Method Statement Pipe Welding

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METHOD STATEMENTFOR

PIPE WELDING WORKS


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IntroductionThis Method statement describes in detail the welding process for pipe work and thewelder's qualification test procedures. This includes addressing programs forimplementing commitments regarding the quality of weldir,g works.

Gontents

1.0 Scope and Purpose of Method Statement2.0 Index-i.0 Description of Activities4.0 List of Main Equipment5.0 Health, Safety and Environment Measures1.0 Scope and Purpose of Method StatementThis document outlines the method for executing welding process for pipe work andwelding procedure qualification test for welders. This method statenrent covers a1lpiping rvelding works for Burj Dubai Tower Project either shop fabricated or siteinstalled.The procedure provides guidance for assessing the activities for jointir"rg rnechanicalpiping system. This guidance is based on the requirements set forth in the SafetyRequirement Document (SRD) and The Quality Assurance Program (QAP)

1.1 ObjectivesThis document provides guidance in implementing an effective progfatn for all pipewelding works. This includes addressing programs for the following: (i; implementingcommitrnents regarding the quality of the lveld joints; (2) rnanaging and providingoversight to ensure installation and related quality control have been adequatelyaddressed by specifications, drarvings, and procedures; (3) managing and providingsupervision and control to assure qualification of welders; and (4) recording installationand test activities.This procedure is one component of a complete construction and inspection prograrn.This and other procedures will be used, as needed, to provide assurance that constructionactivities are beir-rg conducted as required by the specification and manufacturerprocedures. It is not expected that completior, of the entire procedure will beaccomplished during any one inspection and/or every time tl,e inspection procedure isused. lt is a continuing activity until all piping networks are installed and tested.


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1.2 lnspection and Recording RequirementsThe engineer should verify that the supervisor/foreman with constructionresponsibiiities for the pipe welding works is familiar with this method stater.nent and isissued with copies of the inspection checklists and test plans.The engineer should satisfr procedures provided by QA/QC inspections to ensure thepipe welding works meet specified engineering requirements and drawings. As part ofthe assesstnent, the QC Inspection Procedures, must ensure a quantitative or qualitativeacceptance criteria for determining the prescribed activities have been accomplishedsatisfactorily.The QC inspection personnel, in coordination with Site Supervisor, should verify thatthe quality of the pipe welding works and related testing activities are within tlie projectdesign specifications requirernents.The Supervisor should verify that the pipe welding works is accomplished inaccordance with the specifications and the manufacturer's procedures.The Supervisor should verify any as-built record of pipe welding works and testing, andconfinn that the information meets the project requirements.

1.3 Inspection GuidancePipe weldir-rg works need to follow strictly established codes and safety procedures.Care should be taken to ensure that applicable codes and standards be strictly adhered toduring pipe welding rvorks.The Supervisor can choose to follow the most appropriate welding technique applicableat such a given time and in coordination with the construction progress, QA/QCinspection arrd testing requirements. The Engineers should use judgment in detenniningsample selection focusing on examination of tl-re rnost impoftant aspects of the particularwelding activity being inspected. The intent is to establish a high level of assurance thatthe end product meets the project requirements.Review the implementing procedures and safety standards for tlie pipe welding worksprovided by the QA/QC. The QA/QC inspectors should verify tliat the procedures (1)are approved, and (2) specify the requirernents of the design ar-rd/or from themanufacture's technical manual(s) and codes or standards prescribed by tlie Client.

1.4 Training and Qualification of PersonnelThe Supervisor should verify that the personnel have sufficient kr-iorvledge of theprocedure requirements. The Supervisor should review any training and qualification


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records for those individuals who shall do the task to determine whether they are skilledenough to follow the procedure before the actual work is carried out.

2.0 Index2.1 Preparation of Materials and Execution of Works

. General. Pipe Joint Preparation. Pipe to Pipe Fit Up. 45" Elbow to Pipe Fit Up

. 90o Elbow to Pipe Fit Up. Tee to Pipe Fit Up. Flange to Pipe Fit Up2.2 Welding Procedure Qualification Test Requirements

. Welding Process. Base Metais

. Filler Metals. Position of Groove & Weld Progression. TemperatureRequirementso Postweld Heat Treatment' TYPe of Gas. Electrical Characteristics. Travel Speed & Passes. Laboratory Test Results


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3.0 Description of Activities3.1 General

. Check all pipes and fittings to be used forjoint are free fromdefects, dents or defonrities and are straight. Remove pipes andfittings with defects and replace with acceptable materials.. Remove foreign matter or difi from inside of the pipe and fittingsbefore fit up.. For longer work breaks, place suitable stoppers to prevent debris,earlh or water from entering pipe open ends.. Welding electrodes shall be stored and handled as perManufacturer' s instructions.

