KHONAINI PETROLEUM SERVICES K. P. S METHOD STATEMENT – INSTALLATION OF CARBON STEEL PIPE FOR FUEL PIPE LINE RAZ AL KHAIR ALUMINUM SMELTER
Project Doc. No:
CONSTRUCTION OF FUEL AND LUBRICATION STATION Rev. No: Page
Table of Contents 1.0
PURPOSE
2.0
SCOPE
3.0
REFERENCES DOCUMENTS
4.0
DEFINITIONS
5.0
DUTIES & RE RESPON PONSIBILITIES
6.0
PROCEDURE
7.0 7.0
JOI JOINT PREP PREPAR ARAT ATIION AND FITFIT-U UP
8.0
WELDING
9.0
WELDING REPAIR
10.0 10.0
NON NON DEST DESTRU RUCT CTIV IVE E EXAMI EXAMINA NATI TION ON (NDE (NDE))
11.0
INSPECTION
12.0 12.0
COAT COATIN ING G AND AND WRAP WRAPPI PING NG
13.0 13.0
PRES PRESSU SURE RE TEST TESTIN ING G
14.0
REINSTATEMENT
15.0
TOOLS AND EQUIPMENTS
16.0
SAFETY INSTRUCTIONS
KHONAINI PETROLEUM SERVICES K. P. S METHOD STATEMENT – INSTALLATION OF CARBON STEEL PIPE FOR FUEL PIPE LINE RAZ AL KHAIR ALUMINUM SMELTER CONSTRUCTION OF FUEL AND LUBRICATION STATION Rev. No: Page
Project Doc. No:
1.0
PURPOSE
The purpose of this method statement is to describe the method, the sequence and the responsibilities of the erection and welding activities of fuel piping, performed by construction team of Khonaini Petroleum Services (KPS) 2.0
SCOPE
The scope of this method statement covers the following activities
3.0
REFERENCE DOCUMENTS •
Isometric Drawing Latest revision
Documents Number
Description
25457-0000-3PS-P000-0001 25457-0000-3PS-P000-0002 25457-0000-3PS-P000-0003
Piping Design and Materials Shop Fabricated Piping Field Fabrication and Installation of Piping Painting of Mechanical Equipment Piping and Steel Structure
25457-0000-3PS-G000-0002
4.0
DEFINITIONS
ASP MA’ADEN PM KPS NDE PPE WPS
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Aluminum Smelter Project Saudi Arabia Mining Company Project Manager Khonaini Petroleum Services Non Destructive Examination Personal Protective Equipment Welding Procedure Specification
KHONAINI PETROLEUM SERVICES K. P. S METHOD STATEMENT – INSTALLATION OF CARBON STEEL PIPE FOR FUEL PIPE LINE RAZ AL KHAIR ALUMINUM SMELTER CONSTRUCTION OF FUEL AND LUBRICATION STATION Rev. No: Page
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5.0
DUTIES & RESPONSIBILITIES
It is the responsibility of the construction department to perform the work as per the requirements of Contract Documents, IFC Drawings, Project Specifications and Inspection Test Plan. The responsibility of the QC Inspector is to perform all inspections as per the ITP to ensure compliance to the requirements of the IFC Drawings and project specifications and preparing the inspection reports. The QC supervisor will coordinate the inspection activities and verify the QC report for completion and sign the documents. The QC manager will verify the documents as required. The third party laboratories perform the required inspection or test as per the requirements of specification.
6.0
PROCEDURE
6.1
PIPES and SPOOLS CLEANING All pipes spools must free of sand and fabrication debris.
Cleaning of pipes will be done manual or by an air compressor.
Pipe spools end and flanges will be closed with temporary plywood or polyethylene sheets. Inspection and record for pipes and spools cleaning will be held before giving the clearance to the next activity.
KHONAINI PETROLEUM SERVICES K. P. S METHOD STATEMENT – INSTALLATION OF CARBON STEEL PIPE FOR FUEL PIPE LINE RAZ AL KHAIR ALUMINUM SMELTER CONSTRUCTION OF FUEL AND LUBRICATION STATION Rev. No: Page
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6.2
ACCESS and BARRICADES OF TRENCHES After finishing excavation to the required depth according to the relative method statement for “excavation, backfilling and compaction”, barricade should be installed all around the excavation with appropriate access.
6.3
PIPING ERECTION Before starting the erection activities, the spools should be inspected by the concerned supervisor / Engineer. Pipe and piping spools will be installed in the trenches on sand bags respecting the invert level of the pipes according to the relative drawings. Piping slope should be the same as mentioned in the isometric drawings.
7.0
JOINT PREPARATION AND FIT-UP
7.1
BUTT WELDED JOINTS Pipe ends should be cleaned from paint. Cutting and beveling will be done by mechanical means or grinding machine. Fit-up of pipe ends, fittings ad weld neck flanges shall be done to obtain uniform root opening. Gap should be the same as mentioned in the relative WPS. An appropriate clamp will be used for straight runs to easy the joining process. KHONAINI PETROLEUM SERVICES K. P. S METHOD STATEMENT – INSTALLATION OF CARBON STEEL PIPE FOR FUEL PIPE LINE RAZ AL KHAIR ALUMINUM SMELTER CONSTRUCTION OF FUEL AND LUBRICATION STATION Rev. No: Page
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Tack weld will be done using a bridge tacks in the groove in such a way to not affect the root face. The bridge material shall be the same material as the piping. Welding process is the same as mentioned in the WPS. Distance between two consecutive girth welds shall not be less one pipe diameter or 50mm, which is greater, unless otherwise indicated on the drawings or approved by engineering. 7.2
SOCKET WELD All pipes shall be cut in such a way that the cut end of the pipe is straight to enable an even gap between the end of the pipe and socket. The gap between male and female component shall be 1.6mm.
