GSE
GULF SPIC ENGINEERING L. L. C
METHOD STATEMENT FOR ABOVEGROUND ABOVEGROUND PIPING
Doc No: GSE/MS/AGP-002 REV 1
PROJECT: AL-AWEER GAS TURBINE POWER STATION H! PHASE III
GSE
GULF SPIC ENGINEERING L. L. C METHOD STATEMENT FOR AG PIPING
PREPARED By GULF SPIC
ENGINEERING L. L. C
REVIEWED By
APPROVED By
SIEMENS/ETA
MMD/DEWA
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GULF SPIC ENGINEERING L. L. C
GSE
METHOD STATEMENT FOR AG PIPING
CONTENTS
Sl No
DESCRIPTION
PAGE No
I
DEFINITIONS
3
1
INTRODUCTIONS
4
2
SCOPE OF WORK
4
3
REFERENCE
4
4
RESPONSIBILITIES
5
4.1
PIPING ENGINEER
5
4.2
MATERIAL CONTROLLER
5
4.3
QC ENGINEER
5
4.4
SAFET ENGINEER
!
5
"SE CONTROL
!
!
WORK SC"EDULE
!
#
E$ECUTION PLAN
#
#.1
MATERIAL RECEIVING AND "ANDLING
#
#.2
PRE%FABRICATION & INSTALLATION OF PIPILINE
#
#.3
"DROTEST
13
#.4
EQUIPMENT TOOLS & TACKLES
14
#.5
MANPOWER
15
'.
(OB SAFET ANALSIS
15
).
DOCUMENTS ATTAC"EMENT
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GULF SPIC ENGINEERING L. L. C
GSE
METHOD STATEMENT FOR AG PIPING
I.
DEFINITIONS
GSE
%
GULF SPIC ENGINEERING L. L. C
SIEMENS*ETA%
SIEMENS*ETA CONSORTIUM
DEWA
%
DUBAI ELECTRICIT & WATER AUT"ORIT
QA
%
QUALIT ASSURANCE
QC
%
QUALIT CONTROL
AG
%
ABOVE GROUND
"SE
%
"EALT" SAFET & ENVIRONMENT
ASME
%
AMERICAN SOCIET OF MEC"ANICAL ENGINEERS
WPS
%
WELDING PROCEDURE SPECIFICATION
PQR
%
PROCEDURE QUALIFICATION RECORD
NDE
%
NON%DESTRUCTIVE E$AMINATION
PW"T
%
POST WELD "EAT TREATMENT
SS
%
STAINLESS STEEL
CS
%
CARBON STEEL
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GULF SPIC ENGINEERING L. L. C
GSE
METHOD STATEMENT FOR AG PIPING
1.+
INTRODUCTION This method statement is intended to outline the method and sequence of work execution which will be followed for FA!"#AT"$%& '!'#T"$%& #$(("))"$%"%* + T')T"%* of abo,eground -i-ing of A./A0''! *A) T!"%' P$0'! )TAT"$% PA)' """5
2.+
SCOPE OF WORK The acti,ities includes but not limited to recei,ing of -i-es and fittings from 'TA)"'('%)& trans-orting to site& installation of -i-ing& fabrication + welding& %7'& and leak test as -er -ro8ect s-ecifications for the following -i-ing s9stems :not limited to;
F'. *A) P"P"%*
F'. $". P"P"%*
"%)T!('%T A"! P"P"%*
)'!<"#' A"! P"P"%*
F"% FA% #$$.'! )=)T'(
.' $". )=)T'(
"t shall be our res-onsibilit9 to ensure all the requirements as -er )"'('%)'TA a--ro,ed drawings& 7'0A s-ecifications and international standards5
3.+
REFERENCE DOCUMENTS A)(' 3151 A)(' 3153 7'0A P!$>'#T )P'#"F"#AT"$% *?51& *?5? + *?56
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METHOD STATEMENT FOR AG PIPING
4.+
RESPONSIBILITIES SITE ORGANISATION C"ART AS FOLLOWS SITE MANAGER
PIPING ENGINEER
4.1
QA*QC ENGINEER
MATERIAL CONTROLLE R
SAFET ENGINEER
PIPING ENGINEER e shall be res-onsible for carr9ing out all the acti,ities associated with A* -i-ing
works
including
-refabrication and erection5
e will ha,e the
res-onsibilit9 of timel9 execution of -ro8ect acti,ities in line with the -ro8ect schedule5 e will -lan for acti,ities related to A* -i-ing including but not limited to materials& machiner9& and man-ower5 e is also res-onsible for ex-editing missing materials& monitoring drawing re,isions and modifications for meeting the -ro8ect targets5
