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FOR BINDING
Rev. Para. FOR BINDINGRevision Description
FOR BINDING

A Issued for Review

0 Issued for Construction

Hold
Para. Description of Hold
No.
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TABLE OF CONTENTS FOR BINDING

1.0 PURPOSE ……………………………………………………………………………………..4

2.0 SCOPE…………………………………………………………………………………………… 4

3.0 RESPONSIBILITIES…………………………………………………………………………… 4

4.0 RELEVANT REFERENCE DOCUMENTS…………………………………………………… 6

5.0 SEQUENCE OF WORK………………………………………………………………………… 8

5.1 PREPARATION TO ERECTION…………………………………………………………8

5.2 INSTALLATION OF PIPE WORK……………………………………………………… 9

5.2.1 GENERAL………………………………………………………………………9

5.2.2 LIFTING OF SPOOLS & LOADING PIPERACKS……………………… 10

5.2.3 PERMANENT & TEMPERORY SUPPORTING……………………………10

5.2.4 VALVES……………………………………………………………………… 11

5.2.5 CONNECTION OF PIPEWORK TO STATIC & ……………………………11

ROTATING EQUIPMENT.

5.2.6 CLEANING & PROTECTION……………………………………………… 12

6.0 RESOURCES……………………………………………………………………………………. 13

7.0 HSE REQUIREMENTS…………………………………………………………………………. 14

8.0 QA/QC REQUIREMENTS……………………………………………………………………… 15

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1.0 PURPOSE FOR BINDING

The purpose of this method statement is to define the requirements of pipe work erection in
accordance with the requirements of client specification & standards.

2.0 SCOPE
The scope of this method statement covers the field application methodology & requirements
that shall be adopted for aboveground of all carbon steel,stainless steel,alloy & Incoloy pipework
to be erected according to the best practices, standards & project specifications.

3.0 RESPONSIBILITIES

3.1 PETROFAC INTERNATIONAL LTD (PIL)

3.1.1 PIL Construction Manager

Construction Manager shall be responsible to ensure full compliance with this method statement
and that requirements are strictly followed.

3.1.2 Piping Superintendent

Piping Superintendent shall be responsible to ensure that the works are carried out in
accordance with all safety and quality requirements. He shall ensure that the works are planned
correctly, tools and equipment are available and sufficient skilled personnel are assigned to the
work area.

3.2 SUBCONTRACTOR
3.2.1 Construction Superintendent

The construction Superintendent is responsible for the following:

 Overall responsibility to ensure the subcontractor full implementation of the requirements of
this method statement.

3.2.2 Piping Engineer

Piping engineer for pipe work is responsible to support the construction Superintendent
In the following activities :
 Implementation of this Method Statement.
 Planning & Scheduling work Activities.
 Implementation of all safety and quality requirements pertaining to the work.
 Ensure that all field material is available and correct.
 Ensure that pipe / Fabricated pipe spools confirm to Isometric latest revision and
Specification.
 Direct and assist in the execution of the inspection and witness activities.
 Notify Supervisors when corrective action is required.
 Maintain report files and distribute reports.
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3.2.3 Piping Supervisor

The piping Supervisor is responsible for the following:

 Adhere to project drawing and specifications.
 Maintain good workmanship.
 Fulfil all the safety and quality requirements pertaining to the work being
performed.
 Supervise pipe / spool transport,lifting,erection, fit-up and welding.

3.2.4 Piping Foreman

The piping foreman is responsible for the following :

 He is directly incharge of crew ,equipments and material being used to conduct
the work.
 Implementation of pipe erection works ( pipe/spool transport lifting fit-up,erection
etc.) according to supervisor instructions,project requirements and method
statements.
 Fulfil all the safety and quality requirements pertaining to the work being
performed.

3.2.5 HSE Supervisor

The HSE Supervisor is responsible for the following :

 Responsible for daily safety activities.

3.2.6 QC Piping Inspector

 QC Piping Inspectors are responsible for daily monitoring and reporting of all
pipeworks starting from piping material control to pressure testing activities.
 QC Piping Inspectors are responsible for inspection of bevel end fit up
clearance to release for welding.
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4.0 RELEVANT REFERENCES & DOCUMENTS :
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As defined project standards and specifications and relevant International Standards and
Codes to use for installation of pipe work as follows.

