Mr. M.H. Jeon
Const. SMP
20 Aug 2019
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
Rev. 0
REVISION NOTES AND HOLDS
Revision
Description of Changes &Holds
A
B
0
Issued for Approval
Issued for Approval
Issued for Construction
Holds
Description of Holds
Para No.
Sheet
No.
Rev Date
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
Rev. 0
Table of Contents
1.
INTRODUCTION....................................................................................................................................... 4
1.1
Purpose.......................................................................................................................................... 4
1.2
Scope ............................................................................................................................................. 4
1.3
References .................................................................................................................................... 4
1.4
Definitions ..................................................................................................................................... 4
2.
HEALTH SAFETY AND ENVIRONMENT ................................................................................................ 4
3.
PROCEDURE ........................................................................................................................................... 5
3.1
Material Selection ......................................................................................................................... 5
3.2
Material Identification ................................................................................................................... 6
3.3
Pre-requisite - Permit ................................................................................................................... 6
3.4
WPS/PQR Qualification ................................................................................................................ 6
3.5
Welder Qualification ..................................................................................................................... 7
3.6
Production welding ...................................................................................................................... 7
3.7
Electrode Control ........................................................................................................................ 11
3.8
Final Check .................................................................................................................................. 12
3.9
Transportation and Storage ...................................................................................................... 12
4.
ORGANIZATION CHART ....................................................................................................................... 12
5.
RESPONSIBILITIES ............................................................................................................................... 12
6.
EQUIPMENT ........................................................................................................................................... 14
7.
DOCUMENTATION: ............................................................................................................................... 14
8.
APPENDIX: ............................................................................................................................................. 14
Page 3 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
1.
INTRODUCTION
1.1
Purpose
Rev. 0
The purpose of this Method Statement is to spell out the requirements for welding of off- plot pipe works
in Site prefabrication yard and ensure that the welding operation is performed in accordance with the
code requirements & Company Technical specifications.
1.2
Scope
The scope of this document includes WPS/PQR Qualification, Welder Qualification, Preparation and
Welding of Piping Spools, Consumable Control & Documentation for work requiring jobs in Package
LPIC-EPC-3: NGL Extraction Unit with Off-Site Works & Utilities.
1.3
1.4
References
SP 1177 – Ver.3.0 May-2015
- Specification for Welding of Class 1 Pipelines
API 1104 – 2013
- Welding of Pipelines and Related Facilities
ASME B 31.8
- Gas Transmission and Distribution Piping Systems
F920-QA-SPC-50001-00-GSEC
- Welding Specification for Pipeline at Site
F920-PL-ITP-00001-00-GSEC
- ITP for Pipeline
SP 1208
- Pipeline Construction Specification
F000-CN-PRO-00005-00-GSEC
- Preservation of Material during Construction
F000-PI-SPC-00002-01-GSEC
- Specification of Piping Material
F000-MM-PRO-00001-00-GSEC
- Site Material Control Procedure
F000-QA-PRO-50001-00-GSEC
- Material Identification and Traceability Procedure at Site
F000-HS-PLN-00001-00-GSEC
- HSSE Execution Plan
F000-HS-PLN-00002-00-GSEC
- Site HSSE Plan
Definitions
GA
General Arrangement
MTC Material Test Certificate
MTO Material Take Off
PEFS Process Engineering Flow Scheme
PPE
Personnel Protection Equipment
GTAW Gas Tungsten Arc Welding
2.
FW – Field Weld
MPI - Magnetic Particle Inspection
NDT - Non Destructive Testing
WPS - Welding Procedure Specification
PAM – Portable Arc Monitor
SMAW-Shielded Metal Arc Welding
Health Safety and Environment
During site induction all personnel will be made aware of the Contract familiarization, Accident
Reporting and Site Emergency procedures. These will be adhered to at all times. All personnel shall be
familiarized with the policies and procedures to be followed on projects of this nature.
All personnel will be issued with the necessary PPE and shall wear it at all times on site. Special PPE
will be issued as necessary in the hazardous locations following site induction and or issue of a permit
to work.
Page 4 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
Rev. 0
As each new area of work is approached, the Site Supervisor will hold regular Tool Box Talk meetings
with key personnel and, in particular, machine operators in respect of the works to be executed,
highlighting, the factor of risk likely to be encountered during each specific operation.
All areas of work will be supervised at all times. It will be the responsibility of each Supervisor to
constantly assess the ability of each person both before and during the course of execution with regard
to the individual's capabilities with respect to the work he has been assigned to do, in terms of
experience, competence and most importantly, his ability to complete the work in a safe manner without
