVIRONMENT AND SECURITY

8.0 ATTACHMENT

Attachment 1 : Daily Fabrication Inspection Report (DFIR)

Attachment 2 : Material Traceability Record (MTR)

Attachment 3 : Daily Welding Inspection Report (DWIR)

1 { Attachment 4 : Inspection Report for Embedded Plate Fabrication (IREPF)

Attachment 5 : Release Note for Field Installation (RNF)

Attachment 6 : Release Note for Painting (RNP)

Attachment 7 : Job Safety Analysis (JSA)

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1.0 PURPOSE

This method statement is to establish the work plan and inspection instruction for the

assembly, fabrication, inspection and documentation to be performed in order to complete the

construction of pipe hangers and supports which shall be in compliance with applicable

drawings and specifications.

2.0 SCOPE

1 { This method statement covers all pipe hangers, spring, cold shoe, clamped, supports and embedded plate to be assembled, fabricated, installed and inspected at Algeria Oman

Fertilizer Project (AOFP).

3.0 REFERENCE 3.1 6423MP201-00-00100 00 Basis for Piping Engineering

3.2 6423MP202-00-00100 00 Piping Material Specification

3.3 6423MP214-00-00100 00 Piping Standard Drawing

3.4 6423MP214-00-00200 00 Piping Support Standard Drawing

3.5 6423MS230-00-00100 00 Specification for Piping Work

3.6 6423MS231-00-00100 00 Specification for Piping Fabrication By Each Service Class

3.7 6423MS260-00-00100 00 Specification for Painting

3.8 6423DA060-00-00700 00 Welder Qualification Procedure

3.9 6423DJ530-00-00300 00 Material Control Procedure

3.10 6423DA060-00-01300 00 NDE Control Procedure

3.11 6423DP420-00-00420 00 Method Statement for Painting

3.12 6423DP420-00-00500 00 Method Statement for PWHT

3.13 ASME B31.1 Power Piping

3.14 ASME B31.3 Process Piping

3.15 ASME Sec, IX Qualification Standard for Welding and Brazing

3.16 ASME Sec. V Nondestructive Examination

3.17 ASME Sec. II Welding Rods, Electrodes and Filler Metals

NOTE : In case of conf l ic t between this method statement and reference documents, fo l lowed below.

- As a standard pract ice, method statement wi l l fol low the speci f icat ion and

then, speci f icat ion wi l l fol low the code.

- In case the speci f icat ion has conf l ic t wi th method statement . I t would be

decided af ter d iscussions at the meet ing.

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4.0 ORGANIZATION AND RESPONSIBILITIES 4.1 The Construction Manager has the responsibility to :

(1) Plan the fabrication program and report its progress

(2) Manage all fabrication drawings.

(3) Preparation, revision and control of this document.

(4) Managing of raw materials.

(5) Managing of welding consumables.

(6) Inspect the fabrication and installation of support and changes of its design.

(7) Ensuring that design changes are incorporated into the work.

(8) Requesting NDE or PWHT, if any

(9) Requesting inspection to the QA/QC Team.

(10) Preparation of material requisition of material for support fabrication work.

(11) Control of welder and support welding data

(12) Requesting and preparation for welder and welding operator qualification.

4.2 The QA/QC Manager has the responsibility to :

(1) Review of all request including Daily Welding Inspection Report. (2) Managing welder qualification. (3) Managing welding control system. (4) Managing of quality control. (5) Managing inspection and test with regard to support fabrication and installation.

4.3 The Material Control Manager has the responsibility to : (1) Receiving and maintaining of material

(2) Control of material stock status before release to construction team.

(3) Issuance of material to Support shop and other sections.

(4) Request the material receiving inspection to QA/QC team

5.0 GENERAL Material to be installed will be withdrawn from the receiving area in accordance with material

control procedure, the prefabricated sub assembly storage area, or the lay down area.

Transferring the material from the storage area to work site will be performed in a manner

which will not be deleterious to the material.

When storage requirements are not defined, the type of storage and protection shall be

determined through arrangements with project owner.

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5.1 General Work Sequence

(1) Make production plan considering material availability and area priority.