SR.NO DESCRIPTION STANDARD NUMBER

1 Project Quality Plan GB088-2013-200-QA-PL-001.

2 Project HSE Plan GB088-2013-200-PJ-PP-004

3 Welding Specification GB088-2013-200-QA-CN-003.

4 Piping Fabrication,installation And GB088-2013-200-QA-CN-008.

testing Specification.
5 Piping Material Specification. GB088-2013-200-PI-SP-001
6 Piping Support Standard. GB088-2013-200-PI-SS-001.

7 Valve Material Specification GB088-2013-200-PI-DS-001

8 Painting Specification GB088-2013-200-MT-SP-003

9 Insulation Specification GB088-2013-200-MT-SP-004

10 Piping Design Basis GB088-2013-200-PI-DB-001

11 Tag Numbering Procedure GB088-2013-200-PJ-PP-031

12 Specification for Positive GB088-2013-200-QA-SP-001

Material Identification
13 Welding Of Carbon Steel Piping & GB088-2013-200-QA-SP-003
Equipment in Wet H2S Service.
14 ITP For Pipe Work
GB088-2013-200-QA-TP-022.
15 Material Control Procedure GB088-2013-200-QA-PL-007

16 Procedure for welding Consumables GB088-2013-200-QA-PL-017

17 Material Identification & Traceability GB088-2013-200-QA-PL-052

Procedure.
18 GB088-2013-200-QA-PL-040
Material Preservation Procedure
19 Procedure For Material Handling & GB088-2013-200-QA-PL-067.
Rigging
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 Engineering Design and Standard Drawing :
FOR BINDING

 Project P & ID .
 Isometric Drawings.
 Piping General Arrangement Drawings.
 Unit Plot Plan for Respective Area.
 Instrument Hook-up Details.
 Special Pipe Supports.
 Special Parts.( Other than Standard Pipe Fittings)

The Latest Edition of the following International Codes & Standards shall be used
with and are part of this specification.Relevant Standards and codes as Follows :

ASME B31.3 – Process Piping.

ASME Sec IX – Qualification Standard for welding Procedures, welders,welding and

Operators.

ASME B16.5- Pipe Flanges & Flanged Fittings (up to 24 “ Size.).

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5.0 SEQUENCE OF WORK : FOR BINDING

5.1 Preparation For Erection

Prior to starting fabrication /erection of any pipe work the following checks shall be
performed:
 Latest revision of related drawings has been “Issued For Construction” or subsequent next.

 Material Indicated in the drawings shall be available and their size, quantity & Quality.
Shall confirm to the requirements given in the related drawings.

 Ensure WPS,welder qualification ,NDE and PWHT procedure are in place.

 Manufacturers material certificates of all materials to be used in pipe work shall be available.

 The segregation of Carbon steel, low temperature carbon steel, stainless steel and non ferrous
materials during transportation and storage shall be maintained all the times. Only
project approved equipments shall be used to handle stainless steel or non ferrous
materials and they can be stored on soft standing wood dunnage or sand bags. Use non
metallic sling to carry out handling, loading and offloading. Chains or wire ropes shall not
be used.

 During transportation ,spools shall be adequately secured with soft lines to protect from
damage. End cap / protectors shall be installed to prevent ingress of any foreign objects
and damage to the weld preparations. Flange covers shall be left in position on valves and
spools until the time of installation. Overhanging from trailer/truck body of any piping
materials is not allowed.
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5.2 Installation of Pipework

5.2.1 General

 Contractor will set up weld-bays at different locations of pipe racks in order to install rack
piping by an efficient and safe approved method.

 The Bottom of pipe rack’s first deck at pipe landing bay area will be covered as per
scaffolding procedures with approved material for protection over on going activities
underneath from falling objects and injury. Where necessary fire blankets of approved
type will be used to minimize the potential risk of fire.

 Prefabricated and /or field fabricated spools will be installed by placing it in the exact positions
indicated on drawings.

 Small bore piping ,generally below 2”,will be field fabricated as per drawings and layouts.

 Flanges will not be bolted together without insertion of gasket or protective media in between
two mating flange faces. Before connecting of flanges, flange must be clean and free of any
damages. Visual inspection is required.

 Where flanges are loose on a closure length of piping ,a careful physical check shall be
made of closing distance and alignment of flange before cutting of pipe and welding on
the flanges.

 Pipe work shall be fitted into place without springing or forcing.

 Piping connecting to the equipment nozzle shall be installed only after release of equipment
for piping works with proper piping supports. Connection shall be loose, supported and
provide gap between nozzle and piping flange to avoid stress on the equipment nozzle.

