MES for Stainless Steel Piping

REV: 000 DATE: 27.12.2017 PAGE: 1 / 12

REVISION FOLLOW UP PAGE

HSE System Technical

Quality System
Approval Qualification Validity Approval
Approval
Approval

Description of
Revised Page Revision Date Prepared By
Revision

Rev. No 0 1 2 3 4 5 6 7 8
Date 28.12.17

This document contains information confidential and/or proprietary to ENKA and its affiliated companies that is not
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© 2017 ENKA İnşaat ve Sanayi A.Ş.

The document becomes uncontrolled once printed, please check for the latest version in EDMS prior to use.

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ABSTRACT
Sprinkler, heating&cooling and domestical water systems have steainless steel pipes GOST 9941-
81 at TAIF Business Center Project.
Contractor is planning to do jointing by welding and screwed.
For screwed joints special threader dies to be used that are compatible for SS pipes.
Welding is going to be SMAW and shielded filler material will be E308H-17 that is matching with
pipe material for grade 08x18H10. A related WPS can be provided too in case of requisition.

1.0 GENERAL

1.1. Purpose
The purpose of this method statement is to ensure that the methods and procedures shall be carried
out for the stainless steel piping works for all systems at TAIF Business Center Project.
1.2. Abbreviations and Definitions

1.2.1. Abbreviations

Abbreviation/
Description
Acronym
AFC Approved for Construction
PPE Personal Protective Equipment
SDS Safety Data Sheet
TBT Tool Box Talk
ITP Inspection Test Plan
ITR Inspection Test Record
WPS Welding Procedure Specification
SS Stainless steel
SMAW Shielded Metal Arc Welding
MEP Manager Mechanical&Electrical Works Manager, Deputy Project Manager
HSE Health&Safety&Environment

1.2.2. Definitions

Term Meaning
COMPANY
CONTRACTOR
QC Quality Control
ITP Inspection and Test Plan
ITR Inspection Test Record
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2.0 ROLES AND RESPONSIBILITIES

2.1 MEP Manager

2.1.1. Responsible for overall site management, dissemination or execution of quality procedures
that meets project specification and project requirements.

2.1.2. Establishment of construction organization, monitor job quality, schedule control and overall
project management.
2.1.3 Manage daily on-site operations such as headcount, check-ins of employees to ensure staff’s
availability during working hours.
2.1.4 Setting performance targets and communicating with management on a regular basis to
provide an up-to-date status of the project, ensuring compliance with the Project/Company
procedures
2.1.5 Overseeing and management of all aspects of the work at the site. This can include handling
operational duties, such as: coordinating work schedules and ensuring the timely delivery of
materials, also adherence to the project constraints by all his subordinate team

2.2 Mechanical Lead Engineer

2.2.1. Shall be responsible for the execution of this procedure, monitoring and control of activities
pertaining to the fabrication and installation of the piping and its components, compliance with
HSE procedure.

2.2.2. Shall report to concern to MEP Manager

2.2.3 Shall responsible piping external and internal observations
2.2.4 Works with the resident and design engineering personnel to coordinate implementation
activities .

2.2.5 Prepares/reviews schedules, construction methods and procedures as assigned.

2.3 Mechanical Field Engineer

2.3.1. Mechanical Field engineering is in charge of inspection and supervision in the area of the
piping works and ensuring implementation and adherence to project specifications, procedures
and HSE policies.

2.3.2. Shall provide technical support to the operation of piping works and ensure that piping
installation,inspection and testing meet the project specification ensuring with latest AFC
drawings.
2.3.3. Shall coordinate with construction superintendent on execution of work.

2.4 Planning Engineer

2.4.1.Shall be responsible for monitoring progress throughout the construction process and
comparing this with the projected schedule of work with introducing appropriate logistics solutions
and resources.

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2.4.2.Shall be responsible for day to day micro planning in coordination with field engineer and
construction superintendent and report activities to Project Control Manager.