(2) Issuance of Isometric drawing or support style list to support fabrication shop.

(3) Request support material to material warehouse

(4) Receiving support material from warehouse and perform receiving inspection.

(5) Issue work order

(6) Cutting and end preparation

(7) Fit-up and tack welding

(8) Welding

(9) Inspection

(10) Blasting and primer painting work at paint shop

(11) QC documentation

(12) Release support and store on stock yard

(13) Support issuance to Field support team.

5.2 Storage and handling material

(1) Material shall be stored separately by its type and specification and it shall be marked

according to its designated color.

(2) Certificates verifying that materials or items used in the fabrication comply with

Purchasers requirement. Certificates for each category of material shall be submitted.

(3) Materials shall be maintained to comply with any warranty conditions imposed by the

manufacturer.

(4) Nylon slings shall be used for handling stainless steel material and straps.

5.3 Drawing and materials

(1) Pipe support shall be fabricated and installed in accordance with the approved drawing,

pipes support style list.

(2) For pipes requiring post weld heat treatment, attachments required for supporting

purposes shall be indicated on the piping isometric drawings.

(3) Pipe stanchions, pipe dummies and trunnions shall be made with same type of material

as the connecting pipe. All other support material to be welded directly to the pipe shall

be same type of material as the pipe itself.

5.4 Inspection and test

The inspection and test shall be notified to QA/QC team 24hours in advance prior to

inspection and testing, and it shall be performed in accordance with the inspection and test

plan.

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6.0 WORK PROCEDURE 6.1 Control of pipe supports fabrication

(1) Raw material All material of pressure retaining parts shall be identified.

Part number, material specification and heat number shall be marked on the piece to be

cut, and it shall be recorded on the material identification record, and it shall be inspected

by QC inspector before cutting. (2) Cutting

Support materials may be cut to shape and size by flame or thermal cutting.

Stainless steel materials shall be cut by mechanical means or plasma arc cutting, but

flame cutting shall not be allowed. Surface to be welded shall be free from slag and

excessive notch foreign matter.

Pipe support assemblies may be acceptable if items having greater strength are

substituted for those indicated on the drawings.

(3) Welding

Welding shall be performed in accordance with the approved WPS and drawing by

qualified welder.

These fabricated support shall be inspected and recorded using the Daily Fabrication

Inspection Report (Attachment 1).

Field welding to pipes for the purpose of pipe support shall be limited as far as practical.

Field welding for pipe support purposes shall not be performed on the following pipe

materials.

- Materials requiring post weld heat treatment (PWHT)

- Non-ferrous materials

All welding shall be done before post weld heat treatment

Stainless material shall be segregated from normal carbon steel during fabrication and

erection in order to avoid the contamination.

(4) Marking and Tagging

When welding has been completed, designate person will tag on each support body with

stamped tags.

The characters on such tags shall be a minimum of 3/16 inch and tags shall be securely

attached to the assembly.

(5) Painting and Stock

When fabrication of pipe support is done, prepare the painting request form and transport

to painting area. (Attachment 5)

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Painting subcontractor shall paint and submit painting inspection report to contractor.

Painted pipe support should be marked and properly identified and shall be stored in the

designated area and preserved from dust and rust until issue to field erection.

(Attachment 4)

6.2 Control of Pipe supports installation

(1) General

As a general practice, appropriate adjustment / modification / addition of support shall be

made by construction contractor according to the actual field conditions, especially for

small bore piping.

All pipe support must be installed as per specification and drawing.

- Isometric drawing

- Piping arrangement drawing

- Pipe support standard drawing

- Special pipe support drawing

- Pipe support index

Piping shall be properly anchored and guided before pressure testing.

Support should be fabricated and installed prior to the piping installation, and use of

temporary supports is to be minimized.

In case the temporary supports are required, the supports arrangement shall be made

sure so that they have sufficient bearing strength and stable supporting for the piping

system.

All temporary supports shall be removed before hydro test.

Field welded supports shall be set correctly in place and adjusted to the final position

before welding.