 All flanged joints shall be brought up flush and square so that the entire mating surfaces
bear uniformly on the gasket, and then made up with uniform bolt tension.

 When bolting flanges with spiral wound gaskets, the gasket shall be compressed
evenly to the thickness of the guide ring. Gasket compression shall be spot checked
during bolt tensioning in accordance with manufacture’s recommendations.

 It shall be ensured that gasket do not, under any circumstances , protrude into the bore
of pipe.

 All flanges bolting shall be checked for correct grade and that they are free from damage
to the bolt/nut and any coating prior to fitting.

 All flange bolting shall be free to move through mating flanges hole in a plane at right
angle to the flange face and parallel to the pipe run.

 All bolting shall be re-checked for tightness and correct tension on completion of pressure
testing.

 For fitment of orifice flange care to be taken to follow correct orientation as per drawing.
Inner surface of weld joint of orifice flange to be properly grinded to align exactly with
inner surface of pipe.
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 Temporary gaskets will be used at temporary blinds, temporary test connections and/or
temporary filter connections. Final re-instatement will be with the permanent gasket.

5.2.2 Lifting Of Spools and Loading Pipe Racks

 Pipe installation will normally be from lower level and on-going up to the highest level.
The sequence of installation shall generally be as follows :

 Large Bore Field Runs.

 Large Bore Composite Spools.
 Small Bore Field Runs.

 Pipe will be loaded and welded at the loading bays and pulled along the rack on rollers
which will be installed and fixed at support locations.

 Following the pipe loading on pipe-racks, scaffold levels will be set at all rack elevations,
with handrails and safe timber, the access between each level and ground will be through
vertical ladders at every 100 meters of pipe rack.

 Pipe spools shall be rigged by crane into the pipe rack either transferred directly at the
location or on pipe rollers places on the rack beam. Chain blocks and trifors will be used
wherever required. Suitable padding shall be used to prevent damage to pipe.

 Handling of pipe and fittings shall be by nylon slings.

 At limited locations with high workload walkways will be installed at each rack.

5.2.3 Permanent and Temporary Supporting

 Where possible, pipe work shall be erected on permanent supports designated for the
line.

 Supporting steelworks shall be set at the correct elevation, being true and level in all
respects.

 During erection of pipe work, suitable additional temporary supports shall be provided to
ensure that no undue stresses are imposed on the pipe, or connected equipment.

 Tirfors and chain blocks will not be used as temporary support.

 Pipe supports shall not be welded to the pipework unless specified in the related
drawings.

 During installation, force shall not be used to align pipes to support locations.
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 Permanent pipe supports FOR,where
shall BINDINGpossible, be installed before the erection of the
associated pipe work.
 Stainless steel piping shall not be set directly on galvanised structure steel. It must be set
directly on its pipe shoe /support in the pipe rack. If temporary placement makes this
impractical, a layer of plastic sheeting ,rubber or nylon belt shall be placed between
stainless steel pipe and galvanized structural steel.
 The burning of holes in structural steel works or components part is strictly forbidded
 Metallic surfaces of supports which will be inaccessible after erection shall be prepared
and coated before assembly of the component.

 Hanger rods shall be adjusted to hang correctly after tightening of all component parts,
surplus threading may be removed.

 Pipe hangers shall not be used as temporary lifting attachments. Spring support units
shall be installed in accordance with the manufacturer’s instructions and shall not have
“stops” removed until completion of hydro testing and re-instatement.

 All temporary supports and lashing shall be removed before hydro test.

5.2.4 Valves

 All unidirectional items like check valve , globe valve ,strainer etc. must be installed as per
direction indicated / recommended.

 Control valves and all inline instruments will be removed for hydro testing or be
installed after hydro test.

 Special Valves will be installed in accordance with manufacturer’s recommendations.

 Gland packing in all valves shall be checked during hydrostatic testing.

5.2.5 Connection Of Pipework to Rotating & Static Equipments

 Flange connecting to all mechanical equipment static and rotating shall be fitted up in
close parallel and lateral alignment prior to tightening the bolting.

 Tightening of bolting will be carried out with the appropriate control measures in place.

 Flange connection to strain sensitive equipment shall be the last connection made on
completion of a line or interconnecting system of lines complete with permanent supports.

 Flanges of Equipment shall not be used for fit up purposes.

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5.2.6 Cleaning & Protection FOR BINDING

 All machined areas shall be adequately protected.

