MOS For Fabrication and Installation PDF

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet
Nam
Method of Statement for Piping Fabrication and Installation
METHOD OF STATEMENT
FOR PIPING FABRICATION AND
PIPING INSTALLATION WORK
KOBELCO SANKYU JOINT VENTURE Page 1

The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet Nam
CONTENTS
1. PURPOSE
2. SCOPE
3. REFERENCES
4. DEFINITIONS
5. RESPONSIBILITIES
6. PROCEDURES – METHOD OF WORKS – INSTRUCTIONS
6.1 RECEIPT & STORAGE OF PIPE RAW MATERIALS
6.2 PIPING FABRICATION
6.3 CUTTING AND BEVELING
6.4 FIT-UP WORK
6.5 WELDING
6.6 ASSEMBLY AND INSTALLATION
7. INSPECTION, EXAMTION AND TESTING
8. IDENTIFICATION
9. TOOLS & EQUIPMENT
10. SAFETY CONDITION AND ENVIROMENT

1. PURPOSE
o The purpose of this generic method statement is to define the procedure for fabrication and
installation of stainless steel piping in UBCF system for improving An Duong water treatment
plant in Hai Phong city
2. SCOPE
Scope of this method statement covers the following activities.

o Material handling and unloading
o Fabrication
o Welding and welding visual check
o Installation
o Inspection
3 . REFERENCES
3.1 PROJECT DRAWINGS
Project drawings consist of followings:
o Applicable Piping drawings for WTP ( UBCF system ) .

o Piping Layout drawings.
o Others.
3.2 PROJECT SPECIFICATION
Project specification consist of followings:

o Piping Specification
o Approved WPS and MOS for welder’s qualification
o Other related specifications in tender document.
3.3 PROJECT QUALITY PLAN (PQP)
Project quality consist of followings:

o Project Quality plan for SUS piping
3.4 CODES AND STANDARDS
Project codes and standard consist of followings:
 ISO 559 Steel tubes for water and sewerage

 JIS 2311 Steel but welding pipe fitting for Ordinary piping
 AWWA C200 Steel Water Pipe 150 mm and lager

4. DEFINITIONS
The followings abbreviation are used in this document
o PM Project Manager
o SM Site Manager
o CM Construction Manager
o ITP Inspection and Test Plan
o QC Quality Control
o QCI Quality Control Inspector
o PQP Project Quality Plan
o PPE Personal Protection Equipment
o HSE PLAN Health Safety & Environment Plan
5. RESPONSIBILITIES
o It is overall responsibility of PM/SM to organize resources to perform construction activities as per
project specification, in compliance with quality, schedule & safety requirements.
o It is the responsibility of CM that construction activities are executed according to the relevant project
specifications, in compliance with quality, schedule & safety requirements.
o DE will ensure that all the works are performed safely as per latest Approved for Construction (IFC)
drawings & specifications.
o The relevant DE and Supervisor will ensure that all the piping work is conducted in accordance with
this method statement and project specifications
o The QCI will ensure that all work is executed according to PQP and that requirements of quality
dossier are full filled.
o Safety and construction supervision will be carried out under responsibility of Client wherever required.
6. PROCEDURES – METHOD OF WORKS – INSTRUCTIONS

6.1 RECEIPT & STORAGE OF PIPE RAW MATERIALS
o The piping raw material receiving and unloading shall be offloaded in designated lay down yard.
o During offloading, pipes shall not be dropped off the transport. A crane and suitable certified slings
shall be used. Nylon slings with hook will be used to handle SS and coated piping & fittings.
o The pipes shall be placed on wooden bar or concrete blocks with wooden packing in between.

