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GS

GULF SPIC ENGINEERING L. L. C

METHOD STATEMENT
FOR
U/G CARBON STEEL PIPING

PROJECT: AL-AWEER GAS TURBINE POWER STATION H PHASE


III

GULF SPIC ENGINEERING L. L. C

GSE

METHOD STATEMENT FOR U/G PIPING

CONTENTS
Sl No

DESCRIPTION

INTRODUCTION

SCOPE OF WORK

REFERENCE

RESPONSIBILITIES

4.1

PIPING ENGINEER

4.2

MATERIAL CONTROLLER

4.3

QC ENGINEER

HSE CONTROL

WORK SCHEDULE

EXECUTION PLAN

7.1

MATERIAL RECEIVING AND HANDLING

7.2

INSTALLATION OF PIPILINE

7.3

HYDROTEST

7.4

WRAPPING OF FIELD JOINTS

8.

JOB SAFETY ANALYSIS

9.

DOCUMENTS ATTACHEMENT

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GSE

METHOD STATEMENT FOR U/G PIPING

1.0

INTRODUCTION
This method statement is intended to outline the method and sequence of work
execution which will be followed for FABRICATION, ERECTION & COMMISSIONING of
underground piping of AL-AWEER GAS TURBINE POWER STATION H PHASE III.

2.0

SCOPE OF WORK
The activities includes but not limited to receiving of pipes and fittings from
ETA/SIEMENS, transporting to site, installation of piping, fabrication & welding, NDE,
and leak test as per project specifications.

3.0

REFERENCE DOCUMENTS
ASME B 31.1
DEWA PROJECT SPECIFICATION G5.1, G5.5 & G5.6

4.0

RESPONSIBILITIES

4.1

PIPING ENGINEER

He shall be responsible for carrying out all the activities associated with UG piping
works including prefabrication and erection. He will have the responsibility of timely
execution of project activities in line with the project schedule. He will plan for
activities related to UG piping including but not limited to materials, machinery, and
manpower.
He is also responsible for expediting missing materials, monitoring drawing revisions
and modifications for meeting the project targets.
4.2

MATERIAL CONTROLLER

Material controller is responsible for collecting materials from warehouse designated


lay down area and shifting the same to the fabrication area and shifting fabricated
spools from the fabrication area to the erection site.
4.3

QC ENGINEER

He is responsible for preparation of WPS / PQR, welder performance qualification,


selection and control of welding consumables & NDE requirements. He will be incharge for verification & documentation of all relevant drawings and reports;
material, welding and welder traceability on job and all stage inspection as per

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GSE

GULF SPIC ENGINEERING L. L. C


METHOD STATEMENT FOR U/G PIPING

approved QAP. QUALITY ASSURANCE is ensured at all levels of fabrication, erection


commissioning process through phased flow and execution of procedures.
5.0

HSE (HEALTH SAFETY ENVIRONMENT) CONTROL


GULF SPIC ENGINEERING L. L. C will engage qualified safety personnel who ensure
that carbon steel piping works are carried out as per the CONSTRUCTION HEALTH
PLAN which is enclosed with this document.

6.0

WORK SCHEDULE
From the master schedule, related sections of carbon steel piping works shall be
extracted and be used as the timeframe. Work sequence shall be followed while
executing the different activities involved.

7.0

EXECUTION PLAN

7.1

MATERIAL RECEIVING AND HANDLING

7.1.1

The receipt of materials at stores is inspected by the QC Engineer for relevant TCs
and visually checked for damages. A MATERIAL INSPECTION REPORT will be
prepared and submitted to the client. Any discrepancies in the incoming material
inspection will be identified in the report and concerned documentation shall be
made to regularize it.

7.1.2

Material controller ensures only accepted materials are issued to the concerned
Piping Engineer.

7.1.3

Piping Engineer shall identify the list of material as per the approved drawings. He
prepares a material requisition and submits to stores via MATERIAL ISSUE VOUCHER
for drawing the materials.

7.1.4

Any discrepancies in the Isometric drawings shall be referred back to ETA/SIEMENS,


whom shall revert with necessary documentation to get written notice or field
revised drawings.

7.1.5

Piping Engineer will ensure proper handling of materials at all stages of


fabrication, erection commissioning. All pipes are fixed with end caps closed until
it is ready for fabrication/installation to avoid sediments going inside.