2.5 Lead QC Engineer

2.5.1. Actively pursue methods and systems to improve the levels of quality delivered.
2.5.2. Supervise all ENKA representatives are apprised of inspection and test planning
2.5.4. Advise the Field Engineering lead on matters relating to quality of construction
2.5.5. Supervise administration of Quality Control records for the site
2.5.6. Review and approve all daily inspection and test reports
2.5.7. Review all reports of nonconforming conditions and ascertain that all those items are
reconciled, re-inspected.
2.5.8. Obtain specific inspection plans and forms prior to each work day

2.6 QC Engineer

2.6.1. Shall be responsible for inspection of piping works including painting and insulation works.
Make sure installation procedures are being followed in order to ensure that quality standards
being achieved as per project procedures, requirements and specifications.
2.6.2 Monitoring and reviewing defect levels, advising and discussing remedial actions with Lead
QC Engineer and Mechanical Field Engineer.

2.7 HSE Supervisor

2.7.1. Shall be responsible for the implementation of the HSE procedures before and during the
piping works including testing,painting and insulation.

2.7.2.Shall be responsible for check for any unsafe conditions on the working areas and liaise with
field Supervisor ensuring that the work is carried out as per approved project safety plan and
procedure.

2.7.3 Assisting in implementation of HSE requirements on site.

2.8 Warehouse Supervisor

2.8.1 The WS is responsible for, proper storage of delivered pipes and ancillaries. Performing
Material Receiving Inspection on site. Implementing preservation of permanent project
materials&equipments.

3.0 SCOPE OF WORK

The purpose of this method statement is to provide minimum work requirements for the GOST
9941-81 stainless steel pipes threaded jointing and butt weld jointing.

3.1. Ensure that the document received bear the stamp “Approved for Construction” and are of latest
revision.

3.2. The documents submitted/referred with this method statement shall be considered as an integral
part of this method statement and shall be read in conjunction with the same.
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3.3. The engineering drawings and documents received shall be clearly understood to find out the
service, material specification, size, thickness, QC requirements, etc. line wise and area wise.

3.4. Make sure that all the Quality control and Pre-Construction formalities, approvals, and
preparations are done sufficiently in advance to start the construction activity as per the schedule.

3.5. A checklist of all requirements shall be made internally to avoid any omission of them.

3.6. Receipt and storage of fabricated equipment elements and attachments.

4.0 MATERIAL RECEIVING, STORING AND DELIVERY

4.1. Warehouse superviosor shall be responsible for providing all materials and documentation to the
job site. All materials and documentation will be inspected immediately upon receipt by mechanical
Field Engineer to determine that all items included in the transport list, to assure that all
documentation has been received and to check for any damage.

4.2. The receiving materials or equipment found defective or presenting non-conformance that shall
be reported.
4.3. SS pipes and fittings shall be stored at defined locations to avoid any contamination from other
matireals.

4.4. All bolts, washers and nuts shall be packaged and stored seperatley to avoid any contamination.
4.5. Ensure the material is secured properly so that it does not fall, roll or move from its storage
position.
4.6. Shielded materials and INOX consumables shall be stored separately.

5.0 PIPING STEPS

5.1 Threaded SS Piping

5.1.1. 2” and below sizes to be installed by threaded joints.

5.1.2. Flanged joints can be done for where a flanged instrument, valve etc. or pipe class
changement points( i.e. from GOST 9941-81 to VIEGA Sanpress INOX Pipes).

5.1.3. An alectrical threader machine going to be used to thread pipes.

5.1.4. AFC drawings shall be distributed to site installation teams.

5.1.5. Field engineer shall control drawings by considering interfaces with other disciplines to
determine a work sequence and inform other departments at site coordination meeting.

5.1.6. Risk assessment shall be shared with all team members.

5.1.7. Site engineer shall ensure if the team members have work related safety trainings.

5.1.8. Site survey team shall mark +1,00 finish floor elevation on walls and coloumns.

5.1.9. All handtools and electrical powertools shall be tested and color-coded.
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5.1.10. Site teams shall determine piping direction&elevation using measurements on drawing.
Insulation distance shall be considered. In case of missing any measeurements site survey team shall
assist to determine direction.

5.1.11. After direction support installation to be implemented as per approved support details.

5.1.12 Support types and model shall be as per AFC details that had been approved by company.
Between support and SS pipes an isolation gasket to be installed.

5.1.13. Pipe measurements to be done by site installation team and to be ordered threader machine
operator to be cutted and threaded.