o The piping end covers shall be kept in place to prevent foreign particle entry into the pipes.
o All materials shall come with color-coding as per size, material & schedule.
o The piping material shall be segregated accordingly to facilitate location of the items. Alloy. SS, low
Temperature CS, CS and Galvanized pipe & fittings to be stored separately.
6.2 PIPING FABRICATION
o Material will be shifted from lay down area to work shop at site as per relevant piping drawings
o Carbon steel, low temperature carbon steel, NACE and stainless steel pipe fabrication work will be
done in separate areas. Tools & equipment compatible with the material in fabrication shall be used.
o The piping material is to be used in appropriate and economical way. All cuttings should be collected
separately as per material code and place in order to make best use of these.
o Pipes for socket weld joints shall be cut square
6.3. CUTTING AND BEVELING
6.3.1 GENERAL
o The pipes shall be cut as per dimensions mentioned in the drawings and all pipe length shall be marked.
Material traceability shall be maintained as per relevant agreed.
o Based on spool break down of piping drawings, pipe lengths shall be cut 150mm extra length for pipe will
be provided in spools for field adjustment. The pipe ends for 2 inch & above shall be beveled as per
approved WPS for the piping class.
o The cutting and beveling of pipes shall be done by mechanical means cold cutting machine/ flame cutting
or plasma/ arc cutting, cutting shall be acceptable provided that the edges are smooth.
o The fit up of pipe ends, fittings & weld neck flanges shall be done to obtain uniform root opening. The
criterion given in related WPS shall be followed.
o The joint should be free of grease, oil, scales, rust or other foreign material.
o The primer paint coat on pipe & fitting ends shall be removed prior to bevel end preparation.

o The pipes shall be tack welded by a qualified welder. If the pipes are of different thickness, the larger
thickness will be tapered in compliance with standard to match the smaller thickness.
o The adjacent section of longitudinally welded pipes that are to be joined by butt welds shall have
longitudinal weld seams positioned such that they are at least 30 degrees apart from horizontal center
line. The fabricator will also not locate longitudinal weld seams on top or bottom of the pipe so that branch
connections are not located on the seam.
o Reinforcement pads shall be fabricated only if required in the drawings. The material for reinforcement
pad shall be same as that for the pipe unless otherwise authorized by main contractor. The size &
thickness of pad will be as specified in the.
o The Flanges indicated on piping drawings to be supplied loose shall be tack welded with the pipe. Full
welding shall be made after site checking.
FABRICATION AREA DESCRIPTION

6.4 FIT-UP WORK
6.4.1 Groove
 Pipe ends and fittings shall be properly beveled

 Beveled surfaces shall be thoroughly cleaned

6.4.2 Type of welding:
Manual Type
Diameter(mm ) Thickness of pipe
Welding
15A to 125A Up to 3mm I Welding Surface
150A to 500A 3mm or more V Welding Surface
6.4.3 Welding procedure:
Weld layer Process Filler metal Travel speed
1 GTAW ER-308L 2.0

2 GTAW ER-308L 3.2
3 GTAW ER-308L 3.2
4 GTAW ER-308L 3.2
6.4.4 Alignment and Trimming
 Root gap for butt-weld shall be in accordance with the WPS.
 In the case of butt welding pipe and/or fitting having unequal wall thickness, of which the difference is more
than 3 mm in outer surface and/or I .5 mm in inner surface, the end of the thicker pipe shall be trimmed by
grinding as per the Fig. (a), (b) and (c) shown below.

 When a pipe having a longitudinal weld seam is used in a horizontal line, the pipe shall be laid so that the
longitudinal weld seam is not on bottom or top of the pipe. Allocation and relation among circumferential,
longitudinal and other (branch, support, etc.) welds are shown in the Fig. 3.4.4 (a), (b) or (c).
 Circumferential joint
Note: L1 shall be minimum five times the pipe thickness or over.
 Branch pipe and weld line on run pipe

 Butt joint welding of pipes shall be performed as follows:
o Welding shall be performed in accordance with WPS.

o Circumferential butt welding shall be performed without the use of a backing ring unless specified in
WPS.
o Before welding of the root, both ends of the root tack weld bead shall be prepared with a grinder as
shown in the following illustration in order to make complete fusion.
 Fillet welding of pipe to slip-on and socket weld flanges shall be performed as shown in following
 SOCKET JOINT
o The pipe for welded sockets joint shall be ground to remove burrs due to cutting. A gap between
end of pipe & bottom of socket will be maintained as per Project Specifications.