 All materials to be used in the fabrication /erection shall be visually examined for any
damage and internal cleanliness.

 When working with non-ferrous material,supports,vices and workbenches shall be

suitably protected with wood /tape etc. to prevent contamination.

 All open ends will be capped and flange faces protected with plastic flange covers or with
plywood blanks secured by bolts or strong tape.

 Tools for SS piping such as grinders, grinding and cutting wheels ,saw,files,etc.shall not
be used if previously used on carbon steel and shall be recognizable by means of colour
coding as suitable for use on SS material.

 To avoid contamination of SS piping with carbon steel or galvanized piping,SS pipe shall
be isolated using wooden blocks,spacers,rubber sheet or its permanent support.

 Suitable equipment and tools will be used to avoid damaging materials to be erected.

 All openings in tank and other similar equipment items shall be clean and free from
obstruction prior to being connected to the pipe work. A joint inspection to be done
between piping and mechanical for confirmation the equipment is clean and free from
damage.

 Care shall be taken to ensure that the gasket and mating flanges, seal rings and hubs are
clean, true and free from defects.

 Flange covers shall be retained on all flange connections to pumps and similar
mechanical equipment until ready to connect the mating piping.

 All equipment openings shall at all times be protected from unauthorized access.
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6.0 RESOURCES FOR BINDING

 Equipment List :

SR.NO. DESCRIPTION NO.REQUIRED REMARK

1 Crane 7
2 Boom Truck 5
3 Manlift 1
4 Trailer 5
5 Welding Machine 50
6 Welding Tools LOT

7 Hand & Power Tools. LOT

 Manpower List :

SR.NO. DESCRIPTION NO.REQUIRED REMARK

1 Project Manager 1
2 Construction Manager 1
3 Piping Superintendent 1
Piping
4 5
Engineer/Supervisor
5 Foreman 10

6 QA/QC Inspector 4

7 Pipe Fitter/Fabricator 109

8 Welder 75

9 Mechanical Helper. 90

10 Safety Supervisor/Advisor 5
Lifting / Rigging
11 1
Supervisor
12 Rigger/Grinder 125
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7.0 HSE REQUIREMENTS

 HSE requirements prescribed in Appendix 8 to be complied with.

 All personnel will be equipped with the necessary personal protection equipment ,as a
Minimum ,

 Helmet
 Steel Toe Boots
 Safety Gloves And Goggles
 Coverall

 All PPE shall meet the requirements of GPNB prescribed as per Appendix 8.

 Proper approved lifting Plan for all Critical lifts shall be in place.

 The working environment shall be kept clean and tidy.

 Toolbox talks shall be conducted before every new commences.

 It shall be ensured that all lifting and rigging equipments and tackle are inspected and
certified by third party inspection company.

 Scaffolds shall be designed ,erected ,inspected and dismantled by certified and

competent personnel.

 All the work in confined space shall comply with confined space entry permit.

 For Hot works such as welding ,cutting ,grinding,

 Fire Extinguisher must be in place.

 Personnel will be equipped with appropriate PPE for hot work.

 Where other employees may be affected by the work , a non combustible or

flame proof screen must be erected around the work area.

 The work area must be clean and tidy at all times with all flammable and
combustible debris removed from the area.

 All cables and hoses must be coiled up nearly when not in use and run out in
such a manner to alleviate tripping hazard.

 Cables and hoses must not straddle walkways or other employee work area.

 All gas cylinders must be kept upright and secured in the appropriate trolley at
all times.

 Leaks on gas cylinders must not be traced with naked flame, but traced with
appropriate solution around the suspect connections.
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 All equipmentsFOR
must be checked
BINDING prior to use and at least once every day.

 If the electrode holder is left unattended ,the electrode must be removed, and
the holder must be placed so that electrical contact can not be made with
another employee or any conducting object.

 A fire watch should be assigned to guard against fire during the operation and
for suitable time after completion of the work ( 30 minutes ), to ensure that no
possibility of fire exists.

 For Working in summer time

 To prevent heat stress and other heat related illness, people should know the
factors and preventions by giving them proper induction and trainings.

 Sufficient cold water.

 Proper work shelter should be provided at work site.
 Emergency stand by vehicles.
 Certified First Aiders Available at every job location.

8.0 QA/QC REQUIREMENTS

Piping erection works shall be carried out according to this method statement and shall
be inspected in accordance with the approved Inspection and test plan for Installation of
pipework.( Refer GB088-2013-200-QA-TP-022. )