For sliding supports, bearing surfaces shall be sufficiently clean to ensure unrestricted

movement.

Clamp bolts on clamped shoe type support should be checked as per standard pipe

support drawing.

Support shall not be welded to the equipment unless otherwise specified.

In case that stainless steel piping without insulation is resting on the steel structure, pipe

rack or piping support directory, stainless steel plate shall be installed between piping

and structure to avoid direct contact, even if this information is not shown in support

drawing.

(2) Concrete expansion anchor bolts

Installation of concrete expansion anchor bolt shall be performed in accordance with

vendor information.

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(3) Locking devices (Bolts / Nuts)

The support height shall be adjusted by construction team to the actual field condition.

All threaded connections, except high strength bolts, shall be secured by locking devices

to prevent loosening during service.

Wherever possible bolts/stud shall be locked in place with double nut. (Jam nut)

A nut tack welded to the bolt/stud shaft may also serve as a locking device and may be

used except where welding is prohibited on the bolt material.

(4) Installation of Spring hangers

Installation of constant and variable spring hangers shall be in accordance with the

manufacturers instruction, the design drawing and the procedure.

Spring hangers shall be easily accessible after installation within the limits of possible,

and the scales shall be unobstructed and visible.

Field engineer should be ensured that the travel stops are engaged and maintained thus

on all spring hangers until the piping system are placed in service, except during such

time of checking and marking adjustments on the spring hangers.

Spring supports shall be installed with the spring locks in place and the travel shall be

cold set position.

These spring locking plates or pins shall not be removed until hydrostatic testing and

insulation of the piping system has been completed, but before the line is put into service,

as directed by commissioning group.

If the spring force on empty line will cause possible damage to connected strain sensitive

equipment, the spring locks shall remain in position until the line is filled with the actual

service fluid.

The relevant support and support drawing shall bear the warning block against empty

position and the locks shall be attached with the spring support during operation.

The travel stops on spring hangers shall be engaged during filling, testing and draining of

pipe systems for hydro test.

(5) Floor of base mounted supports

Grouting is required between concrete surface and structural pipe support attachment

plates.

All grout work shall be performed in accordance with relevant work procedure.

Non shrink grout shall be mixed and placed in according with the manufacturers written

instruction.

(6) Wall or ceiling mounted supports

Pipe support base plates shall be mounted flat against the wall or ceiling.

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Irregularities on the wall or ceiling surface that prevent flush mounting on the base plate,

such as fins, protrusions, and excessive roughness, shall be removed by grinding.

Grouting is not required except when depression, grooves, holes or other cavities under

the base plate that are not amenable to removal by grinding.

These shall be filled with grout before mounting the base plate.

(7) Hanger rod and turn buckle installation

Threading of hanger rods shall be performed in accordance with ASME B31.3 para

321.1.5, thread designation UNC and, shall have a minimum of three full thread exposed

when the nut is tightened on the hanger rod threads.

Lubricant for threaded portion of rod is not required.

For galvanized threads cut in the fields, the threaded portion of the rod shall have a

touch-up coating.

To compensate for pipe elevation discrepancies, hangers are usually provided with

means to permit vertical adjustment during and after installation

Threaded devices such as turnbuckles, clevises, etc. are acceptable, provided that after

the adjustment the result is no less than full thread engagement.

(8) Shoe or pads installation

For shoes shall be welded to the piping with careful way avoiding any welding defects.

Special care must be taken to the anchor points, as they are to be heavily loaded.

Shoes pads for low alloy steel piping shall be of the same material as the pipes.

In case of lines having shoe or saddle support, site measurement between distances of

supports may be given and marked on the assembly.

The supports are then welded on the spool assembly on the ground.

In case of lines having guide or anchor the supports are to be welded in position.

All supports / saddle welded to main pipe shall undergo the same testing requirement as

that of main pipe.

1 { (9) For the installation of Embedded plate shall be followed in accordance to Concrete Works

Procedure No.6423DC420-00-0080000 6.3 Welding and welding attachment

(1) All welding shall be in accordance with approved welding procedure specification.

(2) The material of the attachment which is directly welded to the pipe shall be as shown on

the pipe support detailed drawings.