incurring risks to himself or third parties. Supervisory charge-hands will be in possession of a set of
documents relating to method of work & associated Hazards.
X-ray Testing shall be fully controlled by the NDT Subcontractor as per their approved Safety
Procedure.
3.
PROCEDURE
3.1
Material Selection
3.1.1
Material
All piping materials shall be conformed to the relevant piping material class specifications on the
isometric drawings and other related documents, if required.
3.1.2
Receiving
Receiving is defined as taking delivery of piping materials from the Company /Contractor with relevant
voucher as per bill of materials. Materials rejected during inspection by subcontractor QC shall be
segregated and tagged with "Rejected" mark to identify prior to repair or return to Contractor.
Subcontractor QC should prepare overage, shortage and damaged report if any.
3.1.3
3.1.4
Handling and Lifting
-
Pipe shall be protected by plastic caps or plywood.
-
Special care shall be taken to protect flange face during handling operations.
-
Lifting shall be done by proper lifting equipment with qualified operators and riggers. All necessary
lifting equipment tools and accessories should pass all safety requirements before use.
-
During transportation, necessary precautions shall be taken to avoid any damages or deterioration
of all piping materials
Material Verification
-
Before fabrication, piping materials should be free of damages, dust dirt corrosion or
contamination.
-
Piping materials shall be verified against the material list on isometric drawing.
-
Identification code on the material corresponding to isometric drawing.
Page 5 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
3.2
Material Identification
3.2.1
Marking
3.2.2
Rev. 0
-
Each spool shall be clearly marked with spool number.
-
All spools shall be marked by proper method which does not result any harmful contamination or
sharp discontinuities and will identify the material until it is installed
Material Identification
Identification marks on piping material shall be maintained until piping is prefabricated. If lengths of pipe
are cut into 2 parts or more, heat numbers and identification code should be transferred prior to cutting
of pipes.
3.2.3
Welding Joint identification.
Welding joints shall be identified by welding joint numbers, welder numbers, fit-up date and welding
date located 50-70mm away from welding seam.
3.2.4
Spool Identification.
-
The spool number marked on prefabricated spool shall be sufficiently large to identify the spool.
-
Tag plate shall be made of aluminum sheets attached to complete fabricated spool and secure by
stainless steel wire.
3.3
Pre-requisite - Permit
3.3.1
Prior to commencing any Welding/Piping work, Mechanical Foreman shall obtain work permit duly
signed by concerned authority were applicable, as per the GS/ORPIC and GPS HSE procedures and
Specifications and shall fully understand and comply with all permit conditions.
3.4
WPS/PQR Qualification
3.4.1
pWPS shall be submitted to GS/ORPIC for approval.
3.4.2
Upon Company approval of the pWPS, welding inspector shall conduct the procedure qualification test
in the presence of Company representative.
3.4.3
The welding inspector shall ensure that:
•
Any field bevels only visual check and for pipe cut backs are checked by visual Inspection after
grinding the bevel end ensures that MT is examined.
•
Material Test certificates, Consumable test certificates & calibration certificates are available.
•
The welding equipment is of correct capacity to produce the welds with range of variables as
specified in the pWPS.
•
Record the variables and attach PAM unit printout.
Page 6 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
•
Rev. 0
Visually check for defects such as cap profile, undercut, arc strikes, excess penetration and
interpret as per specification.
3.4.4
Upon completion of visual inspection (after lapse of 24 hours) and NDT (RT, MPI), the mechanical
tests shall be conducted at Company approved mechanical test laboratory, wherein the tests shall be
conducted in the presence of GS E&C & ORPIC representative. Company shall be notified of test
program in advance so that Company may also arrange for witness. The test coupons shall be
subjected to mechanical test requirements as specified in SP 1177 / API 1104.
3.4.5
Subsequent to successful non-destructive and destructive testing, the original PQR along with
Mechanical Test reports from Test lab showing endorsement and signatures of GPS, the testing
subcontractor, GS E&C and ORPIC, Other
supporting documents such as run records,
Consumable/materials certificates, Calibration certificates shall be submitted for review and approval
by GS E &C & ORPIC.
3.4.6
Upon company approval of above documents, the original records shall be maintained at GPS HO and
controlled copies of WPS approved for Construction shall be distributed as per distribution matrix to
site.
3.5
Welder Qualification
3.5.1
Approved welding procedure specification shall be in place before the start of welder qualification tests.
The welder shall be apprised of WPS requirements.
3.5.2
Each welder shall be assigned a unique ID number. The numbers once assigned to a particular name
shall not be reused for any other person under any circumstances.
3.5.3
Welders shall be selected on the basis of the past experience on off-plot piping works, experienced on
GTAW and SMAW-E7018 for pipe to fitting works and / or by conducting Welder Qualification test.
Additional welders shall be qualified subject to owner approval.
3.5.4
The welders intended to be deployed on fill and cap passes can be qualified on test coupons where
other welder deposits the root pass.
3.5.5
The welding inspector shall:
• Conduct the test in presence of Company’s representative.
• Check and ensure that all parameters as per WPS are followed during welding.
• Record the actual parameters using clamp meter.
• Visually inspect all stages of qualification and present the coupon for company’s approval.
3.5.6
On acceptance of visual inspection, NDT shall be conducted. Subsequent to successful nondestructive testing, supporting documents such as visual inspection report, NDT results, Welder’s
qualification certificate & Welder’s identity card shall be submitted for approval by GS E &C & ORPIC
representative.
3.5.7
Welders shall be issued with qualification cards identifying the WPS numbers. Essential variables for
the welder qualification shall be as per SP 1177/API 1104.
3.6
Production welding
3.6.1
General.