3.2 Pipe Joint Preparationr Cut the pipes to the required length using an appropriate pipecutter, or profile cutter (Oxy-Acetylene), allowing for provision ofDioe fittiris later. Works shall be carried out in accordance with theapproved shop drawings.. The pipes shall be checked by the assigned foreman for itssquareness and straightness, after being cut to the correct angle andsite requirements, as per sample of lvelding details in Figure ishown below.


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Figure 1 - Sample of Welding Details

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3.3 Pipe to Pipe Fit Up. Lay the two (2) pipes on top of the pipe stand or adjustable suppoft,with each pipe ends aligned near each orher using adjustable boltstopper as shown on Figure 2 below.

Ad.ius{able bults($ppef {Re:loveali*r fit-up)slerrd sr Adlustable sLrpport

Figure 2 - Pipe to Pipe Fit UpNote : For larger sizes only, 4"dia. and above

Level one length of pipe using spirit leve1.Bring lengths together leaving only a small welding gap. In normalpractice, a welding electrode of 2.4 mm A size, removed of itscovering and bent in the middle at an angle of 30" is insertedbetween the two pipes to obtain a perfect rvelding gap. It isrecomrnended to weld adjustable bolt stoppers (small piece ofplate about l2 mrn thick with an M-16 hexagon bolt and nutrvelded at one end as shown in Figure 2) for perfect and easyalignment.


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Remove the adjustable bolt stoppers after fit up and grind flush alltack welded points rnaking sure that there is no over grinding ofthe base metal.Place the spirit level over both pipes as shown or-r Figure 2 andmaneuver until both pipes are leveled. Adjusting the pipe suppoftcan easily do this. Ensure that there is no high-loi.v situation ormisalignment between the two outside surfaces.Tack weld at the top and bottom.Rotate the pipes 90'.Repeat the same procedure.

3.4 45" Elbow to Pipe Fit Up. Lay one (1) pipe on top of the adjustable pipe supporl.

Piric slrr:rl cr Ad'tst;r'rltSrrpport

Figure 3 - 45' Elbow toNote : For larger sizes only,

Level the pipe using spirit levei.Place the 45' elbow to the end of the pipe leaving a sn,all weldinggap, similar to item 4.3.i for Pipe to Pipe fit up.Place a 45o snirif level on the face of the elbow until bubble iscentered and ensure that there is no high-low situation or misalignmentbetrveen the two outside surfaces.Tack weld in place both the pipe and the elbow.

r\cijr:s:ab lc b*h stcpl.rvrlZrnnrr MS plale(T;ul rve)cieri tc pipe)

Pipe Fit Up4"dia. and above

Sp:rit l,cvcl rli"-Elbarv


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3.5 90' Elbow to Pipe Fit Up. Lay one (1) pipe on top of the adjustable pipe supporls.. Level the pipe using spirit level.. Place the 90' elbow to end of the pipe leaving a small welding

gap the same as item 4.3.3 for Pipe to Pipe Fit up.. Place a spirit ievel on tlie face of the elbow and maneuver theeibow until it is leveled and ensure that there is no high-lowsituation or misalignrnent between the two outside surfaces.

. Tack weld in place both the pipe and elbow.Spirit Level

.lcl*. -ltF,/ \Pipefl \

Pipe stand or Adjustabl. Suppo.tf-\

Figure 4 - 90' Elbow toNofe . For larger sizes only,

90"- ElboilAdjusrable bolt stopper(Tack rvelded to pipe)

Pipe Fit Up4"dia. and above


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3.6 Tee to Pipe Fit-Up. Lay one (1) pipe on top of the on the adjustablePipe supports.

