C O N U LI E N G IS N
EPC CONTRACTOR:
PROJECT MANAGEMENT CONSULTANT: CONSULTANT:
China Petroleum Engineering & Construction (Group) Corporation Abu Dhabi Branch P.O. Box 1!"#$
P.O.Box !"$ Abu Dhabi *AE
P+O,EC-
%' Consulting Engineers
AB* D/AB% C+*DE O% P%PE%0E P+O,EC-
EPC Contractor Doc. 0o. DOC*2E0- 0o.
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ABU DHABI CRUDE OIL PIPELINE PROJECT
(ADCOP) METHOD STATEMENT FOR PIPELIENE WELDING 30-99-90-1619
REVISION RECORD
REV
DATE
ORIGINATOR
REVIEWED
APPROVED
DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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DA-E 98489
A
18989
Dong :ing7un
:e ;iaopeng
%ssue or +e6ie>
98489
Dong :ing7un
?ibi Peter
%ssue or Construction
DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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CONTENTS
PAGE
10 INTRODUCTION............................................................................................................................................ $ !0 PURPOSE OF THIS DOCUMENT ................................................................................................................ $ 30 DEFINITIONS AND ABBREVIATIONS ......................................................................................................... $ ".1 Deinitions ........................................................................................................................................5 ". Abbre6iations....................................................................................................................................5 "0 REFERENCES............................................................................................................................................... 5 #.1 Pro7ect ?peciicaion an@ Proce@ures.................................................................................................6 #. Other +eerences.............................................................................................................................6 # 0 COMPLIANCE STATEMENT........................................................................................................................5 60 GENERAL...................................................................................................................................................... ! 5.1 APP+OA 8 A*-/O+%?A-%O0 ........................................................................................................7 5. D%?-+%B*-%O0 A0D CO0-+O .......................................................................................................7 $0 ROLE AND RESPONSIBILITIES..................................................................................................................! %0 PROCEDURE................................................................................................................................................. 4 9.1 /?E +euirements ...........................................................................................................................9 90 E&UIPMENTS.............................................................................................................................................. 1 100 PROCEDURE &UALIFICATION ............................................................................................................... 1 110 WELDER &UALIFICATION....................................................................................................................... 11 1!0 METHODOLOG' FOR MAINLINE WELDING ......................................................................................... 11 130 WELDING RETURN CIRCUIT.................................................................................................................. 1 1".1 el@ing........................................................................................................................................12 1". Preheating....................................................................................................................................13 1"." +oot +un Process .........................................................................................................................13 1".# ?tarting.........................................................................................................................................13 1".$ Closing.........................................................................................................................................13 1".5 Cleaning.......................................................................................................................................13 1".! +emo6al o Clamp ........................................................................................................................13 1".9 /ot Pass.......................................................................................................................................14 1".4 'ill an@ Cap ..................................................................................................................................14 1".1 Cleaning an@ +estarting..............................................................................................................14 1".11 Capping an@ %nspection...............................................................................................................14 1".1 ?ubseuent Pipe Alignment ........................................................................................................14 1".1" eather Protection .....................................................................................................................14 DOC*2E0- -%-E
2E-/OD ?-A-E2E0- 'O+ P%PE%0E ED%0G
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1".1# isual Examination .....................................................................................................................14 1"0 FOR TIE-IN WELDING .............................................................................................................................. 1$ 1#.1 2E-/ODOOG:..........................................................................................................................15 1#. +epair el@ing.............................................................................................................................16 1#." isual %nspection an@ 0D- ............................................................................................................17 1#.# el@ 0umbering ?stem ...............................................................................................................17 1#0 ELECTRODE CONTROL.......................................................................................................................... 19 160 DOCUMENTATION.................................................................................................................................... 14 1$0 E&UIPMENT LIST..................................................................................................................................... 14 1%0 &UALIT' ASSURANCE &UALIT' CONTROL ....................................................................................14 190 ATTACHMENTS .........................................................................................................................................