 THREADED JOINT
o In case of threaded pipes (for utilities piping only) screw threads shall be concentric with axis of
pipes with no burrs or stripping. The threading dies shall be sharp & properly designated for the
piping material.
6.5 WELDING.
6.5.1 General
 All welding work will be according to approved WPS and standard as tender document and only qualified
welders shall be employed.
 The welding work piece will be shielded against high winds and rain. If the wind speed exceeding 10
m/sec and 3 m/sec for SMAW & GTAW respectively then welding work will stopping
 The weld surface shall be cleaned with SUS wire brush or grinding prior to welding operations to give a
surface free from rust, scale or mill coating.
 Between each layer of welding any cracks, pores or welding spatters shall be removed by grinding the
surface before application of next layer.
 The appearance of finished welds shall conform to ASME B31.3 code & WPS and shall exclude any
under cuts, spatters, and cracks.
 All branch connections shall be joined to headers with full penetration welding. The bore side shall be
ground smooth, free from cracks.
 For flange to pipe connections if welding shrinkages can lead to misalignment, two similar flanges shall be
joined by inserting a temporary gasket and then welded.
 The distance between centerlines of adjacent girth butt welds and staggering of longitudinally welded pipe
for making butt weld shall be carried out ccording to project specification.
 Welding shall be performed to ensure complete fusion of the weld deposit and the base metal in order to
obtain homogeneous bound over the entire cross section area of the weld.
 Welding current and polarities shall comply with the approved WPS. And or instruction given by the
manufactures of the filler metal.
 Number of layers shall never be less two layer.
 The welding seam of welder are not meet quality regularly when visually inspected by main contractor and
consultant. The welder will be rejected or qualification again

6.5.2 Pre-treatment of base metal
Adhering substances such as oil, paint, dust, water, etc, shall be completely removed before welding. A piece
of cloth with organic solvent like thinner or gasoline, a stainless steel wire brush and/or sand paper may be
used to remove any adhering substances.
6.5.3 Pre-treatment of base metal
 Tack welding
 Pure Argon (AR) gas shall be used during the welding
6.5.4 Tack welds

o Tack welds on pipe fit-up shall be minimum eight (8 ) points with pipes alignment
o carefully checked. Minimum heat shall be applied on executing tack welds. Internal
shielding not necessary on tack welding

6.6 ASSEMBLY AND INSTALLATION
6.6 .1 General
o Before assembling of piping, actual tolerance causing from foundation, steel structure, equipment
installation work shall be considered for the piping assembling work.
o Excessive stress shall not be allowed to the nozzles of rotating machine when the flange of
fabricated component is connected, such work shall be carried out in the presence of person in
charge of the mechanical work. And openings such as flanged joints of a pump, compressor, etc.
shall be kept covered with thin metal plate or other solid blinds with a handle to prevent dust and/or
foreign material from entering into the machine.
o If the hot work (welding or cutting …) to be performed in the vicinity of instrument control or power
cable duct, an adequate protective cover shall be provided in advance so as not to damage the
cables.
o When work is carried out in the vicinity of piping made of, or lined with special materials such as
plastics, rubber, glass, etc., care shall be taken so as not to damage them.
o Valves shall be assembled in clean condition, they shall not be opened during piping erection except
that welding and heat treatment of a welded valve joint shall be carried out with valve opened.
o If cutting, making of holes to the assembled piping and such kind of work is carried out at
assembled place due to the reason of modification, improvement, etc., cut piece and foreign
materials shall be removed from inside of piping and it shall be confirmed that the inside of piping
is cleaned.
o Valves having flow direction shall be installed to conform the flow direction in accordance with
piping drawings. Care shall be taken to the valves in case valve flow direction is reversed against
the flow direction of pipe line.
o It is prohibited to use small size piping, pumps, instrument etc. as scaffolding or working stage.
A. The following requirement shall be observed for piping support.
o Pipe supports shall be fabricated and installed in accordance support drawings
o As a rule, the location of pipe-supports shall be in accordance with the piping arrangement drawing
and support drawing.
o The pre-setting pieces of the pipe hanger shall be removed after completion of leak test of the pipe
line. However, pipe lines which will be insulated, it shall be removed after completion of the insulation
work.
o A shoe support shall be attached to the pipe in accordance with the drawings. It is not permitted to
tack-weld a shoe support to the pipe rack, where the shoe support is not to be permanently fixed to
the pipe rack.