4.2
MATERIAL CONTROLLER (aterial controller is res-onsible for collecting materials from warehouse designated la9 down area and shifting the same to the fabrication area and shifting fabricated s-ools from the fabrication area to the erection site5
4.3
QC ENGINEER e is res-onsible for -re-aration of 0P) P@!& welder -erformance qualification& selection and control of welding consumables + %7' requirements5 e will be in/charge for ,erification + documentation of all rele,ant drawings and re-orts material& welding and welder traceabilit9 on 8ob and all stage ins-ection as -er a--ro,ed "TP5 @A."T= A))!A%#' is ensured at all le,els of
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METHOD STATEMENT FOR AG PIPING
fabrication& erection commissioning -rocess through -hased flow and execution of -rocedures5
4.4
SAFET ENGINEER
!e-orts to the )' "n charge5
"m-lements the -ro8ect safet9 -lan5
#onducts safet9 awareness training for site -ersonnel
(onitors the site to ensure safe working -ractices5
'nsure all tools + tackles& hea,9 equi-ments and machiner9 do com-l9 with the safet9 requirements of the -ro8ect5
5.0
Pre-ares dail9& monthl9 safet9 re-orts5
"SE ,"EALT" SAFET ENVIRONMENT- CONTROL *.F )P"# '%*"%''!"%* .5 .5 # will engage qualified safet9 -ersonnel who ensure that carbon steel -i-ing works are carried out as -er the #$%)T!#T"$% 'A.T P.A% which is enclosed with this document5 $nl9 the (ott a--ro,ed #onstruction )' -lan will be im-lemented5 All -ersons in,ol,ed will use necessar9 PP' and will be made aware of all the safet9 requirements on 8ob5 0ork -ermit at site for the field 8obs will be acquired and will be made a,ailable at site5
!.+
WORK SC"EDULE From the master schedule& related sections of -i-ing works shall be extracted and be used as the timeframe5 0ork sequence shall be followed while executing the different acti,ities in,ol,ed5
#.+
E$ECUTION PLAN
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METHOD STATEMENT FOR AG PIPING
#.1 B5151
MATERIAL RECEIVING AND "ANDLING The recei-t of materials at stores is ins-ected b9 the @# 'ngineer for rele,ant T#s and ,isuall9 checked for damages5 A (AT'!"A. "%)P'#T"$% !'P$!T will be -re-ared and submitted to the )"'('%)'TA5 An9 discre-ancies in the incoming material
ins-ection
will
be identified in the
re-ort
and
concerned
documentation shall be made to regulariCe it5
B5152
(aterial controller ensures onl9 acce-ted materials are issued to the concerned Pi-ing 'ngineer5
B5153
Pi-ing 'ngineer shall identif9 the list of material as -er the a--ro,ed drawings5 e -re-ares a material requisition and submits to stores ,ia (AT'!"A. "))' <$#'! for drawing the materials5
B5154
An9 discre-ancies in the "sometric drawings shall be referred back to )"'('%)'TA& :after checking in the P + "7& .a9out drawings; whom shall re,ert with necessar9 documentation to get written notice or field re,ised drawings5
B515?