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Description
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%nspection an@ -est Plan
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el@ing Parameters +ecor@ ?heet
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el@ing Euipment Calibration +ecor@ Pipe BooF 'orm -O
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el@er Perormance +eport
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el@er ualiication -est Certiicate
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el@er ualiication Car@ ualiication +ange
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P? isual %nspection +eport
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Dail el@ +epair ist -ie in el@ing %nspection +eport
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0D- +euest +a@iographic %nspection +eport
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DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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10 INTRODUCTION -he
*nite@ Arab Emirates (*AE) authorities ha6e assigne@ %nternational Petroleum
%n6estment Compan (%P%C) to execute the Abu Dhabi Cru@e Oil Pipeline (ADCOP) Pro7ect >hich >ill acilitate the transerring o cru@e oil rom /abshan pro@uction acilities to the 'u7airah 2ain Oil -erminal (2O-) on the eastern seaboar@ o the *AE. -he propose@ pipeline is o approximatel "!1 Fm in length. -he pipeline is @esigne@ or transerring o .$H1.$ 22BBD o cru@e oil. China Petroleum Engineering & Construction Corporation (CPECC) has been assigne@ as EPC construction or the entire ADCOP pro7ect b %P%C >ith %' as Pro7ect 2anagement Consultant. !0 PURPOSE OF THIS DOCUMENT -he purpose o this metho@ statement is to @escribe the metho@olog in6ol6e@ in pipeline >el@ing acti6ities an@ to @etail out the steps to be taFen to meet the reuirements as speciie@ b the Pro7ect ?peciications. 30 DEFINITIONS AND ABBREVIATIONS 31 D*+,++.,/ CLIENT OWNER %nternational Petroleum %n6estment Compan (%P%C) CPECCCONTRACTOR means China Petroleum Engineering & Construction Corporation TPI means the part >hich carries out the inspection o the purchase@ pro@ucts all the reuirement o calibration Construction process inspection. PMC means%' Consulting Engineers S2 45/ +/ . A man@ator reuirement /.57 A non3man@ator reuirement WOR8S 2eans all plans to be pro6i@e@ an@ >orF to be @one b the Contractor un@er the contract. P-WPS Propose@ el@ing Proce@ure ?peciication beore an mechanical test >hich is onl to all the necessar inormation about >el@ing to C%E0- or CO2PA0: WPS el@ing Proce@ure use@ or the >el@ing acti6ities on site >hich is ualiie@ b mechanical test. P&R the process recor@ an@ report o ualiing the P3P?. NDT 0on3Destructi6e -est >hich inclu@e the ra@iograph 2- P-. 3! A+2+.,/ ADCO
Abu Dhabi Compan or Onshore Oil Operations
ADCOP
Abu Dhabi Cru@e Oil Pipeline
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AP%
American Petroleum %nstitute
'EED
'ront En@ Engineering an@ Design
%P?
%nterme@iate Pump ?tation
2O-
2ain Oil -erminal in 'u7airah
2P?
2ain Pump ?tation
22BPD
2illion barrel per @a
P2C
Pro7ect 2anagement Consultant
PP
Pro7ect ualit Plan
PPE
Personal Protecti6e Euipment
/?E
ualit /ealth ?aet & En6ironment
A
ualit Assurance
C
ualit Control
"0 REFERENCES "1 P.;< S=<+*+<2+.,/ 2,7 P.<75/ Particular reerence is ma@e to the ollo>ing pro7ect speciications "3!931355 ?peciications an@ Proce@ures "34434315# 2ainline el@ing Proce@ure "34434315#" Pipe el@ an@ Cut3Out Proce@ure "34434315## Pipeline el@ 0D- Proce@ure "34434315$ -ie3in Proce@ure "! O R*,</ "3443431511 Pro7ect ualit Plan "34434315! Pro7ect /?E Plan #0 COMPLIANCE STATEMENT -his @ocument is in ull compliance >ith the contract except or the ollo>ing points. Description o @e6iation
+eerence (De6iation 0ote)
Appro6al @ate
3 0one 3
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60 GENERAL 61 A==.2A5.+>2+., -his @ocument shall be issue@ 6eriie@ an@ appro6e@ b pro7ect members as @escribe@ in the IPro7ect Proce@ureJ "3443431514 +E.A 6! D+/+5+., 2,7 C.,. -his @ocument shall be @istribute@ in a controlle@ manner b the Document Control Centre accor@ing to the respecti6e @ocument control proce@ure PP 1# IEngineering Document 2anagementJ. $0 ROLE AND RESPONSIBILITIES C.,/5<+., M2,2? -he Construction 2anager (s) in con7unction >ith %nterace Coor@inators Permit Co3 coor@inators an@ Public +elation Oicer are responsible or the implementation o the >orF in accor@ance >ith saet regulations an@ also shall be responsible or ensuring all reuire@ permits an@ appro6als are in place prior to commencement o the Construction >orFs. HSE M2,2? -he ?ite /?E manager monitors the >orF to ensure compliance >ith saet regulations at site. /e is responsible or preparation an@ implementation o all saet proce@ures an@ practices or all acti6ities as >ell as imparting training or super6isor >orFmen or execution o the >orFs in a sae manner. &C M2,2? ?ite ualit control manager >ill be responsible or implementation o pro7ect ualit proce@ure an@ inspection o >orF as per %nspection an@ -est Plans. I,*2< C..7+,2. %nterace coor@inator >ill coor@inate >ith %' CPECC /igh>a contractors other sub3 contractors an@ o>ners o all other utilities an@ acilities interacing >ith ne> pipeline. Arrange or meetings as reuire@. S5@ E,?+, ?ur6e Engineer shall be responsible or ensuring all construction sur6e acti6ities to be carrie@ out in strict accor@ance >ith the appro6e@ proce@ures an@ saet reuirements. a) -he Permit Co3coor@inator (s) shall be responsible to coor@inate all permits an@ appro6al reuirements beore commencement an@ ater completion o >orFs at site DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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>hich shall be han@le@ as expe@itiousl as possible. b) -he Permit Co3coor@inator (s) shall also be responsible or ensuring ull @etails o permits an@ appro6al issue@ are Fno>n to appropriate personnel inclu@ing an restrictions or impe@iments to progress list >ithin. c) -he Permit Co3coor@inator (s) shall ha6e the urther responsibilit o compiling an@ maintaining a IPermit an@ Appro6al +egisterJ >hich lists ull @etails o each permit an@ appro6al inclu@ing expir @ate. W7+,? I,/=<. a)
Ensure compliance o ualit reuirement as per the %-P.