Rust, grease, mill scale or other undesirable foreign material from bevel ends shall be removed by
power brushing at least 25mm on the outside surface and inside pipe surface.
Page 7 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
Rev. 0

Before fit up, pipes shall be checked for any damages such as dents and bevel damages. For bevel
damages between 1 and 3 mm deep, the repair shall be by grinding and for bevel damage depth
greater than 3 mm, the repair shall be by re-beveling. Any bevelled edge that has been damaged shall
be restored to within the tolerances required by the welding procedure to be applied. Restoration
involving welding is not permitted. MPI shall be performed for the cut and re-bevel face for restoration
of pipe. Pipes with laminations or split ends will be subjected to full ultrasonic examination before
partial reuse is considered as per clause 7.4.2. of SP 1177.

Arc burns (arc strike) outside of the weld groove shall not be permitted.

Arc burns caused by a faulty attachment for earthlings shall be removed by careful grinding or filing,
until visible signs of the arc burns are removed.

Welding shall not be used to repair arc burns.

The dressed area shall be blend smoothly into surrounding base metal and shall be examined by
visual inspection and Magnetic Particle Inspection, and if required a UT examination for thickness
check also be engaged.

Repair on the pipes and fittings body by welding shall not be permitted.

Production welding shall be carried out only after relevant WPS is approved for use.

Copy of the approved WPS shall be displayed at the place of work.

Only qualified welders with valid identity cards shall be used on the job.

Welding equipment’s to be used for production welding shall be calibrated with calibrated clamp meter,
and the stickers shall be available on the equipment.

Calibration certificates for equipment’s and instruments shall be available at site/Fab shop.\

Welding Foreman and Inspector/QC Representative shall be responsible to ensure that all pipes,
fittings and welds are fully traceable.
3.6.2
Alignment/ Fit up

If necessary, pipes ends shall be rotated to achieve best possible fit up for welding.

High-low or mismatch during alignment shall be equally distributed around the pipe circumference. The
maximum permitted offset at any point is 3 mm. When joining two pipes of different wall thickness and
where the offset could not be adjusted within 3mm, the ID of the thicker pipe shall be tapered 1:4
(maximum).

Weld separation: The minimum distance between girth welds shall be D. The minimum length of Pup
piece shall be the larger of D or otherwise agreed by GS E&C & ORPIC. There shall be no more than
3 girth welds in any 10M length of pipeline, unless otherwise indicated in AFC drawing.