Pi-ing 'ngineer will ensure -ro-er handling of materials at all stages of fabrication& erection commissioning5 All -i-es are fixed with end ca-s closed until it is read9 for fabricationinstallation to a,oid sediments going inside5
#.2 B5251
PRE%FABRICATION & INSTALLATION OF PIPELINE Pre/fabrication of the -i-es and s-ools will be identified as -er .A=$T + ")$ drawings5 7oubling of -i-es will be carried out at a suitable identified location :offsite;5 The work front shall be made a,ailable b9 )"'('%)'TA to cater the desired work -rogress as -er the -ro8ect schedule5
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GULF SPIC ENGINEERING L. L. C METHOD STATEMENT FOR AG PIPING
B5252
The -i-ing engineer on referring the P+"7 and ")$ drawings will identif9 the sco-e for -re/fabrication + doubling of -i-es5 )"'('%)'TA shall also decide on the sco-e for -re/fabrication5
B5253
The -riorities for -re/fabrication of -i-es& s-ools will be identified based on the o,erall -ro8ect schedule5 )"'('%)'TA shall also ad,ice on the -riorities of the -i-ing s9stems to be made read9 for erection5
B5254
0elder Performance @ualification will be carried out as -er a--ro,ed 0P)P@! and the same will be witnessed b9 )"'('%)'TA5 'ach welder will be -ro,ided with identification no5s for traceabilit9 of welders on 8ob5
B525?
0elding of the -i-es will be carried out as -er the a--ro,ed 0P) b9 qualified welders5 The 8oint design will be ensured for com-liance with 0P) checking the edge -re-aration& root ga-& be,el angle& land etc5 Preheat of weld 8oint will be done at a--licable areas which will be identified based on -ro8ect s-ecificationscodes + standards5
B5256
The fitu- of connected fittings with the -i-e will be gi,en additional concern to ha,e a -ro-er orientation as de-icted in the ")$ drawing for matching with the connected -i-ings at site5
B525B
The welding consumables will be under the control of @# 'ngineer5 The electrode selection as -er 0P)& baking of electrodes where,er required b9 calibrated baking o,ens& -ortable holding o,ens issued for welders on 8ob& calibration of welding machines and electrode baking record will be maintained and ensured b9 the @# engineer for clients re,iew5
B525D
The %7' for the -re/fabricated -i-es will be carried out based on the segregation made on -i-ing class and Pro8ect )-ecifications5 The sco-e for !T :decided based on -ressure rating as -er -ro8ect technical s-ecifications; will
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METHOD STATEMENT FOR AG PIPING
be identified at site and the same will be ensured for its com-liance :as test re-orts;5
B525E
P0T for the required -i-e weld 8oints will be identified based on the Pro8ect )-ecifications *?56 a--licable codes and standards :A)(' 3151;5 efore P0T& all the required %on/7estructi,e 'xaminations will be carried out in the -i-ing weld 8oints and the same will be com-iled as %7' records5
B5251 The stage ins-ection to be carried out during welding as -rescribed in the a--ro,ed "+TP will be executed and all the res-onsible -artici-ating -arties will be called during ins-ection5 The following ins-ection re-orts will be maintained and be concurred from )"'('%)'TA after successful com-letion of subsequent stages&
Fitu- and Alignment "ns-ection !e-ort
0elding
!T re-ort
Post 0eld eat Treatment !ecord
B52511 The 8oint reference will be identified near the weld 8oint where the details including weld 8oint no5& welder no5& line ")$ no5 etc5& will be transferred b9 suitable means :,ia5& -ermanent -aint markers or direct hard -unching on surface;5 )uch 8oint references will be retained till the final -ressure test5
B52512 The routing of the -i-es on steel columns& slee-er ba9s will be studied b9 the -i-ing engineer5 This feasibilit9 stud9 will include
)-ace adequac9 for -ositioning of lifting equi-ments which shall be clarified from )"'('%)'TA end for conformance at site5
)-ace adequac9 near the ,icinit9 of erection area for tem-orar9 storage of tools and tackles which shall be clarified from )"'('%)'TA end for conformance at site5
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GULF SPIC ENGINEERING L. L. C
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METHOD STATEMENT FOR AG PIPING
'rection clearance from the -receding contractor for structures + -i-e racks5
"dentification no5s of su--ort columns and slee-er wa9s :to be marked on the res-ecti,e columns for eas9 identification;