B. Flanged Joint
o Any damage to the gasket seating surface which would prevent gasket seating shall be repaired,
or the flange shall be replaced.
o Flanged joints shall be bolted up, after checking the alignment of the flange centers and the
parallel ness of flange faces, to ensure that the contact faces bear uniformly on the gasket.
Bolting-up shall ensure that bolt tension is spread uniformly around the flange.
o Particular care shall be exercised to ensure that all bolt, nut and gasket are correctly installed in
accordance with the requirements of piping specification for piping material.
o When assembling flange connections, paste shall be applied to the gasket and bolts. These
prevent seizure of nuts and adherence of gaskets. Reference of pastes and their applications shall
be in standard and drawing.
C. Threaded Joint
o The standard to be applied to all threads shall be ANSI/ASME Bl.20.l Pipe Threads (NPT).
o Lubricant shall be removed completely from the thread and inside of pipe after threading.
o In a threaded joint between pipe and flange, the length of thread on the pipe shall be such that the
end of the pipe is short of the gasket surface on the flange by 1.5 to 3.0 mm when screwed-in.
o Thread shall be jointed with full coupling between straight pipes, and piping shall have union joints
in consideration with repairing at leak test.
o Threaded joints shall be sealed with tape or threading compound, unless there is restriction from
process requirement
o Seal welding of threaded parts, if specified, shall be performed after the part is screwed-in
completely without using paste or oil and fully cleaned, decreased and dried out. Reinforcement of
the seal weld bead shall cover completely the remaining thread and must be at least 2-layers weld
using a suitable size of electrode.
D. Mechanical Joint
o Mechanical Joint other than flanged joint and threaded joint shall be in accordance with
manufacturer's Instruction or drawing.
o Care shall be taken to avoid distorting the sheet when incorporating such joint into piping assemblies
by welding.
E. Valve Installation
o Where carried out ever valves are to be installed, the installation/orientation of valve handles and
flow direction shall be according to the piping layout.
o All valves to be installed will be cross checked according to the number to ensure that the proper
valves are installed in the proper location.

o Valves shall be installed in the closed position except for ball valves and plug valves.
o New gaskets will be installed between the valve flange and pipe flange. Final tightening of all nuts
shall be done once proper alignment is achieved.
o Bolting of flanges will be done in a cross pattern.
o All bolts, gaskets and valves shall be properly stored to avoid contamination with the environment.
Valve ends will be sealed until installation and gaskets and bolts shall be kept clean of any debris
such as sand.
F. Scaffolding Work
o Scaffolding if required shall be erected by qualified personnel in a safe and suitable manner.

o Scaffolding above 2 m in height shall be inspected by a scaffolding inspector and a scaffold-tag shall be
signed and provided on the scaffolding near the ladder. No one shall use the scaffolding without the
staff-tag being approved.
o Scaffolding material to be used shall be in good conditions, brass hammer shall be used to assemble
and tighten the scaffolding locks.
7.INSPECTION, EXAMTION AND TESTRNG
In-Process Inspection
(1) Prior to Commencement of Work
Examination and Testing Acceptance Criterion

(a) Material check To satisfy the requirement of Engineering
Specification
( b) Welding Procedure Specification To satisfy the requirement of Welding Specification
(c) Welder's performance Welder's performance qualification certificate.
qualification
(d) Electrode and welding Material certificate (material name, brand). To
consumable satisfy a applicable codes and standards.
(2) Prior to Welding

