METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

Method Statement for

Fabrication and Erection of Piping

PROJECT NAME : NPK-500,000 PROJECT

CLIENT : PT. PUPUK ISKANDAR MUDA

CONTRCTOR : PT. PP ( PERSERO ) TBK

DOCUMENT N0 :

ISSUED FOR : APPROVAL

JOB NO :

LOCATION : KRUENG GEUKUEH, NORTH ACEH,

INDONESIA.

0 10-Sep-2021 Issued for Approval Ade

REV. DATE DESCRIPTION PRPD TPI APPD
 METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

INDEX
1. INTRODUCTION

2. DEFINITION

3. APPLICABLE DOCUMENTS

4. SCOPE OF WORK

5. PROCEDURE

6. MATERIALS RECEIVING & STORAGE

7. FABRICATION

8. PIPING ERECTION

9. MECHANICAL CLEARANCE AND PRESSURE TEST

10. INSPECTION AND QUALITY RECORDS

11. SAFETY PROCEDURE

12. ATTACHEMENT: SAMPLE OF WELD MAP

 METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

1) Introduction

The purpose of this method statement is to ensure that the methods and procedures
shall be carried out for the fabrication, erection and testing of piping work as per the
Technical / Contractual specifications of PT. PP ( persero ) tbk

2) Definitions

Project : NPK- 500,000 MTPY Project – Lohksemawe

Contractor : PT. PP (pesero) tbk

Subcontractor : PT. INDO FUJI ENERGI

3) Applicable Documents

3.1 Codes & Standards

ASME B 31.3
ANSI B 16.25
ASME SEC II Part C
ASME SEC IX
ASME SEC V
AWS D 1.1

3.2 Ref. Project Specifications

 METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

4. Scope

The scope of this method statement is limited to fabrication, Erection and Testing
procedures followed for Carbon Steel and Stainless Steel piping.

5. Procedure

The Engineering drawings and documents received from Client shall be clearly
understood to find out the service, material specification, size, thickness, NDT
requirements, pipe routings quantity etc.

Ensure that the documents received bear the stamp “Issued for Construction” and are
of latest revision.

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

6. Materials Receiving and Storage

1) Material Requisition form prepared by supervisor shall be forwarded to the

material controller who shall collect the piping materials as per the piping
specifications and drawings from Consultant, respecting the material issue
procedure of Consultant.
2) Handling and transportation of piping materials shall be done with utmost care
to avoid any damage.
 METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

3) Separate area shall be assigned for the storage of Carbon Steel and Stainless
Steel piping materials. Pipes shall be stored in open area resting on wooden
sleepers and small pipe fittings, bolts, nuts, and gaskets shall be stored in
shelved containers. Storage & issue procedure of piping materials shall be in
time with the requirements of Consultant.
4) Documents shall be maintained by the material controller till the end of the
project.

7. Pre – Fabrication

7.1 Replacement

1) Determine the safe location on the Rejected Fittings to start the cutting
and remove the cut items to scrap area by safely procedure.
2) Select the proper cut method either flame cut or cut machine.

7.2 Cutting and Beveling

1) Pre-fabrication of Carbon Steel and Stainless Steel Pipes shall be done in

separate fabrication ways.
2) Proceed with cutting of pipes, edge preparation, joint alignment, and fit-ups
as per the WPS.
3) The edge cleaning and beveling shall be done using abrasive grinding disc/
beveling machines.
4) Line Number, Spool Numbers, and Joint Numbers are to be clearly
identified and marked on the spools with the welder identification for
each joint.

7.3 Fit – Up and Tack Welding

 METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

1) Fit-up assembly shall be carried out by using locally prepared couplers.

All the required pipe holding work benches, assembling brackets, ‘U’
bolts etc. would be made in house to suit the pipe sizes.
2) For butt welds a uniform root opening as specified below shall be
maintained.
1.5 mm for pipe diameters < 50 mm
1.5 / 2.5 mm for pipe diameters 50 mm to 250 mm.
2.5 / 3.5 mm for pipe diameters > 250 mm
3) For all socket weld joints the pipe end shall be free from cutting burrs. A
clearance of 1.6 mm shall be provided between the end of pipe and
bottom of socket.
4) Internal misalignment shall be limited to
1.6 mm for pipe diameter 24” and below.
3.2 mm for pipe diameter 26” and above.
5) The pipes shall be tack welded in three equidistant positions. Tack Weld
shall be done as per approved WPS by a qualified welder.

