IWSS P2 - Method Statement For Internal Welding (Commented)

CADANGAN PAIP AIR UTAMA DARI TANGKI IMBANG BUKIT ENGGANG, LOJI RAWATAN AIR LANGAT 2 KE SAMBUNGAN
PAIP DI JALAN BARU, KAJANG DI MUKIM KAJANG, DAERAH HULU LANGAT, SELANGOR DARUL EHSAN. – PACKAGE 2
(JALAN SUNGAI LONG KE JALAN SUNGAI S.M.A.P.)
METHOD STATEMENT FOR INTERNAL PIPE WELDING
CADANGAN PAIP AIR UTAMA DARI TANGKI IMBANG BUKIT

ENGGANG, LOJI RAWATAN AIR LANGAT 2 KE SAMBUNGAN
PAIP DI JALAN BARU, KAJANG DI MUKIM KAJANG, DAERAH
HULU LANGAT, SELANGOR DARUL EHSAN. – PACKAGE 2
(JALAN SUNGAI LONG KE JALAN S.M.A.P.)
METHOD STATEMENT FOR INTERNAL PIPE

WELDING
The content of this procedure is the proprietary and confidential information of BUMIRAYA SETIA SDN BHD (BSSB) and as such shall not be
copied or reprouced in any manner without the written consent of the Managing Director of the company
TABLE OF CONTENT
1.0 INTRODUCTION ................................................................................................... 3
1.1 Objectives........................................................................................................... 3
1.2 Site Location ....................................................................................................... 3
1.3 Working Time...................................................................................................... 3
2.0 SCOPE OF WORKS ............................................................................................. 4
2.1 General Description ............................................................................................ 4
2.2 Welding Method.................................................................................................. 4
3.0 SAFETY AND HEALTH ......................................................................................... 6
3.1 Job Safety & Health Analysis.............................................................................. 6
3.2 Environmental Issues ......................................................................................... 7
3.3 Quality Assurance & Quality Control................................................................... 7

1.0 INTRODUCTION
General
The method of statement for internal pipe welding is for “Cadangan Paip Air Utama Dari
Tangki Imbang Bukit Enggang, Loji Rawatan Air Langat 2 Ke Sambungan Paip Di Jalan
Baru Kajang Di Mukim Kajang, Daerah Hulu Langat, Selangor Darul Ehsan – Package 2
Jalan Sungai Long Ke Jalan Sungai Sekamat”
1.1 Objectives
The objectives of this Method Statement on Pipes installation are listed below:-
a) Outline the procedure that will be adopted for internal pipe welding for 2000mm
dia. Composite Pipe.
b) Understand the requirements to perform the above work safely.
c) For approval by the SO/Project Consultant.
This method statement shall not be deemed as conclusive nor shall it be regarded as a
replacement of the original design and is solely proposed without prejudice.
1.2 Site Location
Site is located at Taman Rakan and Lebuhraya SILK, Kajang Selangor.
1.3 Working Time
Site activity is from 0800 hours till 1700 hours daily except Sunday. No activities will be
held during national public holiday accept with permission by Local Authorities. Actual
working hours is subject to Local Authorities approved work permit. Additional working
hours if required.

2.0 SCOPE OF WORKS
2.1 General Description
This Method Statement intends to outline the procedure that will be adopted for the
internal pipe welding of 2000mm dia. Composite Pipe or Reinforced Concrete Jacking
Pipe (RCJP).The 2000mm dia. pipeline shall serve as water pipe crossing the main road
which form part of the new water supply system.
2.2 Welding Method
2.2.1 Making of welded joint

i. The welding personnel and welding certificates shall be submitted to S.O for his
approval. Only qualified welders shall be allowed to carry out all welding works
at site. The welders shall be identified through authorized welder identification
tags.
ii. Each joint will require a internal split collar consist of 4 pieces of plate which is
15.7 mm thick and 250 mm wide. On the 250 mm wide side, the plate shall be
cut/grind to form a beveled butt joint. The portion of the internal split collar and
composite pipe to be welded shall be cleaned. The surfaces to be welded shall
be smooth, uniform and free from tears, scale, slag, grease, paint and other
materials that might affect the quality of welding.
iii. The welder shall make test specimen with the same material and thickness of
the pipelines to be welded. The joints shall be tested in the presence of the S.O.
All welded joints shall be visually examined. All undercutting shall be repaired
and reinspected. Fillet weld shall be checked for surface defects.
iv. The process of welding is using shielded metal arc welding (SMAW) and the
type of welded rod to be used is Kobelco MS 6013 with dimension of 4.0mm.
Welding of steel pipes shall be internal only for concrete cladded pipe.
v. The weld shall be of the convex full fillet type for lap welded joints made
manually by the metal arc process using approved type of electrodes. Each time

the arc is started shall be manipulated to obtain complete fusion of the weld
metal with the pipe and any deposited weld metal. Before welding over any
previously deposited metal all slag shall be completely removed and the weld
metal shall be cleaned by wire brushing.
2.2.2 Making for Grouting Void between the Internal Split of Composite Pipe
i. Upon completion of welding works, 8 mm holes shall be drilled at the lowest

point and the highest point of the internal split collar.
ii. A seam socket shall be welded on to the bottom of the hole and shall be fitted
with the grouting hose.
iii.
iv. Grout shall be pump from the bottom of the internal split collar and shall stop
once the grout is seen coming out from the top hole.
v.
vi. After the grouting work is completed the seam collar shall be removed and shall
be welded to seal of the hole.
2.2.3 Completion of internal cement lining.

