Document No:

Method Statement for Alloy steel POFSC-MS-P-A-01

pipe fabrication Work
Rev 0
 
 
 
 

METHOD STATEMENT FOR ALLOY STEEL PIPE

FABRICATION WORK

0 04/05/2020 Issue for approval Sugumar

REV DATE DESCRIPTION PREPARED REVIEWED APPROVED

  Document No:
Method Statement for Alloy steel POFSC-MS-P-A-01
pipe fabrication Work
Rev 0
 
 
 

INDEX

1. PURPOSE

2. SCOPE

3. REFERENCES

4. DEFINITIONS

5. RESPONSIBILITIES

6. PROCEDURE

7. TOOLS AND EQUIPMENTS

8. SAFETY INSTRUCTION

   

 
  Document No:
Method Statement for Alloy steel POFSC-MS-P-A-01
pipe fabrication Work
Rev 0
 
 
 
 

1. PURPOSE 

The purpose of this method statement is to define the procedure for fabrication of alloy
steel piping under the DPC project specification.

2. SCOPE

Scope of this method statement covers the following activities.

 Material handling
 Fabrication
 Welding
 NDE
 Inspection

3. REFERENCE

3.1 PROJECT DRAWINGS

 Applicable Project piping Isometrics.

3.2 PROJECT SPECIFICATION

 Piping Design Table

 Approved WPS
 Approved PQR

3.3 PROJECT QUALITY PLAN

3.4 CODES AND STANDARDS

ASME B31.3 Pressure Piping

ASME B31.1 Power Piping
ASME Section V
ASME 16.25 Butt Welded Ends
ASME 16.5 Pipe Flanges and Flanged Fittings

4. DEFINITIONS
  Document No:
Method Statement for Alloy steel POFSC-MS-P-A-01
pipe fabrication Work
Rev 0
 
 
 
CL Client
PM Project Manager
SPE Senior Piping Engineer
PS Piping Supervisor
ITP Inspection and Test Plan
QC Quality Control
QCE Quality Control Engineer
PQP Project Quality Plan
PPE Personal Protection Equipment
PMI Positive Material Identification
NCR Non-Conformance Report

5. RESPONSIBILITIES

 It is overall responsibility of PM to organize resources to perform construction

activities as per project specification, in compliance with quality, schedule &
safety requirements.
 It is the responsibility of Senior piping Engineer that construction activities are
executed according to relevant project specification, in compliance with quality,
schedule & safety requirements.
 PS will ensure that all works are performed safely as per latest approved
isometric drawings & specification.
 PS will ensure that all the piping work is conducted in accordance with this
method statement and project specification
 QCE will ensure that all work is executed according to PQP and that requirement
of quality dossier are full filled.
 Safety and construction supervision will be carried out under responsibility of
client whenever required.

6. PROCEDURE – METHOD OF WORKS – INSTRUCTIONS

6.1 RECEIPT & STORAGE OF PIPE RAW MATERIALS

 The piping raw material received from client shall be offloaded in designated
lay down yard.
 During offloading, pipes shall not be dropped off the transport. A crane and
suitable certified slings shall be used.
 The pipes shall be placed on wooden bar and they shall be adequately
supported to minimize sagging.
 The piping end covers shall be kept in place to prevent foreign particle entry
into the pipes.
  Document No:
Method Statement for Alloy steel POFSC-MS-P-A-01
pipe fabrication Work
Rev 0
 
 
 
6.2 PAINTING

 Painting shall be done according to project specification no.

6.3 SPOOL BREAKDOWN

 The piping isometrics shall be marked into number of spools to facilitate the
fabrication & erection work.
 Each spool shall be marked with a piping tag number.
 Each joint on the isometric will be given a unique number preparing a welding
map for traceability. Separate numbering system will be followed for butt welds,
fillet welds and threaded joints etc.
 The details of piping isometric breakdown into spools and joints will be recorded
for reference.

6.4 PIPING FABRICATION

 Material will be shifted from lay down yard to work shop as per relevant piping
isometric drawings.
 Carbon steel, stainless steel and alloy steel fabrication work will be done in
separate area. Tools & equipment compatible with the material in fabrication
shall be used.
 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.

6.4.1 CUTTING AND BEVELING

6.4.1.1 BUTT JOINT

 The pipes shall be cut as per dimensions mentioned in he

isometric and all pipe length shall be marked with relevant spool
no. as given in the isometric. Material traceability shall be
maintained as per relevant QIP.
 Based on spool break down of piping isometrics, pipe lengths
shall be cut 150 mm extra for pipe will be provided in spools for
field adjustments. The pipe ends for 2 inch and above shall be
beveled as per approved WPS for the piping class.
 The cutting and beveling of pipe shall be done by mechanical
means cold cutting or cutting & grinding wheel, cutting shall be
acceptable provided that the edges are smooth.
  Document No:
Method Statement for Alloy steel POFSC-MS-P-A-01
pipe fabrication Work
Rev 0
 
 
 
 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.
 The joint should be free of grease, oil, scales, rust or other foreign
material.
 The primer paint coat op pipe & fitting ends shall be removed prior
to bevel end preparation.
 The pipes shall be tack welded by a qualified welder.