b)
Ensure no >el@ers shall >orF on an phase o the pipeline unless he has been teste@ an@ appro6e@.
c)
el@ing parameters shall be monitore@ @uring pro@uction >el@ing an@ repair >el@ing.
@)
+esponsible or o6erall control o >el@ing at site an@ or the implementation o appro6e@ proce@ure.
e)
*p@ate@ P? register an@ ualiie@ an@ appro6e@ >el@ers list shall be a6ailable >ith the >el@ing inspector.
)
Generate @ail >el@ing inspection reports an@ 0D- reuest shall be gi6en or 6isuall accepte@ butt 7oints.
g)
Explain to >el@ing oreman an@ all other persons in6ol6e@ in >el@ing o the @etaile@ operations to be @one @uring 6arious phases o acti6it.
W7+,? *.42, a) ?hall be the team lea@er o >el@ing cre> an@ shall report to the pipeline superinten@ent. b) el@ing oreman shall con@uct the @ail tool box talF. c) 'rom it up stage to >el@ completion his close super6ision is man@ator an@ he shall control the 7ob acti6ities to achie6e target pro@uction. e) /e shall ensure en@ caps are in place o the pipe string beore lea6ing the site. P+=+, /5=+,,7, a) ?hall report to the construction manager an@ be responsible or super6ision o the 7ob at site. b) ?hall be responsible or co3or@ination >ith CPECC8%' regar@ing acti6ities at site. c) ?hall ha6e o6erall responsibilit to ensure all necessar >orF permits saet an@ ualit at site or the >orFing group as >ell as the public an@ en6ironment. %0 PROCEDURE %1
HSE R5+4,/ DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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a) All personnel shall ha6e atten@e@ /?E in@uction 8 a>areness training programs con@ucte@ in3house. -his shall be @ocumente@ a@euatel. +egister shall be maintaine@ >ith ?ite /?E 2anager. b) 0OC 8 orF permits shall be obtaine@ rom the concerne@ authorities prior to start o the acti6it. c) orF permits >ill be obtaine@ rom the concerne@ authorities. All permits passes shall be issue@ prior to start o an exca6ation >orF. @) -ool box talF shall be con@ucte@ beore starting the >orF an@ all /a=ar@s an@ saet measures shall be @iscusse@. e) arning tapes o re@8>hite stripes shall be use@ to cor@on o the area o operation to pre6ent entr o unauthori=e@ persons an@ 6ehicles )
Barrica@es shall be put up on either si@e o the area o operation at least 1 meters a>a. -he barrica@es shall ha6e blinFing lights on them to catch the attention o @ri6er as >ell as the users o the roa@ to be crosse@.
g) A clearl 6isible >arning boar@ stating K@i6ersionK >ith arro> marF in@icating the @irection o the @i6ersion shall be place@ at the point o @i6ersion on both si@es o the area o operation. h) imits o the b3pass roa@s shall be clearl in@icate@ b installing >arning tapes @istance boar@s -raic spee@ boar@s on either si@e o the b pass roa@. i)
0ecessar banFs men or traic regulators shall be @eploe@ on both si@e o the area o operation to control the traic @uring the operation through the b3pass route 8 tracFs till the entire operation is complete@ an@ at least temporar restoration is @one on the crossing areas.
7)
%t shall be ensure@ that onl authori=e@ personnel or the operations an@ inspections shall be allo>e@ to enter into the area o operation @uring the exca6ation o the roa@ an@ installation o the pipe.
F) % the operation is @uring night the entire area o operation shoul@ be illuminate@ >ell so that the >orFers an@ the super6isor personnel are sae >ithin the area an@ area is clearl 6isible or the possible users o the roa@. -he @i6ersion signs an@ the b pass roa@ shall be >ell illuminate@. l)
0ot >ithstan@ing the abo6e an other measure as @eman@e@ b the site con@itions an@ the climatic con@itions at the time o operation shall be a@opte@ to ensure saet o the public propert an@ the en6ironment.
90E&UIPMENTS -he ollo>ing instruments an@ euipments ha6e been i@entiie@ or the execution o acti6ities
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91
I,/54,/
9!
L
+a@io Detector P#
L
Gas Detectors
M2<+,+/ L
Exca6ator
3
PC# or eui6alent.