(an/access at -lace of ad8acent -i-ing s9stems for its non/hindrance :es-eciall9 near the field weld 8oints;
)u--ort -edestals at -i-e racks confirming to drawing requirements5
)caffolding requirements5
"f an9 inadequacies exist& the same will be re-orted to )"'('%)'TA for clarification5
B52513 All the -re/fabricated -i-es will be co,ered at the ends b9 suitable means so as to ensure debris free inside surface5 efore co,ering the -i-es& the remo,al of foreign -articles will be ensured5
B52514 The -re/fabricated -i-es will be coated as -er the technical s-ecifications following all the stage ins-ection -rocess for surface -re-aration& -rimer coat 7FT and final coat 7FT5 The details will be recorded :as ins-ection re-orts; and submitted for clients re,iew5
B5251? #oating on weld 8oints will be carried out onl9 after successful com-letion of the -ressure test5
B52516 efore shifting the -re/fabricated -i-es to site& it shall be ensured for its com-leteness in all res-ects :%7'& P0T& -aint coating etc5&;5 All the -re/ fabricated -i-es are identified b9 their ")$ drg no5& line no5& 8oint no5& welder no5 and will be ensured b9 su--orting documents for conformance of the test results5
B5251B 7uring transit of -re/fabricated -i-es to site& -ro-er care :b9 suitable means like wra--ing with -lastic co,er sheets& using rubber sheets to a,oid contact
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GSE
GULF SPIC ENGINEERING L. L. C METHOD STATEMENT FOR AG PIPING
with metal slings while lifting etc5&; will be taken not to damage the coating on -i-e surface5
B5251D After shifting the -i-es to site& the recei,ing end ins-ection will be carried out for an9 transit damages :like coating damage etc5&;5 Presence if an9 will be tended before -roceeding with the erection5
B5251E 7imensional check of the -i-es will be carried out at site to identif9 trimmingshortcoming requirements5 For this a detailed stud9 of the ")$ drg with the la9out drg will be carried out b9 the -i-ing engineer to inter-ret the feasibilit9 conditions5
B5252 'rection of -i-es on structures will be carried out in concurrence with the >$ )AF'T= A%A.=)") :refer
attachment 1;
to ensure safe working -ractices5 Tools&
tackles and the lifting equi-ments are ensured for its adequac9 and suitabilit9 for the 8ob requirements5 Pro-er concurrences are met and a--ro,ed -rior to execution5 !isk assessment stud9 will be carried out b9 the )afet9 'ngineer and will be submitted se-aratel9 to client for re,iew5
B52521 For multi/tier -i-e racks& the erection sequence of -i-ing will be followed from the lower tier to the u--er tier5 To insert -i-es in the lower tier& the columns at the road cross/o,er section shall not be installed with interconnecting beams5 This would enable free access for sliding the -i-es into the -i-e rack with an extended boom length from the lifting equi-ments5 This -re/requisite shall be ensured b9 )"'('%)'TA before the starting of erection acti,ities5 )uch locations will be identified b9 the -i-ing engineer in co/ordination with the 'TA engineer -rior to the erection acti,ities :refer
attachment 2 for
main -i-e/rack
-i-ing G areas highlighted for crane access requirement;5
B52522 0here,er a--licable& the erection of u--er tier columns and tie beams shall be on/hold till the com-letion of erection of lower tier -i-ings to ensure sufficient
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GULF SPIC ENGINEERING L. L. C METHOD STATEMENT FOR AG PIPING
man + material access for -erforming site erection acti,ities5 The same should be ensured b9 )"'('%)'TA -rior to starting of the erection acti,ities5 )uch locations will be identified b9 the -i-ing engineer in co/ordination with the 'TA engineer -rior to erection acti,ities :refer
attachment 3 for
-i-e/racks in Fuel
$il )torage Tank / areas highlighted;
B52523 The necessar9 scaffolding -latforms to enable rigging acti,ities and the subsequent 8oint fitu-welding should be ensured b9 )"'('%)'TA -rior to the execution5
B52524 Prior to 8oint fitu-& the -ro,ision of -ermanent su--orts will be confirmed with the ")$ drawing5 0here,er required& tem-orar9 su--orts will be -ro,ided to a,oid line distortion while welding5 The -ro,ision of tem-orar9 su--orts will be concurred from )"'('%)'TA before further execution5