(3) Welding must be carried out by qualified welder in accordance with approved welding

procedure specification.

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(4) Material traceability report shall be recorded the heat-number of attachment and verified

by QA/QC inspector and Contractors inspector for stainless steel and alloy steel.

(Attachment 2)

(5) Daily welding inspection report shall be signed off by QC inspector after visual

inspection.

(6) All weld attachment on pipe shall be identified by marking the weld and welder number.

(7) All welds will be identified on the isometric drawing and shall be inspected by welding

inspector and recorded in daily welding inspection report. (Attachment 3)

6.4 Post Weld Heat Treatment (PWHT)

(1) Performance of PWHT shall be in accordance with post weld heat treatment procedure.

(2) The QA/QC shall review PWHT record and submit to owner for review.

6.5 Non Destructive Examination (NDE)

(1) The management and request of NDE shall be in accordance with NDE control

procedure.

(2) The QA/QC shall review NDE record and submit to owner for review.

6.6 Paint and Touch up painting

(1) At completion of fabrication and installation, painting subcontractor shall paint or touch

up paint the pipe support according to painting specification and procedure.

(2) Pipe construction manager is responsible for keeping and maintaining all related

documents.

6.7 Progress check

(1) Progress of fabrication and installation in pipe support shall be measured together with

piping progress using progress measuring program.

(2) Every support item shall be tracked by this system.

7.0 Health Safety Environment and Security 7.1 All workers shall wear PPE required as below.

(1) Safety helmet

(2) Safety glasses

(3) Safety shoes

(4) Gloves

(5) Mask, if required to prevent inhalation of dust and welding gas

(6) Ear plug, if required by conditions.

7.2 Machinery like grinding wheel cutter shall have a protection method.

7.3 Safety shall be requested and carried out in accordance with safety procedure.

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8.0 Attachments Attachment 1 ; Daily Fabrication Inspection Report (DFIR)

Attachment 2 : Material Traceability Record (MTR)

Attachment 3 : Daily Welding Inspection Report (DWIR)

1 { Attachment 4 : Inspection Report for Embedded Plate Fabrication (IREPF)

Attachment 5 : Release Note for Field Installation (RNF)

Attachment 6 : Release Note for Painting (RNP)

Attachment 7 : Job Safety Analysis (JSA)

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Attachment 1

Daily Fabrication Inspection Report (DFIR) Algeria Oman Fertilizer Project Report No. : Date :

No. Area Isometric Drawing No. Pipe Support Type Heat No. WPS No. Welder

No. Qty Weight

(kg) Remarks

Prepared by : (Construction) Name Signature Date

Inspected by : (QC Inspection) Name Signature Date

6423DP420-003-01(0)

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Attachment 2

Material Traceability Record (MTR) Algeria Oman Fertilizer Report No. : Date :

Isometric Drawing No. Rev. No. Pipe Support Type Material Size Cut Length QC Sign Contract Sign

Line No. Spool No. Pipe Support Name Heat No. Thickness Qty Date Date

SHOP The shop components have been verified against the fabricated piping and are complete and accurate.


Inspected by (QC Inspector) Name Signature Date

FIELD The field components have been verified against the erected piping and are complete and accurate.


Inspected by (QC Inspector) Name Signature Date

6423DP420-003-02(0)

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Attachment 3

Daily Welding Inspection Report (DWIR) Algeria Oman Fertilizer Project Report No. : Date :

No. Area Isometric Drawing No. Sheet No.

Rev. No.

Support No.

Joint No.

Spool No. Material

Piping Class Size Sch. Pipe Support Type Qty

Weight (kg).

Heat No.

WPS No.