L
?i@e boom8 Crane
3
C$4#85-
L
Do=er
3
D4 M +ipper or Nomatsu D9$
L
+ocF breaFer
3
PC #
L
Asphalt cutter
3
L
Gra@er
3
CA- 1#G
L
Dump -rucF
3
5x#
L
'ront3en@ loa@er
3
CA- 4$'
L
ater -anFer
3
5x#
L
+oller 8 Plate Compactor
3
1- BO2AG 8 - -A0DE2
L
/oli@a -ester
3
-o $ N
L
/an@ -ools
A@euate nos. o euipment (o suitable tpe 8 capacit) in goo@ >orFing con@ition >ill be @eploe@. 100 PROCEDURE &UALIFICATION a)
Proce@ure ualiication shall be carrie@ out as per the reuirement o "3!931355 +e6..
b)
el@ing parameters shall be obser6e@ an@ recor@e@ b calibrate@ instruments @uring proce@ure ualiication.
c)
2echanical test to be con@ucte@ as per the reuirement o AP% 11# in a@@ition to the reuirement o pro7ect speciication "3!931355 +e6.
@)
P?8P+ as per AP% 11# ormat shall be prepare@ an@ submitte@ to %' 8 -P% or acceptance b illing the parameters measure@ an@ the results o 0D- an@ @estructi6e tests. 'ollo>ing supporting @ocuments shall be attache@ >ith P+.
e)
As run >el@ parameter recor@ing sheet
)
el@ 6isual inspection reports.
g)
Other 0D- +eports
h)
2echanical test reports
110 WELDER &UALIFICATION a)
Appro6e@ >el@ing proce@ure speciication shall be in place beore the start o >el@er ualiication tests. el@ers shall be ma@e a>are o the P? reuirements
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prior to commencement o an ualiications b)
'ront en@ >el@ers (or root an@ hot pass) shall be ualiie@ or all pass an@ @eploe@ or both ront en@ an@ bacF en@ >el@ing as reuire@.
c)
BacF en@ >el@ers (iller an@ cap) inten@e@ to be @eploe@ on ill an@ cap passes can be ualiie@ on test coupons >here other all pass ualiie@ >el@ers has @eposite@ the root pass.
111 T 7+,? +,/=<. /2: a)
ChecF an@ ensure that all parameters as per P? are ollo>e@ @uring >el@ing.
b)
2onitor an@ recor@ the actual parameters ran@om b using a clamp meter.
c)
isuall inspect all stages o each ualiication an@ present the test coupons or Compans appro6al.
-he ollo>ing recor@s shall be compile@ an@ submitte@ or Client appro6al a) As run parameters recor@ sheet b) +a@iograph reports c) el@ers ualiication certiicate @) el@ers i@entit car@. el@ers shall be issue@ >ith ualiication car@s i@entiing the P? numbers that he can be allo>e@ to >el@Q Essential 6ariables or the >el@er ualiication shall be as per AP% 11#. 11! W7/ 52+*+7 ., +-+, 7+,? <2, 5/7 *. *+ 2,7 <2= ., 42+,+, 7/ Each >el@er shall be assigne@ a uniue %D number. -he numbers once assigne@ to a particular >el@er shall not be reuse@ or an other >el@er un@er an circumstances. 1!0 METHODOLOG' FOR MAINLINE WELDING 1!1 C2,+,? .* P+= B+,? I,/=<+., C2+,? a)
Each length o pipe shall be thoroughl examine@ internall an@ externall to maFe sure it is ree rom 6isual @eects corrosion @irt or oreign matter.
b)
Each pipe length shall be a@euatel s>abbe@ to remo6e oreign matter an@ pulle@ through proper to ensure it is ree rom @irt beore lineup. hile using pull through proper care shoul@ be expresse@ to a6oi@ @amage o coating beore >el@ing
c)
All rust an@ oreign matter shall be remo6e@ rom the be6ele@ en@s b po>er3 operate@ tools. -his shall be aecte@ insi@e an@ outsi@e an@ or a minimum @istance o $mm rom the e@ge o the >el@ be6el.