7.3
THREADED JOINT
Threaded joint connection should be made in accordance with the requirements of project specification.
Threaded should be free from any dirt. Tape and/or sealant shall be used for threaded connection for utility services pipes (air and water) a special care should be take to wound the tape in the correct direction. Care shall be taken, not to damage the threaded, during installation. Seal welding of the Threaded connection shall be done for process and steam lines to cover all exposed threaded and shall have a smooth contour between the two surfaces (if required). KHONAINI PETROLEUM SERVICES K. P. S METHOD STATEMENT – INSTALLATION OF CARBON STEEL PIPE FOR FUEL PIPE LINE RAZ AL KHAIR ALUMINUM SMELTER CONSTRUCTION OF FUEL AND LUBRICATION STATION Rev. No: Page
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8.0
WELDING
Welding shall be done by certified welders. Oil, moisture, rust, scale, sand, paint or other foreign matter shall be removed from weld surface ≥ 25mm of adjacent base metal prior to welding, including any such coating on temporary attachments. Each weld pass shall be thoroughly cleaned and all slag, porosity, cracks, spatter or other foreign matter to be removed before the next pass is deposited. All slag and spatter shall be removed from the completed weld and surrounding areas to suit the requirement specification. All branch connections shall be joined to headers with full penetration welding. The bore side shall be ground smooth free from cracks.
Welding parameter shall comply with the WPS. All pre-heating shall be done as per the requirements of Project Specification and relevant. Weaving width (maximum 3 time of electrode dia.) Welding shall not be performed when the wind is strong enough to affect arc stability or shielding gas coverage. Windshield or tents shall be required when the wind or blowing sand is sufficient to adversely affect weld quality. Weld layers shall not start the completion of the previous one and shall never start and finish in the same point.
KHONAINI PETROLEUM SERVICES K. P. S METHOD STATEMENT – INSTALLATION OF CARBON STEEL PIPE FOR FUEL PIPE LINE RAZ AL KHAIR ALUMINUM SMELTER CONSTRUCTION OF FUEL AND LUBRICATION STATION Rev. No: Page
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9.0
WELDING REPAIR
A weld defect to be repaired shall be removed to sound metal by chipping or grinding, the excavated area will be inspected my PT to ensure complete removal of the defects. Repair welds shall be made using the same welding procedure. Welding shall be performed by qualify welders. The repair area shall be re-examines using the same examination method and procedure by which the defect was originally detected.
10.0
NON DESTRUCTIVE EXAMINATION (NDE)
NDE shall follow the following procedure:
•
11.0
Procedure for radiographic testing (RT)
INSPECTIONS
Inspections shall be done in accordance with: •
•
12.0
ITP for Mechanical and Plumbing (see Section 3.0) ITP for welding and NDE
COATING AND WRAPPING
Coating and wrapping will follow: •
Method statement for coating and wrapping KHONAINI PETROLEUM SERVICES K. P. S METHOD STATEMENT – INSTALLATION OF CARBON STEEL PIPE FOR FUEL PIPE LINE RAZ AL KHAIR ALUMINUM SMELTER CONSTRUCTION OF FUEL AND LUBRICATION STATION Rev. No: Page
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13.0
PRESURE TESTING
Pressure testing will be done in sections. Limits should be defined in test pack. 14.0
REINSTATEMENT
Before final documentation handing over, all the lines should be checked and prepared to suit the project specification and requirements.
15.0
TOOLS AND EQUIPMENTS
15.1
EXECUTION
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Surveying Equipment (Total Station, Theodolite, Dumpy level) Welding machine
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Hand tools
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15.2
Painting equipment
SAFETY • • • • • • • •
Nomex coverall Safety Helmet Safety Goggles Face Shield Working and welding gloves Welding Helmet H2S toxic clip Fire Blankets KHONAINI PETROLEUM SERVICES K. P. S METHOD STATEMENT – INSTALLATION OF CARBON STEEL PIPE FOR FUEL PIPE LINE RAZ AL KHAIR ALUMINUM SMELTER CONSTRUCTION OF FUEL AND LUBRICATION STATION
16.0
SAFETY INSTRUCTIONS •
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STARRT card shall be obtained prior to start and commencing the work. Care shall be taken for rigging activities to ensure a safety handling. Arrange tool boxes and continuous training for labors. Work execution shall be carried out in accordance with the method statement and Project specification. The erection crew shall carry out a safety risk assessment prior to start of activities. Pre-task and tool box meeting shall be conducted prior to commencing the work. All equipment shall be inspected prior to use. Daily equipment checklist shall be maintained. Dust control measure shell be accounted. Fire extinguishers should be provided for any hot work activity. Good housekeeping must be maintained in the duration works. Condition monitoring and inspection shall be implemented to detect and correct unsafe practices while performing the work activities.
•
Barricade shall provide for work areas.