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METHOD STATEMENT FOR U/G PIPING

7.2

INSTALLATION OF PIPELINE

7.2.1

Excavation for the UG piping should be made available by ETA/SIEMENS at the time
of installation. The width & depth of excavation shall confirm to the drawing and
site requirements for carry out the field joint welding and rapid coating. Also for
allowing sufficient man access.

7.2.2

The field weld joints will be identified at site which requires further earth
excavation to allow man access for site fabrication works. For man access, in the
field joints minimum of 1.50 mtr spaces is required around the pipe from C/L of
the pipe for field joint fit up and welding. Earth excavation should be made
available by ETA/SIEMENS

7.2.3

The excavation shall be secured with side shoring so as to avoid sand slides.

7.2.4

All the pre-fabricated pipes shall be brought to the site area and the same shall be
tape wrapped prior to installation (leaving sufficient gap of 1m on either ends).

7.2.5

Routing check will be carried out prior to installation for in the excavated areas
for ensuring elevational interferences (if any) with the nearby existing piping
systems.

7.2.6

After pipe wrapping, the pipe ID will be checked for any foreign material
accumulation. This check is pre-requisite for all pipes before installation.

7.2.7

Piping Engineer will ensure that safe installation practices are followed during
erection. Proper fit-up and alignment of the piping as per the drawing
requirements will be confirmed and ensured prior to offering to QC Engineers.

7.2.8

After getting fit up clearance, welding will be carried out as per approved WPS, by
qualified welders. Traceability of the welders on the job will be ensured by the QC
engineer by transferring stencil marks near the weld joint. Also relevant details
like joint no., line no. etc., will be marked near the weld joint.

7.2.9

All the required NDT will be carried out and confirmed by the QC Engineer as per
the approved stage inspections prescribed in the QAP/ITP. The record of the NDE
performed will be traced based on the P& ID drawing no., Layout drawing no., ISO
drawing no., line no., joint no., and welder no.

7.2.10 PHWT will be carried out at the joints wherever applicable (as per project
specifications)

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GSE

METHOD STATEMENT FOR U/G PIPING

7.2.11 After completion of the NDE & PWHT, the HYDROSTATIC TEST (as per approved
procedure) will be carried out.
7.3

HYDROTEST

7.3.1

A punch list of jobs carried out and jobs to be carried out will be prepared by the
QC Engineer and submitted to the client. A walk down inspection of the entire loop
will be performed for confirming the drawing requirements.

7.3.2

Pipe cleanliness on the surface shall be carried out and same will be ensured prior
to start of Hydro test.

7.3.3

A TEST PACK will be compiled by the QC Engineer which will contain the following,

TEST DRAWING showing test limits


ISO & Drawings list
Piping NDE test reports
PUNCH list (post/pre)
Line welding History Sheet
HYDROTEST check list
Calibration certificates of pressure gauges used for testing
Reinstatement check list
HYDROTEST certificate

7.3.4

Water to be used will be from a portable & agreed location.

7.3.5

Fill water through hoses at the lowest points in the loop. After ensuring priming in
the loop, start pressurizing to the test pressure (1.5 times the design pressure or
as per the project specifications).

7.3.6

Holding time for the test pressure shall be as per ASME B 31.1/project
specifications.

7.3.7

Failure in the test (if any) shall be reverted with draining, repairing and retesting
with the above procedure.

7.3.8

On completion of Hydrotest, the water shall be drained, ensuring proper safety


precautions. After complete draining of water, the loop should be air flushed to
ensure removal of moisture entrapment. Dry compressed air shall be supplied by
ETA/SIEMENS.

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METHOD STATEMENT FOR U/G PIPING

7.3.9

The separation of loops for Hydrotest will be considered for road crossings,
culverts piping etc. For the same, Hydrotest will be conducted prior to installation
underground. A separate TESTPACK will be provided for such loops for traceability
at the time of final HYDROTEST.

7.3.10 Reinstate the test loops.


7.4

WRAPPING OF FIELD JOINTS

7.4.1

Completion of all the NDE, PWHT & Hydrotest shall be ensured prior to pipe
wrapping at field joints.

7.4.2

The field joints shall be tape wrapped as per the approved procedure. A minimum
overlap of 4 on either ends of the existing wrapping shall be maintained and
ensured.

8.

JOB SAFETY ANALYSIS.


The job safety analysis for the under ground pipe line erection & testing work is
prepared and enclosed as reference documents.
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