@) On pipes >hich ha6e been cut bacF a =one exten@ing $mm bacF rom the ne> be6el shall be ultrasonicall teste@ to the reuirement o the line pipe speciications to DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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ensure ree@om rom laminations. -he ne> be6el shall be 1R 6isual 8 2P% teste@. A report shall be >ritten or all testing an@ recor@s. 1!! A+?,4, F+ 5= a) Pipes shall be checFe@ or correct thicFness @ia. an@ spec. >ith respect to the appro6e@ alignment sheets. b) Beore el@ing the pipes shall be checFe@ to conirm that the insi@e is clean an@ ree o an ob7ects. -he supports shall be strong enough to support the line pipes. ?an@ bags are suggeste@ as supports. 1!3 T .. ?2= /2 <<7 2<<52@ 2,7 /2 2/ = 52+*+7 WPS a) ongitu@inall or spirall >el@e@ pipes a minimum @istance o 1 inches ($# mm) bet>een each longitu@inal an@ spiral >el@ shall be maintaine@ in lining3up pipes an@ these >el@ seams shall be locate@ in the top hal o the pipe (1S) Particular relaxation in case o >el@ing pipe to ben@ or ben@ to ben@ shall be sub7ect to appro6al. b) 'or pipe o same nominal >all thicFness the o set shall not excee@ " mm. -he oset ma be checFe@ rom outsi@e b @ial gauge. 1!" A+?,4, 2,7 *+-5= /2 <<7 *. 7+,? Beore starting o >el@ing >orFs el@ing engineer shall submit batch Certiicates o the electro@es or re6ie> b %'8-P%. Onl appro6e@ batch o electro@es 8iller >ires shall be use@ at site. 130 WELDING RETURN CIRCUIT Earthling clamp shall be use@ an@ the po>er connection on line pipe cant maFe arc striFe. 131 W7+,? el@ing shall be @one as per the appro6e@ >el@ing proce@ure speciications (P?). Onl ualiie@ >el@ers shall be engage@ an@ each >el@er shall bear an i@entit car@ @uring >el@ing operation. el@ box shall be use@ to meet the reuirement o i@entiications. 13! P2+,? Pipe shall be heate@ using the metho@ as per P? reuire@ Preheat temperature shall be maintaine@ prior to commencement o root run an@ subseuent runs. -he burners shall be euall space@ so as to ensure uniorm heating all aroun@ the 7oint. -he temperature shall be checFe@ b calibrate@ temperature craons an@ @igital prometers. DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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133 R.. R5, P.<// a) -he root gap shall be accuratel checFe@ an@ shall be as per appro6e@ P?. -he use o internal clamp is man@ator an@ shall not be release@ beore 1R completion o the root pass an@ hot pass. b) -he root pass o butt 7oints shall be execute@ properl so as to achie6e ull penetration >ith complete usion o the root e@ges. el@ing shall not be interrupte@ @uring a pass an@ shall be complete@ as earl as possible. c) An Fin@ o mo6ement o components shocFs 6ibrations bumping an@ stresses are prohibite@ >hile >el@ing is in progress. Peering shall not be permitte@. Once the @eposit o the irst pass has been starte@ it must be complete@ as rapi@l as possible to re@uce interruption to the minimum. -he >el@ing spee@ shall be approximatel same as that establishe@ in the ualiie@ >el@ing proce@ure. 13" S2+,? ?tart the >el@ing must accor@ing to the appro6e@ P? ater ualiication an@ the earthing shall be connecte@ strong enough. hen the >el@ing arc is starte@ the electro@e arc can not be ignite@ at the surace o line pipes. 13# C./+,? -he >el@er >ho start the >orF an@ the >el@ers ollo>ing shall meet each other at the en@ o the >el@ 7oint. 136 C2,+,? +emo6ing the lux craters >el@ing irregularities slag etc. b Grin@ing. 13$ R4.2 .* C24= Clamp shall be @isengage@ an@ taFen out o the secon@ pipe. 'or line pipe >el@ing onl ater the root an@ hot pass is inishe@. 13% H. P2// el@ing progression shall be same as root pass secon@ pass shall start >ithin the time ualiie@ @uring proce@ure ualiication. 139 F+ 2,7 C2= a) ?oon ater cleaning the hot pass illing an@ capping starts >ithin the time ualiie@ @uring proce@ure ualiication. ->o >el@ bea@s shall not be starte@ rom the same location i reuire@Q >el@ing ma be suspen@e@ ater the completion o the thir@ pass or $R o pipe >all thicFness >hiche6er is greater so as to allo> the 7oint to cool DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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@o>n. b) Arc striFes outsi@e the be6el surace shall not be permitte@. % an such arc striFes are cause@ acci@entall such areas shall be repaire@ as per the metho@ appro6e@ b %'. -he sFi@s use@ in @uring >el@ing shall be remo6e@ onl ater completion o ull >el@ing. 1310 C2,+,? 2,7 R/2+,? E6er pass shall be cleane@ b po>er3brush grin@ing machine an@ chisel starting an@ inishing point shall be staggere@ or e6er pass. 1311 C2==+,? 2,7 I,/=<+., Capping shall be max 1.5 mm o6er the surace o the pipe. ?patters shall be remo6e@ an@ cleaning shall be @one b po>er brush an@ an reme@ial grin@ing necessar shall be perorme@ limite@ to @ressing. 