Welder No.1

Welder No.2

PWHT Reqd VT Remarks

Prepared by : Inspected by :

Name : Name :

Date : Date :

(Construction) (QC Inspector)

6423DP420-003-03(0)

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Attachment 4

6423DP420-003-04(0)

INSPECTION REPORT FOR EMBEDDED PLATE FABRICATION (IREPF) Embedded Plate Anchor Bar

S/No Reference Dwg (Standard Dwg) Type Plate No Thk (m) W W' H a b c d e f p

Length tolerance 5mm/1m

Dia (mm)

Length (mm)

No of Anchor

Bar Tolerance Remarks

1 Dwg Requirement Actual Deviation







Prepared By: (Construction Team) Name Signature Date

Inspected By: (QC Inspector) Name Signature Date

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Attachment 5

Release Note for Field Installation (RNF) Algeria Oman Fertilizer Project Report No. : Date :

No. Area Isometric Drawing No. Sheet No. Rev. No. Pipe Support Type Qty

Weight (kg) Remarks

Prepared by : (Pipe Support Field Team) Name Signature Date

Confirmed by : (Pipe Support Field Team) Name Signature Date

Checked by : (Pipe Support Fabrication Team) Name Signature Date

Approved by : (Pipe Support Fabrication Team) Name Signature Date

6423DP420-003-05(0)

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Attachment 6

Release Note for Painting (RNP) Algeria Oman Fertilizer Project Report No. : Date :

No. Area Isometric Drawing No. Sheet No. Rev. No. Pipe Support Type Qty

Weight (kg)

Paint Code Remarks

Prepared by : (Pipe Support Fabrication Team) Name Signature Date

Approved by : (Pipe Support Fabrication Team) Name Signature Date

Received by : (Painting Team) Name Signature Date

Reviewed by : (QC Inspector) Name Signature Date

6423DP420-003-06(0)

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Attachment 7

JOB SAFETY ANALYSIS

Date of Issue JSA No.

Work Group Preparing JSA Piping Prepared by

Job Description Pipe Support Fabrication & Installation Approved by

Sequence of Task Potential Hazards Recommendations / Control Measures

Worksite Housekeeping Slips Trips Falls

Access egress and emergency routes are not to be obstructed

All waste to be removed sorted and placed in Authorized storage

/sort bins

Wires and cables to be secured to avoid tripping hazard, and/or

provide walkway clearance storage /sort bins

All electrical system connections to be secured off ground and

protected from rainfall

Structure and scaffold projections to be signposted and masked

when possible

Holes and ground/floor openings to be barricade and signposted

Fluid spills to be cleared as they occur

Hoses and cables crossing roadways/paths to be protected with

suitable covers

Tools to be returned to store after use

Materials to be stored in correct locations

Flammable material are not to be left unattended at worksite

Gas Cutting, Welding and Grinding operation

Fire Explosion Electric shock Hot spot re-ignition Skin & eye damage

Equipment to be operated by competent person only

Electrical supplies to inspected and to be fit for purpose

Welding sets and transforms to be correctly earthed

Equipment to be inspected, labeled and in date for use

Competent fire watcher to be appointed (two if work on bulkhead

/ floor / deck head)

Clear area of combustible materials

Equipment liable to spark or spatter damage to be covered

Barriers and warning signs to be posted

Fire extinguisher to be at worksite

Electrical supply leads to be run so as not to provide a trip or

fouling hazard

Correct eye and body protection to be worn during work

Eye line glare shields for adjacent by firewatcher 30 minutes after

hot work ceases

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Crane operations and Lifting