5.1.14. Threader machine fixing jaws and vice clamps jaws to be isolated with a special plastical
sheet to prevent any damage / contamination on SS pipes.

5.1.15. Threader machine dies shall be compatible with ss pipes and related manufacturer
documents to be provided.

5.1.15. Workbench to be insulated with special plastical sheet to prevent contamination on SS

pipes.If possible workbench to be fabricated from wood.

5.1.16. Flax and auxiliary chemical to be used on threads to provide leak-tightness.

5.1.17. Clamps tightening bolts to be fixed after installation of pipe.

5.2 Butt Weld SS Piping

5.2.1. Above 2” sizes jointing to be done by SMAW.

5.2.2 Shielded filler material shall be compatible with pipe material and to be approved by Company.

5.2.3. All cutting and grinding consumables and handtools shall be special for ss pipes.

5.2.2. Pipe to be cut as per measurement that calculated by installation team.

5.2.3. Pipe ends to be 30° bevelled for welding.

5.2.4. Fit-up to be done by tack weld at least 4 points on circumference to avoid any distortion while
welding operation.

5.2.5. Fitted-up pipes straightness to be inspected by a spirit level to avoid rework after welding.

5.2.6. Mobile thermoses and baking ovens shall be marked to not be used for any other type
electrodes.

5.2.7. Shielded electrodes shall be baked in oven 2 hours to remove moisture from shield as per
shocking temperature given by electrode supplier.

5.2.8. Mobile electrode thermoses shall be used on site to protect electrode from moisture.

5.2.9. Welded joints to be inspected visually after welding by Mechanical Field Engineer and QC
Engineer.
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5.2.10. After pipe installation end of pipes to be closed to avoid any unwanted particles or dust to be
get into the pipes.

5.2.11. For flanged joints stainless steel bolts,nuts and washers to be used.

5.2.12. After hydrotest, prior to painting&insulation, passivation to be done with an asidic solution to
prevent oxidation on weld joints.

6.0 Hydrotest

6.1. Hydrotest to be done after installation prior to insulation.

6.2. Hydrotest pressure to be Operating Pressurex1,5.

6.3. Test limits to be determined by Mechanical Field Engineer and to be attached test pack.

6.4 2 ea calibrated and ceritified manometers to be used for testing.

6.5 On a drawing air discharge valves,manometer placements, filling points to be sepicified and
that drawing to be attached test pack.

6.6. After installation of pipes QC Engineer and Mechanical Field Engineer shall inspect pipe work
within the determined test limits prior to test.

6.7. Make sure that pipe elevations, directions and network is done as per AFC drawings.

6.8. After releasing of pipe work to hydrotest to be commenced.

7.0 Passivation & Insulation

7.1. Proper PPE shall be used by team members as insulation and passivation materials have high
hazardous effects for human health ( proper gloves, proper respiratory mask, coveralls etc.)

7.2. Passivation shall be done with an proper asidic chemical.

7.3. Passivation shall be done as per chemical manufacturer procedure that is mainly guides to
clean joint with asid and rinse / wash with clean water.

7.4. After passivation weld joints to be inscpected visually.

7.2. Insulation materials to be stored in a dry and clean area.

7.3. Pipe surface shall be free from dust and moisture.

7.4. Any paint defects to be repaired prior to insulation.

7.5. For auxiliary chemicals SDS to be shared with insulation team members.

7.6. Correct insulation types and thickness shall be verified by Mechanical Field Engineer as per
contract specifications.

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7.7. Cut insulation as per installed pipe length where necessary.

7.8. Clean pipe surface from dust and moisture.

7.9. Cover pipe with insulation.

7.10. Remove self-seal adhesive protection tape and apply affixing.

7.11. Apply self adhesive tape pipe to seal insulation joints.

7.12. Reinforce insulation with plastical tie strips.

8.0 EQUIPMENT

8.1. Pipe Threader Machine

8.2. Welding Machine

8.3. Grinding&Cutting Machine

8.4. Drilling Machine

8.5. Wheel Type Pipe Cutter

9.0 HEALTH, SAFETY and ENVIRONMENT

9.1 General

9.1.1. HSE Lead shall ensure that the work is performed accordance to the approved Construction
Safety Manual and precautions specified in the work permit. He shall ensure that barricades,
warning tapes, warning signs, firefighting equipment and first aid kits are readily available at the
working area.