(a) End Shape and dimension To satisfy the requirements of Par. 3.4 of
preparation this specification.
Cleanliness To be free from paint, oil, rust, scale or other
foreign material.
(b) Tack weld Root opening (Gap) To be within the tolerance specified in WPS.
Alignment (Mismatch) Misalignment is not more than 1.5 mm for
internal surface and 3.0 mm for outer surface.
(c) Preheating Preheating temperature To keep the Preheating temperature within the
tolerance specified in Table 3.5.2. and WPS.
(d) Electrode Drying temperature To be in accordance with manufacturer's
standard.
Drying time - ditto -
(3 ) During fabrication and assembling
Dimension checking and inspection see photo 7.3 as below

o Flattening ratio and reduction of thickness acceptance criteria, which shall be decided in accordance
with practical conditions, shall not be applied for steam trace piping.
End preparation for weld shall not
Description photo 7.3

(4) After Welding

(a) Visual examination of Crack None
welding
Under cut Less than 0.3 mm. But for low
Girth weld and Branch temperature service and high
connection temperature service materials, under cut
is not permitted.
Overlap (Cold lap) Less than I .0 mm
Throat thickness of fillet weld Over 0.91 (Hatful Coupling)
Over 1.01 (SO/SW Flange) t:
thinner i e thickness
Weld reinforcement or WallMax.
internal weld protrusion (Root Thickness (mm) 6.4 or under
Penetration) 1.6 over 6.4upto 12.7 3.2
over 12.7 up to 25.4 4.0 over 25.4
4.8
Weld scars from jigs and arc Visual check and no defect. Liquid
strikes penetrant examination as per following
part (b) for high temperature and low
temperature service.
Lack of fusion
Girth weld and Branch Nil
connection
Incomplete penetration
Girth weld and Branch Lesser <= 0.8 mm or 0.2 t, but not more
connection than 38 mm cumulative length in any
150 mm of weld length depth <= 0.2 t.
But for low temperature service and high
temperature service materials,
incomplete penetration is not permitted.
Surface porosity None
(5) After Completion of Work

(a) Visual check No extra distortion.
(b) Hydrostatic and/or pneumatic leak test According to piping specification and no
leak shall be acceptable.

(6) When an unacceptable defect of welds is revealed, the following remedial action shall be taken:
o The repair or replacement shall be carried out, then the new work shall be re-examined in accordance
with piping specification.
o If the repair is again found to be unacceptable, then it shall be carried out once more. Permissible
number of welding repairs at the same place shall be a maximum of 2(two). If a further repair is
required, then a cut out shall be the sentence. The welder concerned who made repair more than 2
times shall be retrained and requalified.
8. STORAGE
o The pipe spool complete in all respect shall be stored separately.

o All spools shall have their identification/piece number clearly designated on each spool.
o The spool will be cleaned in an inclined position by tapping so that all foreign materials are removed.
o The spool shall be placed on wooden baton to avoid direct contact with soil.
o The open ends shall be covered by polyethene sheets or end caps. In case of flanged spools, the same
shall be covered by securely tied wooden blanks to avoid foreign material entering the pipes.
o The spool shall be handled using nylon lifting slings.
o Alloy / SS to be stored separate form CS.
9. TOOLS & EQUIPMENTS

EXECUTION
o Hand Tools
o Cutting, Beveling & Grinding Machines
o Cranes (Mobile)
o Plasma machine
o Gridding machine
o Welding Machine
o Hack Saw
o PPE and Protect equipment
o Scaffolding
o Drilling machine
o Electric panel and wire
o Other equipment