7.4 Welding

1) Welding procedures and welders shall be qualified as per Project

Specifications and relevant codes, prior to start of the welding.
2) Ensure that the edges are free from dirt, rust, oil, grease, paint etc.
3) Welding shall be done as per approved WPS for the particular piping. Pre
heating and welding consumable shall be checked before starting of
welding.
4) Each weld layer shall be cleaned before starting to weld next layer. The
cleaned area shall be free from slags. Any visual defects like cracks,
 METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

pores, spatters weld shall be removed by grinding before the next layer is
applied. The ends of weld layer shall be removed by grinding at tack
points of each weld. Any possible weld excess layer will be removed by
grinding.
5) For the fabrication & welding of Stainless Steel pipes, only Stainless Steel
tools & consumables (Wire Brush Chipping, Hammer, and Abrasive
disc) shall be used.
6) Appearance of finished weld shall be as even as possible and free from
spatter, under cutting, cracks, excess reinforcement etc.

7.5 Non Destructive Examination

1) The extent of NDT will be in accordance with Project General Specification

for different piping systems. The acceptance criteria shall be in accordance
with ASME B 31.3.
2) Welding record shall be maintained with proper identification of joint,
welder etc. for all joints.
3) NDT shall be carried out as per approved procedure and the results shall be
recorded properly.

8. Piping Erection

1) Fabricated spools shall be identified by spool and line numbers before and after
priming.
2) Care shall be taken while handling and stacking of spools to prevent any
possible damage.
3) Open ends of spools shall be covered by caps after thorough cleaning.
 METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

4) Erection of spools shall be carried out area by area as per piping layout drawing
and Isometric drawings.
5) Scaffolding and temporary platforms shall be arranged to carry out fit up and
welding of field joints at elevated positions.
6) Fabricated spools shall be shifted to site carefully as per daily erection plan.
7) Before erection of spools ensure for inside cleaning of the spools and their
items.
8) Erect the spools in position using crane or other lifting devices as per the
drawings.
9) Supports to be welded on to the pipe (shoes or saddles) shall be done before
erection.
10) Check the pipe supports details in the piping layout drawings and Isometric
drawing for location and type of supports.
11) Install the pre-fabricated supports as per drawings.
12) Joints shall be aligned and complete the fit-up / welding as per applicable WPS.
13) NDT and other inspection shall be completed for the field joints and recorded
properly.
9. Mechanical Clearance, Inspection & Pressure Testing

1) Identify the test loops for the completed line system wise.
2) Upon obtaining mechanical clearance, Hydrotest shall be carried out as per
project specification.
3) Arrange for Hydrotest Pump, Calibrated Pressure Gauges, Test medium (Water)
etc.
4) Blind flanges shall be installed on all required locations and items which are not
to be included in pressure testing, shall be isolated.
 METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

5) Water shall be filled and vented properly before pressurising.

6) Line shall be pressurized to the required pressure of that piping class and hold
the pressure till the inspection is completed.
7) Pressure Test shall be witnessed by contractor representative.
8) On satisfactory completion of test, pressure shall be released and line is to
drained off completely.
9) Reinstate the line with all the permanent items and remove all the blinds.

10) Inspection and Quality Records

Inspection, Testing and Recording shall be in accordance with the approved

Inspection & Test Plan.

11. Safety Procedure

Prefabrication and Erection of Piping and Pipe Supports.

Equipment and tools

1) Portable cranes, column cranes.

2) Scaffoldings
3) Small items (lifting jacks, slings, chain block, D-shackles, etc.)
4) Oxygen Acetylene Cutting, Portable Power Tools, and Welding units.

Safety Measures

Protective Clothing

1) Helmet
2) Gloves
3) Safety shoes
4) Full Body Safety Harness
5) Face shields
 METHODE STATEMENT FOT FABRICATION AND ERICTION OF PIPING

Accident Prevention Safety Procedures

1) Area shall be barricaded adequately with warning barriers prior to any lift.
2) All Equipment shall be checked for good conditions before commencing the work.
3) Unauthorized persons shall be excluded from the area.
4) When lifting, the personnel shall not remain in the lifting equipment work area.
5) Adequate caution boards and warning signs shall be provided.

6) Only trained and authorized personnel shall operate the hydraulic lift.
7) Observance of the lifting equipment capacity.
8) Electrical installations and equipment shall conform to standards.
9) Application, maintainence, storage of electric, and oxygen cutting welding units
shall conform to applicable standards.
10) Do not stand under suspended loads.
11) On Completion of job, the area shall be cleared of any materials and kept clean
and tidy.
12) Hazard analysis for hazardous operation shall be carried out prior to commencing
the works.