131! S5/5, P+= A+?,4, 'urther 7oints shall be >el@e@ in t he same manner as explaine@ abo6e. 1313 W2 P.<+., in@ shelter shall be pro6i@e@ to co6er the >el@ers an@ 7oint @uring >el@ing i necessar to protect against rain8@ri==ling8>in@. 131" V+/52 E24+,2+., a) All inishe@ >el@s shall be 6isuall inspecte@ or excessi6e reinorcement conca6it o >el@s shrinFage cracFs un@ercuts @imensions o >el@ surace porosit an@ other surace @eects. % an such @eects are notice@ the shall be rectiie@. b) 0ight Caps to be >el@e@ ater completion o main line section as per %' speciication. 1"0 FOR TIE-IN WELDING 1"1 METHODOLOG' a) 'iel@ >el@ing o pipelines -%E3%0 7oints shall be @one b metho@ as appro6e@ P? ater ualiication. b) ualiie@ >el@ing proce@ures shall be use@ or >el@ing o -%E3%0 7oints ater @ue appro6al rom %'8%P%C. c) Onl %'8%P%C appro6e@ bran@s o >el@ing consumables as speciie@ or each run in the P? shall be use@. @) A -%E3%0 pit o suitable length @epth an@ >i@th shall be cut to enable to >orF reel DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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e)
)
g) h)
i) 7) F)
insi@e the trench. Proper care shall be taFen so as not to allo> pit to collapse or pit >all ca6ing in. 0ecessar supports shall be use@ >here6er reuire@. %n connecting pipes special items ittings on 7oints o @iering material thicFness as supplie@ transition piece >ith 1# taper shall be use@ an@ the >el@s shall be sub7ecte@ to +a@iographic an@ *ltrasonic examination. Cut pipe en@s shall be examine@ >here6er or laminations b *ltrasonic o6er @istance o $ mm minimum. Deecti6e pipe length shall be cut bacF until laminate@ section is remo6e@ an@ re3be6ele@ 'or pipe >hich ha6e been cut Pipe no. /eat no. Coating ar@ no. Balance length has to be transerre@ on to remaining pipe length. Alignment o the -%E3%0 7oint shall be @one using external clamp capable o remo6ing oset an@ misalignment shall be minimi=e@. ?eam orientation o >el@e@ pipe shall be selecte@ to ensure that the longitu@inal >el@s shall be staggere@ in the top 1 T o the pipeline or $# mm. >hich e6er is the less an@ shall be positione@ in the upper hal o the pipe. %n case the seams come closer than as @eine@ abo6e a pup piece o minimum . m shall be use@. 'or pipes o same >all thicFness. -%E3%0 shall be @one in such a >a as to lea6e minimum stress in the pipe. % an pup en@ is reuire@ or -%E3%0 the minimum length shall not be less than !$ mm. -%E3%0 7oint >el@ing inclu@ing necessar cutting be6eling grin@ing an@ line up etc shall be carrie@ out as per this proce@ure an@ appro6e@ P?. -he ne> iel@ be6els shall be examine@ 6isuall beore oering or 2P% an@ ultrasonic testing. All reports o -%E3%0 along >ith 0D- reports shall be prepare. Cleaning Priming coating an@ other acti6ities shall be perorme@ as per appro6e@ proce@ures.
l) -he root gap shall be accuratel checFe@ an@ shall conorm to the ualiie@ >el@ing proce@ure. All spaces bet>een bars or at least $R o irst pass shall be >el@e@ beore the clamp is release@ an@ pipe remaining a@euatel supporte@ on each si@e o the 7oint. m) ?egments thus >el@e@ shall be euall space@ aroun@ the circumerence o the pipe. ?lag etc. shall be cleane@ o an@ the en@s o the pass shall be prepare@ b grin@ing so as to ensure continuit o the >el@ bea@. n) ualiie@ >el@ers shall carr out >el@ing. hile >el@ing is in progress care shall be taFen to a6oi@ an Fin@ o mo6ement o the components 8 pipe shocFs 6ibration an@ stresses to pre6ent occurrence o >el@ cracFs. o) Electro@e starting an@ inishing points shall be staggere@ rom pass to pass. p) Arc striFes outsi@e the be6el on the pipe surace shall not be permitte@. Acci@ental arc striFes shall be repaire@ as metho@ appro6e@ b C%E0-. ) All inishe@ >el@s shall be 6isuall inspecte@ or parallel an@ axial alignment o the >orF >el@s surace porosit an@ other surace @eects. r) Parts being >el@e@ an@ the >el@s shall be protecte@ b >in@shiel@s ma@e o metallic rame co6ere@ b Can6as >hene6er necessar to protect rom rain an@ strong >in@s. s) -he complete@ >el@s shall be co6ere@ >ith asbestos cloth co6ere@ b G% sheets >hene6er necessar to protect rom ba@ >eather con@itions. t) 'or -%E3%0 o a@7acent sections o pipeline alrea@ pressure teste@ also calle@ gol@en 7oints an@ or inal 7oints a single length pup or o cuts >hich ha6e been DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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h@rostaticall pre3teste@ shall be use@. u) All ualit recor@s generate@ @uring the >el@ing o -%E3%0 7oints shall be re6ie>e@ an@ appro6e@ b %' 1"! R=2+ W7+,? a) el@s i@entiie@ or repair shall be recor@e@ in the Dail repair list an@ >el@ing chart. -his list shall be up@ate@ @ail to i@enti the repairs on the pre6ious @a pro@uction an@ also the status o pen@ing repairs. A cop o this report shall be gi6en to the Pipeline ?uperinten@ent
I
el@ing %nspector.