. Levelthe pipe using spirit level.. Place the tee at the end of the pipe leaving a smallwelding gap the same as item 4.3.3 for Pipe to Pipe fit up.. Place a spirit level on the face of the tee and maneuver thetee until leveled and ensure that there is no high-lowsituation or misalignment between the two outsidesurfaces.. Tack weld in place both tlie pipe and tee.

Spirit l.evel

Pipe stand or Roller supportAdjustable bolt stopperl2mmt MS plate(Tack rvelded to pipe)

Figure 5 - Tee to Pipe Fit UpNote : For larger sizes only, 4"dia. and above

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3.7 Flange to Pipe Fit-Up. Lay one (1) pipe on top of the adjustable pipe supporl.. Level the pipe using spirit level.. Bring the flange at the end of the pipe leaving a smallrvelding gap the same as item 4.3.3 for Pipe to Pipe fit-up (ln

case a Weld neck type of flange is used). lf a slip-on ti'pe offlange is to be used, inseft the pipe to the flange bore up to5mnr depth from the flange face to give enough space for afillet weld.. Align the top two (2) holes of the flange with the spirit level.. Tack weld in place the pipe and flange.

Figure 6 - Flange to Pipe Fit Up

Spirit Level


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Spirit Levei

Pipe stand orAdjustable Support

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I PrPt FoR ri'-uPiPi ,l*1FiTTYPICAL DETAILS OF ADJUSTABLE BOLT

STOPPER USE FOR PIPE FIT UP and ALIGNMENTNote : For larger sizes only, 4"dia. and above

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4.0 List of Main Equipment, Tools, lnstruments4.1 EQUTPMENT AND TOOLS

A. Boom truckB. Chain blocks (1Ton * 5Ton Cap.)C. A-frame (steel fabricated)D. Nylon sling or straps (New and tested)E. Set ofshacklesF. Adjustable bolt stopperG. Adjustable pipe supportsH. Spirit levelI. Alignment Tools (Plumb Bob, Chalk line, Nylon String Line, Felt Tip Marker)J. Welding Personnel Protective Equipn,entsK. Hand toolsM. Steel measuring tapeN. Angle & Straight GrindersO. Welding MachinesP. Steel Scaffolding and Ladders

5.0 Health, Safety and Environment Measures5.1 Preparation

Notify all concerned in site for the date of material delivery.- Coordinate with Safeti, Deparlrnent for delivery trucks access routes.- Ensure all rvorkers involved in the hauling operation put on PPE al1 times.- Brief individual worker the roles and responsibilities of each.- Ensure transporter route is cleared ofobstruction.- Coordinate with Construction Department for Pipe Hoisting area.- Erisure designated hoisting area is cleared of obstruction.- The lorry transporling the pipes will be guided to the designated hoistingarea and released ali the latching belts only after the lony parked firrrrly.

5.2 Pipe LiftingEnsure safe rvork procedure for lifting operatior-t is observed.- Ensure proper lifting rnethod - with the correct equipments are used.- Ensure the pipes are firrnly placed on the designated location beforereleasing the hoisting hook.

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5.3 During Site Execution- Ensure workers are distributed to each designated place.- Ensure workers at all times to be in proper gear where required.- Ensure all workers assigned are involved in its pal1icular task.- Brief individual worker the roles and responsibilities before starl work.- Ensure the pipe lengths to suit site routes into desigrated work area.- Ensure pipe suppofi systerns are installed accordingly as required.- Ensure all tools to be used have been inspected and tag by Safety Dept.- Ensure work areas are clearly marked to restrict access to authorized

personnel only.- Ensure that equiprnents to be used are properly tagged and checked.- Ensure that welders are qualified, with the correct PPEs, and well versed on the

job at hand rvith the latest revised drawing/s.

5.4 Housekeeping- Maintain cleanliness and orderly stocking of materials & tools.- Pick up and dispose wastes & other debris prior to leaving site area.Remove safety yellow tape or other warning devices that were used tocontrol access to the work area.- Store tools, equiprnent and unused materials properly at the end of theworkday.

5.5 Safety Inspections- It shall be responsibility of the Supervisor to routinely inspect the physicalareas under their control in pipe welding works. This inspection shallinclude detennining if pipes, suppofts, scaffolds and ladders areappropriately installed and/or use, and if the job site is cleaned up a11er theday's work.

Method Statement Pipe Welding

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