i. The steel exposed by the gap in the internal lining, together with the adjacent
lining shall be thoroughly cleaned and wire brushed. The adjacent lining shall be
wetted with thick cement slurry. The water cement ratio is between 0.30:1 and
0.45:1.
ii. The internal cement lining shall be applied in layers to ensure a smooth
continuous lining throughout the pipeline. Any convex or concave surface shall
be subjected to further repair. The Engineer shall check the final surface finishing.

3.0 SAFETY AND HEALTH
3.1 Job Safety & Health Analysis
The following personal protective equipment shall be worn at all times during the working
site:-
a) Safety helmet
b) Safety vest
c) Safety shoes
d) Welding gloves
e) Welding mask
In addition to the control measures proposed in above, additional safety measures shall
be put in place at the project site and these include:-
a) Barricades, Guards and Safety Provisions – Adequate barricades, construction

signage, torches, red lanterns and guards shall be placed as required and maintained
during the progress of the construction work. This is important to protect public from
injury and to avoid property damage.
b) Structure Protection – Temporary support, adequate protection and maintenance of
all underground and surface structures, drains, sewers and other obstructions
encountered in the progress of the work shall be furnished and under the direction of
the Resident Engineer. Any structures that have been disturbed shall be restored
upon completion of the work.
Protection of Surface Structures – Trees, shrubbery, fences, poles and all otherproperty
and surface structures shall be protected unless their removal is shown onthe drawings
or authorized by the Authorities. When it is necessary to cutroots or tree branches, such
cutting shall be done under the direction and in consultation with the Local Authorities.

3.2 Environmental Issues
The environmental aspects that relate to the pipe laying work and their respective
mitigation measures are as follow:-
a) In relation to site condition and drainage system, proper silt trap shall be prepared
before commencement of the work.
b) All opened surfaces of excavation shall be kept covered with a canvas to prevent
surface runoff during a downpour.
c) All excavated soil shall be contained in a dump container and before carting them off
site to approved disposal tip.
d) In the event of any spillage of diesel onto the ground, an earth bund shall be
constructed around the spillage area to contain the spillage. Sand shall then be used
to absorb the spilled diesel and swept away thereafter.
e) All noise activities near residential area shall be restricted to the approved working
hours by local authorities.
f) Temporary drainage to be provided wherever necessary.
3.3 Quality Assurance & Quality Control
The quality assurance requirements for this project shall be adhered to through the use
and recording of the following documents: -
a) Request for Inspection (RFI)

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CADANGAN PAIP AIR UTAMA DARI TANGKI IMBANG BUKIT ENGGANG, LOJI RAWATAN AIR LANGAT 2 KE SAMBUNGAN

METHOD STATEMENT FOR INTERNAL PIPE WELDING

CADANGAN PAIP AIR UTAMA DARI TANGKI IMBANG BUKIT

METHOD STATEMENT FOR INTERNAL PIPE

METHOD STATEMENT FOR INTERNAL PIPE WELDING

1.0 INTRODUCTION ................................................................................................... 3

1.2 Site Location ....................................................................................................... 3

1.3 Working Time...................................................................................................... 3

2.0 SCOPE OF WORKS ............................................................................................. 4

2.1 General Description ............................................................................................ 4

2.2 Welding Method.................................................................................................. 4

3.0 SAFETY AND HEALTH ......................................................................................... 6

3.1 Job Safety & Health Analysis.............................................................................. 6

3.2 Environmental Issues ......................................................................................... 7

3.3 Quality Assurance & Quality Control................................................................... 7

METHOD STATEMENT FOR INTERNAL PIPE WELDING

1.2 Site Location

Site is located at Taman Rakan and Lebuhraya SILK, Kajang Selangor.

1.3 Working Time

METHOD STATEMENT FOR INTERNAL PIPE WELDING

2.1 General Description

2.2 Welding Method

2.2.1 Making of welded joint

METHOD STATEMENT FOR INTERNAL PIPE WELDING

i. Upon completion of welding works, 8 mm holes shall be drilled at the lowest

2.2.3 Completion of internal cement lining.

METHOD STATEMENT FOR INTERNAL PIPE WELDING

3.1 Job Safety & Health Analysis

a) Barricades, Guards and Safety Provisions – Adequate barricades, construction

METHOD STATEMENT FOR INTERNAL PIPE WELDING

3.3 Quality Assurance & Quality Control

a) Request for Inspection (RFI)

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