b) 2P% an@ 6isual %nspection shall be @one on the exca6ate@ groo6e to ensure that the repair is completel remo6e@. c) -he reuirements o repair P? such as parameters time lapse bet>een passes preheat inter pass temperature pass seuence an@ the electro@e >ea6ing limitations shall be complie@ >ith at all time. All >el@ repairs shall be complete@ as per appro6e@ P?. @) el@ repair shall be anal=e@ & the root cause o repairs shall be in6estigate@ an@ reme@ial action implemente@. % the cause is @ue to the perormance o >el@ers those >el@ers shall be gi6en an agree@ perio@ o re3training b the CO0-+AC-O+ ater >hich the >el@er shall be re3teste@. hen a re3test is accepte@ the re3ualiie@ >el@er can return to pipeline pro@uction >el@ing. e) Onl once repair is allo>e@ in one >el@ unless prior appro6al rom CPECC8%'. hen re3repair occurs in the same location the 7oint shall be cut an@ remo6e@ inclu@ing the heat aecte@ =one rom both en@s an@ shall be re3>el@e@. )
All repairs shall be sub7ecte@ to 1R 6isual inspection an@ 1R 0DE b the same techniue use@ or original examination.
g) Onl -DC an@ Engineer appro6e@ technician shall be engage@ on the 7ob. 1"3 V+/52 I,/=<+., 2,7 NDT a) All inishe@ >el@s shall be 6isuall inspecte@ or excessi6e reinorcement conca6it o >el@s shrinFage cracFs un@ercuts @imensions o >el@ surace porosit an@ other surace @eects. % an such @eects are notice@ the shall be rectiie@. -he 6isuall accepte@ 7oints s hall be oere@ or +a@iograph. b) -he extent o 0on3 Destructi6e -esting or the >el@ing is as table@ belo>. -he acceptabilit reuirement is as set orth in AP%311# latest e@ition J. T@=
NDT 1 R isual %nspection 1 R +- or manual an@ 1R automatic *- or
2ainline >el@s
semi8automatic >el@ing or as per speciication 0o ".!9.1.5$.
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1 R isual %nspection -ie %n >el@s
1 R +1 R *1 R isual %nspection
+epair >el@s 1 R 2P% on the repair exca6ate@ area. Attachment8 Branch >el@s
1 R 2P% on the complete@ >el@ 1 R isual %nspection
'iel@ cut be6els 1 R *- i pipe is cut $ mm rom the actor be6el
Arc ?triFes
1 R isual %nspection 1 R 2P% on the aecte@ area
1"" W7 N54+,? S@/4 a) -he total pipeline section is @i6i@e@ into Nilo3meter points (NP) >hich shall be sho>n on marFer posts along the line. el@s shall be numbere@ continuousl in ascen@ing or@er starting rom the isolating 7oint to>ar@s the lo> @irection till the en@ o each N2 an@ >ith preix o N. b) Example -he >el@ number shall be starting rom isolating 7oint as N 21 N 2 ... Continue@ up to the start o ne> N2 an@ start again >ith >el@ 0o.1 >ith the ne> NP (N1 21 N1 2 ... continue@ up to the next NP). c) 0ote N is or the section bet>een start point an@ up to Nilo3meter 1. ?imilarl N1 is or the section bet>een Nilo3meter 1 & . @) hen t>o pipe strings are tie@ in the tie in 7oint number shall be suixe@ >ith letter - or tie in. e) Example N - # ) % a@@itional pipes8 pups ha6e to be >el@e@ bet>een open en@s an@ >here the reser6e@ numbers are not suicient the shall be numbere@ b suixing letter A B C etc to the last 7oint number. g) Example N 2 #A N 2 #B N - #C 3 -ie %n h) +epair ,oints shall be i@entiie@ as N 21+ or -1+ as applicable. i) +e3>el@s shall be numbere@ >ith suix + attache@ to the original >el@ number. Example N 2 # + an@ N 2 # +1. 7) % a re3>el@ is reuire@ to be ma@e as -ie 3 %n the 7oints shall be numbere@ as ollo>s. Example N -# + an@ N -# +1. F) -ransition 7oints in mainline shall be numbere@ >ith suix K-+3 attache@ to the original >el@ number. Example N 2# -+ l) % a >el@ is repaire@ o -ransition 7oints shall be numbere@ as ollo>s. m) Example 'or 2ainline 7oints N 2# -+3+ 'or -ie3in ,oints N -# -+3 + DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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n) o)
% cut out 8 +e3>el@ reuires to be ma@e in -ransition 7oint the 7oint shall be numbere@ as ollo>s. Example N -# -+3+1 el@ ,oints ma@e ater h@ro test shall be numbere@ as N G- #.