6.4.1.2 SOCKET WELD

 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 specification.

6.5 WELDING

 All Welding work will be according to approved WPS and only qualified welders
shall be employed.
 Heat treatment will be indicated on NDT matrix, where required.
 The welding work piece will be shielded against high winds and rain.
 The weld surface shall be cleaned with 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 B 31.3 code & WPS
and shall exclude any under cut, 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.
 Preheating shall be done in accordance with the welding requirement related to
each class of piping base metal material.
 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.

6.6 POST WELD HEAT TREATMENT (PWHT)

6.6.1 GENERAL
  Document No:
Method Statement for Alloy steel POFSC-MS-P-A-01
pipe fabrication Work
Rev 0
 
 
 
 Before starting any heat treatment process, it will be checked that
welding has been completed.
 The temperature can be checked with the aid of thermochrome
crayons or thermocouples.
 The preheating temperature shall be maintained throughout the
welding cycle and it should be done over sufficient width on either
side of welds.

6.6.2 POSTWELD HEAT TREATMENT PROCEDURE

 PWHT shall be according to approved procedure no.

6.6.3 PRECAUTIONS

 Heat treatment operations involve electrical heating up to 2000oF

bringing hazards of burning & electrocution due to a lot of cables &
other electric equipment. Following precautions shall be taken.

A. Appropriate visual & physical barricading of area to avoid

unauthorized personnel’s entry.
B. To avoid physical hindrance du to other nearby activities.
C. Warning signs/ boards shall be installed on barrications.
D. Proper dressing up of cables through appropriate routed to avoid
entangling with other activities.

6.7 INSPECTION

 The fabricated pipe spool shall be checked against project drawings to verify its
compliance.
 The dimensions, angle and direction of spool and allowances for field welding
shall be according to the isometrics & project specification.
 NDE shall be performed as per approved NDT matrix sheet.
 The acceptance criteria for visual inspection shall be done according to the
ASME b 31.3
 NDE tests shall be performed & recorded as per approved NDT matrix sheet.
 The NDE result shall be interpreted by qualified inspectors
 All welding records for each joint shall be maintained throughout the fabrication
work.

6.8 IDENTIFICATION
  Document No:
Method Statement for Alloy steel POFSC-MS-P-A-01
pipe fabrication Work
Rev 0
 
 
 
 Each fabricated spool shall be clearly marked with a number. This number
include line number & spool number as shown on the piping isometric drawing.

6.9 STORAGE

 The pipe spool complete in all respect shall be stored separately.

 All spools shall have their identification clearly designated on each spool.
 The spool shall be placed on wooden baton to avoid direct contact with soil.
 The pipe end shall be covered by end caps. In case of flanged spools the same
shall be covered by polyethene sheet to avoid foreign material entering the pipes.
 The spool shall be handled using nylon lifting slings.

7. TOOLS & EQUIPMENTS

7.1 EXECUTION

 Hand tools
 Cold cutting machine
 Cutting & grinding machine
 Overhead crane
 Forklift/ Boom loader
 Welding machine
 PWHT machine

7.2 SAFETY

 Safety helmet
 Safety Goggles
 Gloves
 Safety Shoes
 Welding Helmet
 Ear Plug
 Dust Mask

7.3 TESTING

 Radiography
  Document No:
Method Statement for Alloy steel POFSC-MS-P-A-01
pipe fabrication Work
Rev 0
 
 
 
8. SAFETY INSTRUCTION

During execution of the job all measure shall be adopted to ensure safe working.
POFSC will ensure that, PTW system shall be implemented as per client requirement at
site.

 All personnel involved in work will used necessary PPE as required.

 The workers will be made aware of safety requirement related to this activity
through daily, weekly and monthly toolbox and safety talks.
 Safety notice board will be installed.
 All equipment will be inspected by POFSC safety Engineer as per routine while
execution supervisor should inspect it prior to use.
 During transportation of pipe and fittings, the material shall be properly supported
and tied on the trailer.
 Ensure that pipes are properly wedged or blocked to avoid rolling.
 Correct rigging procedure should be observed.
 Access and good housekeeping should be maintained in all fabrication areas.
 Fire extinguisher should be available in all working area.
 Proper storage, handling and us of gas cylinders will be observed.
 All cylinders shall be kept in trolly and in an upright position.
 Welding sets should be checked and maintained regularly for wear and tear.
 Waste management should be strictly followed to keep the job site neat and
clean.
 HSE shall provide due support to the execution team in the fulfillment of HSE
requirements.