9.1.2.Tool box talk shall be conducted on a daily basis to inform the workers of the recent safety
issues and incidents and to get feedback of any unreported unsafe acts. Feedback will then be
processed and resolved.

9.2 Accident Prevention Safety Procedures

9.2.1. All Equipment shall be checked for good conditions before commencing the work.

9.2.2. Unauthorized persons shall be excluded from the area.

9.2.3. Adequate caution boards and warning signs shall be provided.

8.2.4. Only trained and authorized personnel shall perform the job.

9.2.5. On completion of job, the area shall be cleared of any materials and keep clean and tidy.

9.2.6. TBT shall be conducted to all team members prior to commencing job.
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9.2.8. Risk Assessment shall be conducted and and signed by all team members.

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10.0 Risk Assessment

RISK ASSESSMENT FORM

Project: Prepared Date: 27/12/2017

Work Description: Piping Works for Heating System. Last Revision Date: 27/12/2017

Risk (Before Precautions) Risk (After Precautions)

N Exposed
Work / Hazards Impact of Hazard Preacutions
o on
Human Environment Equipment Human Environment Equipmen
Material Transportation
-Toolbox talk to be conducted prior to work.
-Man-machine interface -Fatality
-Human -Trained personnel
1 -Load Fall Down -Property E2 B3 E1 E1
-Asset -Flagman
-Load Strike Damage
-Inspected lifting equipments
-Crane Failure
Pipe Cutting&Threading
-Toolbox talk to be conducted prior to work.
-Hand injury
-Trained personnel
-Noise -Fatality
-Poper ppe to be used, proper gloves, ear plug
2 -Electrocution -Serious Injury Human E3 E1
face shield etc.
-Sparking materials -Amputation
-All electrical powertools to be inspected and color coded.
Splash into the eye
-Cable Management to be followed.
-Pinch Points

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Pipe Installation&Welding -Toolbox talk to be conducted prior to work.

-Fall from height -Trained personnel
-Eye Flash -Fatality -Poper ppe to be used proper gloves, ear plug
3 -Sparking materials -Serious Injury Human E3 face shield etc. E1
splash into the eye -Amputation -All electrical powertools to be inspected and color coded.
-Hand injury&Hand burn -Inspected scaffolds
-Fire -Cable Management to be followed.
Insulation&Passivation -Toolbox talk to be conducted
-Fatality
4 -Chemical contact Human E2 -SDS to be followed. E1
-Serious Injury
-Cehimcal inhalation -Proper PPE to be used, mask, goggles, tyvek coveralls etc.

SEVERITY / POSSIBILITY
Medium Possibility High Possibility Very High
INCIDENT/ACCIDENT IMPACT and RISK ASSESSMENT MATRIX Remote Possibility Remote Possibility
Similar Incident Has been occurred Possibility
Has not been Has not been
has been occurred several times on Oftenly Occurred
recorded yet occurred on Sites
on sites sites on sites
Human Environment Property 1 2 3 4 5
No Injury-Near Miss No Impact-Near Miss No Damage-Near Miss
Hazardous Condition Hazardous Condition Hazardous Condition A A1 A2 A3 A4 A5
Low Impact Minor Damage
-Spill -Equipment parts
First Aid
-Medical Treatment
-Local pollution replacement B B1 B2 B3 B4 B5
-No public concern -Short term quickly
-Short term cleaning repair
Medium Damage
Medium Impact
-Equipment parts
-Spill
replacement
-Local pollution
Restircted Work Case
-No public concern
-Medium term C C1 C2 C3 C4 C5
interruption of
-Medium term
equipment usage
cleaning
-Medium term repair
Major Damage
Very high impact -Equipment parts
-Massive Spill replacement
Lost time incident
-Non compliance with -Long term interruption D D1 D2 D3 D4 D5
regulations of equipment usage
-Long term repair
Fatality / Permanent Diability Environmental Extensive Damage E E1 E2 E3 E4 E5
Disaster -Substantial loss of
-Serious public Equipment
concern -Substantial loss of

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-Massive Spill plant/facility

-Non compliance with -Proect shutdown
regulations

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