0ote N U N%O 2E-E+ 2 U 2A%0 %0E - U -%E %0. + U +EPA%+ -+ U -+A0?%-%O0 + U +E3ED G-U GODE0 -%E %0 1#0 ELECTRODE CONTROL AND STORAGE a) Electro@es shall be supplie@ >ith the manuacturers batch certiicates compling >ith the reuirements o C%E0-. b) Electro@es shall be store@ in clean an@ @r con@itions in accor@ance >ith the manuacturers recommen@ations or in a @r location at a temperature o at least S C an@ in a manner that shall pre6ent @amage. Consumables shall remain in their original containers >hich contain the inormation o manuacturers name bran@ name an@ the batch number. Dierent classes o electro@es shall be segregate@ an@ store@ separatel. ?toreFeeper shall issue the electro@es on irst come irst issue basis. c) *nuse@ electro@es shall be checFe@ b the storeFeeper e6er@a an@ i the coating @amage is obser6e@ the same shall be put into the uarantine@ containers. 2aterial controller shall ensure that @amage@ 8uarantine@ electro@es are not issue@ to >el@ers to >el@ on the pro7ect relate@ >orFs. @) -he >el@ing oreman shall be responsible to collect correct electro@es (tpe an@ si=e as per P?) an@ to ensure that the correct issue is ma@e to each >el@er. e) Electro@es >hich are >et rust or ha6e @amage@ lux coating or >hich ha6e been bent or unshape@ or ha6e lost the i@entiication shall be remo6e@ rom site. ) Electro@e shall al>as be Fept in the container an@ it shall be taFen onl or >el@ing an@ han@ling. /ol@ing o electro@es >ith bare han@s shall be a6oi@e@. 160 DOCUMENTATION -he ollo>ing @ocuments shall be prepare@ a. P? +egister P? I P+ b. Electro@e batch certiicate c.0D- +eports @. 2echanical -est +eports e. el@ing Parameter +ecor@ ?heet . el@er ualiication -est Certiicate g. el@er ualiication Car@ h. P? isual %nspection +eport i. Dail +epair ist 7. -ie in el@ing %nspection +eport F.+epair el@ing %nspection +eport l. Pipe BooF m. 0D- +euest On completion o each shit >el@ing oreman an@ >el@ing inspector shall ill up the reports in the attache@ ormat as applicable an@ han@e@ o6er to A I C. DOC*2E0- -%-E METHOD STATEMENT FOR PIPELINE WELDING P+O,EC-
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1$0 E&UIPMENT LIST
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el@ing 2achines
�
DG sets
�
Prime 2o6ers
�
%nternal Camp
�
External clamps
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Compressors
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Grin@ing 2achines
1%0 &UALIT' ASSURANCE &UALIT' CONTROL a) ualit Assurance shall be maintaine@ b ensuring the sstematic implementation o this proce@ure an@ ensure that necessar ualit recor@s are generate@. b) -he >orFing Cre> super6isor shall report to the concerne@ A8C Engineer about the >orF complete@ an@ the >orF planne@ or next @a @ail basis. (Dail construction report).-he le6el o inspection o respecti6e construction acti6ities >ill be as per the attache@ %nspection -est Plan (%-P Attachment 1). Beore I/J points are achie6e@ the >orFing cre> super6isor8AC engineer shall noti to the %'8%P%C representati6e b means o issue reuest or inspection (+'%) beore # hours an@ A8C Engineer on site shall sche@ule or the planne@ acti6it an@ maintain the +'% recor@. % the %' 8 -P% representati6e aile@ to get the place on time the conseuent >orF beon@ the I/J point shall not procee@ but the >orFing group shall Feep the correspon@ing recor@. c) # hours beore the >itness () points are achie6e@ the >orFing cre> super6isor8AC Eng. shall noti the %' 8 %P%C representati6e b means o issue reuest or inspection (+'%) beore # hours an@ A8C Engineer on site shall sche@ule or the planne@ acti6it an@ maintain the +'% recor@. % the %' 8 -P% representati6e aile@ to get the place on time the conseuent >orF beon@ the IJ point shall be procee@ an@ the -DC >orFing group shall Feep the correspon@ing recor@ also it shoul@ be highlighte@ in the @ail construction report o -DC. Beore I+J points are achie6e@ the >orFing cre> shall not in6ite %' 8 -P% representati6e or such acti6it but the necessar recor@s shall be maintaine@ an@ submitte@ or re6ie> o %'8-P% representati6e b -DC A8C Engineer ater I+J points are achie6e@. 190 ATTACHMENTS 0O.
Description
"34434315143P31
%nspection an@ -est Plan
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el@ing Parameters +ecor@ ?heet
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el@ing Euipment Calibration +ecor@
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Pipe BooF 'rom
1
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el@er Perormance +eport
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el@er ualiication -est Certiicate
1
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el@er ualiication Car@
1
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ualiication +ange
1
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P? isual %nspection +eport
1
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Dail el@ +epair ist
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-ie in el@ing %nspection +eport
1
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0D- +euest
1
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+a@iographic %nspection +eport
1
-o
N.: %n case o an conlict bet>een the reuirements o this proce@ure an@ %' ?peciication the later shall go6ern until an@ unless speciic intention is meant.
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