B5252? 0elding of field 8oints will be carried out as -er a--ro,ed 0P)5 For -i-es with connected fittings& the orientation of noCCles& weldolets& half cou-lings etc5& will be checked with the connecting -i-ing orientation5 The alignment of the -i-e fittings will be gi,en adequate care :,ia tem-orar9 su--orts where,er required; to a,oid line distortions during welding5
B52526 The orientation of drains and ,ents shall follow the uni,ersal rule of highest -oint ,ents and lower -oint drains5
B5252B 0here,er )) connected -i-ing and fitting exist& -ro-er care will be taken to a,oid contact corrosion of )) s-ools with #) materials5 As far as -ossible& onl9 belt slings will be used for lifting )) materials5 "f metal slings be used& then the contact location will be suitabl9 masked + co,ered5
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GULF SPIC ENGINEERING L. L. C
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METHOD STATEMENT FOR AG PIPING
B5252D 0here,er flange connections exists& the9 will be co,ered at their faces to a,oid damages at transit :es-eciall9 at gasket seating faces; b9 suitable means like wooden blinds& -lastic ca-s etc5&
B5252E The regulariCation works after the 8ob com-letion& like remo,al of fitu- cleats& weld s-atters :if an9;& tem-orar9 su--orts etc5& will be carried out and ensured5
B5253 %7' + P0T for field weld 8oints will be carried out where,er a--licable as -er -ro8ect technical s-ecifications5 )uch stage ins-ections will be backed b9 %7' and P0T test re-ort and submitted for clients re,iew5
#.3 B5351
"DROTEST A -unch list for 8obs to be carried out will be -re-ared b9 the @# 'ngineer and submitted to the )"'('%)'TA5 )"'('%)'TA on their discretion will adddelete on the 8obs listed5 A walk down ins-ection of the entire loo- will be -erformed for confirming the drawing requirements5 The acti,ities listed out will be carried out based on the -riorit9 status and the same will be confirmed5
B5352
Pi-e cleanliness for inside and outside surface will be carried out5 For inside cleaning& card board bursting will be carried out for the entire test loo- and cleanliness will be ensured -rior starting of 9drotest5
B5353
A T')T PA#H will be com-iled b9 the @# 'ngineer which will contain the following&
T')T 7!A0"%* showing test limits
")$ + 7rawings list
Pi-ing %7' test re-orts
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GULF SPIC ENGINEERING L. L. C
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METHOD STATEMENT FOR AG PIPING
P%# list :-ost-re;
.ine welding istor9 )heet :with %7' re-orts;
P!'))!' T')T check list
#alibration certificates of -ressure gauges used for testing
!einstatement check list
=7!$T')T certificate
The test -ack will be submitted for clients re,iew and a--ro,al before the starting of =7!$T')T5
B5354
0ater to be used will be from a -ortable + agreed location5
B535?
Fill water through hoses at the lowest -oints in the loo-5 After ensuring -riming in the loo-& start -ressuriCing to the test -ressure :15? times the design -ressure or as -er the -ro8ect s-ecifications;5
B5356
olding time for the test -ressure shall be as -er A)(' 3151-ro8ect s-ecifications5
B535B
Failure in the test :if an9; shall be re,erted with draining& re-airing and re/ testing with the abo,e -rocedure5
B535D
$n com-letion of 9drotest& the water shall be drained& ensuring -ro-er safet9 -recautions5 After com-lete draining of water& the loo- should be air flushed to ensure remo,al of moisture entra-ment5
B535E
!einstate the test loo-s G Paint coating at weld 8oints& isolation of -ressuring equi-ment& moisture remo,al b9 air flushing etc5&
#.4
EQUIPMENT TOOLS AND TACKLES
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METHOD STATEMENT FOR AG PIPING
B5451 All required 'qui-ments& Tools and tackles shall be de-lo9ed to meet the work )chedule and satisfactor9 installation5 This equi-ment is a,ailable at *)') )ite store5 B5452 All required measurement tools shall be made a,ailable to enable correct installation and ins-ection of )tructures5
#.5
MANPOWER )ufficient man-ower as required to meet the safe& satisfactor9 and timel9 com-letion of the 8ob shall be de-lo9ed as -er enclosed list and these will consist of but not limited to the followingI
'.
•
)u-er,isors
•
Foreman
•
)killed workers
•
!igging *rou-
•
)ite #leaning #rew
(OB SAFET ANALSIS. The 8ob safet9 anal9sis for the abo,e ground -i-e line erection + testing work is -re-ared and enclosed as reference Attachment G " documents5
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