10.SAFETY CONDITION AND ENVIROMENT

o Basically, all person taking care of work shall be equipped enough PPE such as Helmet, Glove, Glass,
Safety belt etc.
o Arrange the required safety signs, barricades and other related safety precautions highlighted in the risk
assessment and permit prior to commencing the works.
o The works shall only commence after the job performer has checked and ensured that all safety
precautions and safety requirements are in place.
o Ensure employees understand the hazards and control measures related to the critical activities, i.e.
lifting, welding.
o Ensure personnel stay away from lifting zone and do not enter under the suspended loads.
o Qualified First Aider must be on site and identified by a sticker on his helmet.
o Display Emergency Contact number on site.
o Advise the construction crew on HSE aspects and ensure their safety.
o Arrange through Job performer for tool box talk covering risk assessment in language understandable
by workers.
o Cross checking certified material devices and equipment’s are used.
o Do weekly, monthly HSE audit.
o Ensure appropriate safety measures are taken as per the risk assessment and controlled documents.
o Ensure that all staff adhere to the HSE plan and HSE requirements.

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The Project for Improving An Duong Water Treatment Plant in Hai Phong City in the Socialist Republic of Viet

KOBELCO SANKYU JOINT VENTURE Page 1

6. PROCEDURES – METHOD OF WORKS – INSTRUCTIONS

6.1 RECEIPT & STORAGE OF PIPE RAW MATERIALS

6.2 PIPING FABRICATION

6.3 CUTTING AND BEVELING

6.4 FIT-UP WORK

6.6 ASSEMBLY AND INSTALLATION

7. INSPECTION, EXAMTION AND TESTING

9. TOOLS & EQUIPMENT

10. SAFETY CONDITION AND ENVIROMENT

KOBELCO SANKYU JOINT VENTURE Page 2

Scope of this method statement covers the following activities.

3.1 PROJECT DRAWINGS

Project drawings consist of followings:

o Applicable Piping drawings for WTP ( UBCF system ) .

3.2 PROJECT SPECIFICATION

Project specification consist of followings:

3.3 PROJECT QUALITY PLAN (PQP)

Project quality consist of followings:

3.4 CODES AND STANDARDS

Project codes and standard consist of followings:

 ISO 559 Steel tubes for water and sewerage

KOBELCO SANKYU JOINT VENTURE Page 3

6. PROCEDURES – METHOD OF WORKS – INSTRUCTIONS

KOBELCO SANKYU JOINT VENTURE Page 4

6.2 PIPING FABRICATION

o Pipes for socket weld joints shall be cut square

6.3. CUTTING AND BEVELING

KOBELCO SANKYU JOINT VENTURE Page 5

FABRICATION AREA DESCRIPTION

 Pipe ends and fittings shall be properly beveled

KOBELCO SANKYU JOINT VENTURE Page 6

6.4.2 Type of welding:

6.4.3 Welding procedure:

Weld layer Process Filler metal Travel speed

1 GTAW ER-308L 2.0

6.4.4 Alignment and Trimming

 Root gap for butt-weld shall be in accordance with the WPS.

KOBELCO SANKYU JOINT VENTURE Page 7

Note: L1 shall be minimum five times the pipe thickness or over.

 Branch pipe and weld line on run pipe

KOBELCO SANKYU JOINT VENTURE Page 8

 Butt joint welding of pipes shall be performed as follows:

o Welding shall be performed in accordance with WPS.

KOBELCO SANKYU JOINT VENTURE Page 9

 Number of layers shall never be less two layer.

KOBELCO SANKYU JOINT VENTURE Page 10

6.5.2 Pre-treatment of base metal

6.5.3 Pre-treatment of base metal

 Pure Argon (AR) gas shall be used during the welding

6.5.4 Tack welds

KOBELCO SANKYU JOINT VENTURE Page 11

6.6 ASSEMBLY AND INSTALLATION

A. The following requirement shall be observed for piping support.

o Pipe supports shall be fabricated and installed in accordance support drawings

KOBELCO SANKYU JOINT VENTURE Page 12

KOBELCO SANKYU JOINT VENTURE Page 13

KOBELCO SANKYU JOINT VENTURE Page 14

(1) Prior to Commencement of Work

Examination and Testing Acceptance Criterion

(2) Prior to Welding

Examination and Testing Acceptance Criterion