Dropped objects crushing Trapping moving machinery

Hazard assessment to be conducted for all heavy (75% crane

capacity) or unusual movements

Every lift to be supervised by competent controller

Weight of lift to be known

Lift brief to be held on site

Lifting equipment to be correct color code

Lifting gear to be inspected fit for purpose each time of use

Only authorized crane to operate crane

Banks man to be trained and wear identifying clothing

Enough men to control load to be at site

Tag lines to be fitted and used at all times

Area under lift and immediate vicinity to be vacated

Overhead and jib swing hazards and obstructions to be noted

and clearly marked where applicable

Crane operating lift limits to be observe

Gear to be inspected and stored after lift

Vehicles on site Trapping crushing collision

Vehicle pass to be obtained an entry to site

Only authorized vehicles allowed on worksite

Only qualified and authorized drivers to operate vehicles

Vehicles to keep to directed routes

Speeds to be appropriate to site

Reversing warning tone to be operational

Banks man to be present when vehicles are reversing

Only authorized maintainers to work on vehicles whilst on site

Seat belts where fitted are to be worn by drivers and passengers

Passengers in vehicles only allowed in fitted seats, no riding

Vehicles are not to be overloaded

Wide or high loads are to be escorted whilst moving on site

Vehicle are only to be used for designed purpose

Vehicle and auxiliary engines are to be stopped when refueling

Engines to be stopped and keys are to be removed when

vehicles are left unattended

Work on or with scaffolds Falling Dropped objects

Only trained scaffolders are to erect, modify or dismantle scaffold

structures

Only authorized people to be scaffolds

Scaffolds are not to be used unless properly inspected and

certified with a current scaffold tag

Scaffolds are not to be overloaded with materials or men

Access ladders are to be secured to scaffold structure

Toe boards and guardrails must be fitted

Scaffolds must be tied into the parent structure to provide stability

Intermediate stage boarding to be provided for access ladders

Dropped object catchment netting to be provided as appropriate

Walkways under scaffolding to be bridged by hard barriers

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Work at height Falling Dropped objects

Only authorized people to go aloft

Ladders scaffolds and platforms to be properly erected and

certified

Hard points established for fall arrester and safety line anchor

points

Fall arresters and harnesses inspected for defects/damage

before each use

Fall arrester and harness to be worn and secured prior to

commencement of operations at height

Barriers and signs posted to keep people out from drop zone

Area lookout safety man appointed

Other PPE appropriate to task to be worn

Tools for use are attached to lanyards and secured

Area below worksite inspected for conflicting activities

Appropriate precautions taken for adverse wind/weather

Open Flame Cutting, Welding and Burning

Fire Explosion Hot spot re-ignition Skin & eye damage

Clear area of combustible materials

Equipment to be operated by competent person only

Competent fire watcher to be appointed (two if work on bulkhead

/ floor / deck head)

Equipment to be inspected and fit for purpose

Flashback arresters to be fitted and functional

Equipment liable to spark or spatter damage to be covered

Fire extinguisher to be at worksite

Gas bottles not to be placed in confined spaces

Gas bottles to be secured upright and away from hot site

Hoses to be clear of walkways

Bottle key to be attached to gas bottle by chain

Correct eye, ear and body protection to be worn during work

Worksite to be inspected by firewatcher 30 minutes after hot work

ceases

Pollution control Damage to environment and water courses

Always use hazardous substances with care, ensuring they are

suitably stored and empty containers are property disposed of

Oil and fuel cans, etc, should be stored and used so that

leakages /spillages can be contained consider hard standings

bund, spill trays, spill absorbs, etc

Ensure all plant and equipment is well maintained to ensure it is

running efficiently-no smoke, oil leaks etc

Do not run plant or equipment when not in use

Do not waste water by using leaking hoses of running taps

unnecessarily

Reduce dust by damping down materials, roads, truck loads

Be aware if your site borders any watercourse.

Do not allow dumping near banks.

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Pollution control Damage to environment and water courses

Water can carry pollutants over significant distances, and can

contaminate local drinking supplies

Near pour any contaminants down storm drains or gullies

Near use watercourses for cleaning tools, etc, and never store

hazardous substances nearby

Store potential contaminants in authorized stowage and do not

take more than is required to the worksite

Keep secure storage facilities locked with appropriate key control

Comments 1. JSA should be used in conducting Tool Box Talks(TBT0 with all concerned workers

2. Provide that all the necessary PPE are used, relevant PTW requirements are followed and all the control

measures stated above are adhered to, the activity can proceed.

PPE & Safety Equipment Required to Perform Task (tick as Appropriate)

Safety Helmet Face Shield Goggle Barricade Harness Hand Gloves Safety Shoes

Ear Plug Coverall Safety Glasses Work Permit Fire Extinguisher Dust Mask Others

Method Statement for Pipe Support Fabrication and Installation 6423dp420!00!0030000_rev01

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Transcript of Method Statement for Pipe Support Fabrication and Installation 6423dp420!00!0030000_rev01