Weld of branch connections shall be at least 100mm from any girth weld. The minimum distance
between any adjacent welds other than girth welds shall be larger of 4t or 50mm.

Inside diameter of dissimilar thickness material shall be tapered 1:4 by grinding and inspected prior to
welding.

Slight misalignment may be corrected using a bronze headed or other soft faced hammer of mass not
exceeding 5Kg. It shall be ensured that hammering not impinge on the weld area.

Heating shall not be used to correct excessive misalignment.

Pipe Heat nos shall be transferred before cutting of the pipes with crayon/permanent markers.

Field bevel shall be examined by visual examination.

Weld repairs to pipe ends shall not be permitted.

Tack welds shall be deposited by qualified welders using low hydrogen welding consumables in
accordance with the approved Welding Procedure Specification.
Page 8 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
Rev. 0

The joints to be tacked shall be adequately supported.

Lifting of the tack welded joints to be minimized.

If lifting is unavoidable it shall be carefully done and shall be placed on temporary pipe supports or
wooden skids for welding.

The preferred method is bullet tacking. (bridge tacks)

The bridge tack/bullet tack material shall be made from the same base material and shall be removed
as the welding progresses.

All the portable appliances such as angle grinder, pencil grinders shall be inspected and tested
periodically.

Abrasive wheels, guards on the machine also to be checked.

If root tack welds are to be incorporated into the final weld, they shall be at least 25mm long and shall
be thoroughly cleaned and tapered at each ends to ensure complete root continuity.

A minimum of 4 tacks shall be used for diameters greater than 100mm (4”). More tacks may be
provided for diameters greater than 300mm (12”)

If preheat is specified in the WPS, it shall be applied before tack welding.

Preheating shall be applied over a distance equal to three times the wall thickness or 75mm whichever
is greater and shall be maintained until the joint is complete.

Preheating shall be measured at a minimum distance of 75mm (3”) from each edge of the weld bevel
at four circumferential locations, each approximately 900 apart.

Preheating shall be measured on the heated face after 1 minute per 12.7mm of wall thickness.

Preheat temperature shall not exceed the minimum preheat temperature given in the approved WPS
by more than 50°C
3.6.3
Welding.

Welding shall be done by the qualified welders and as per approved welding Procedures.

Welding shall be carried out when the weather/or degree of protection permits satisfactory
workmanship.

Manufacturer, brand and size of the welding electrodes shall be used as the same as approved in
welding procedures.

The requirements of WPS such as parameters, time lapse between passes, preheat, interpass
temperature, pass sequence and the electrode weaving limitations shall be complied with.

All the portable appliances such as angle grinder, pencil grinders shall be inspected and tested
periodically.

Abrasive wheels, guards on the machine also to be checked.

Inter pass temperature shall be measured on the parent material at the edge of the weld bevel near
the weld start location.

The maximum specified inter pass temperature shall not be exceeded from approved WPS.

Normally welds shall be completed by continuous welding.

If the weld interruption is unavoidable, minimum 4 full circumferential passes shall be completed
before interruption.

The pipe area surrounding a branch weld shall be tested for lamination by UT up to a distance of
100mm.

The welds shall be identified in the following manner, and shall be traceable at all stages of the
Fabrication.
Page 9 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
3.6.4
Rev. 0
Inspection and Testing of Production Welds.

Each joint shall be thoroughly cleaned using power driven wire brushes and hand tools following
welding and before inspection, and spatters and extraneous materials shall be removed.

All the joints shall be 100% visual inspected before offering to NDT.

The root bead penetration shall not be exceed 3 mm at any point for joints made of pipe diameter
more than 60.3mm (2” and above). Pipe diameter less than 60.3 mm (below 2”) maximum root
penetration shall be 1.5mm at any point.

NDT method for butt welds shall be radiography with X-ray. If X-ray is impractical then Gamma Ray
can be used with prior approval from Company.
Table – 1 NDT Requirements
Type of
Joint
VT
RT
UT
MPI
Butt Welds
100%
100%
N.A
N.A
Branch Welds
100%
N.A
N.A
100%
Field Bevel
100%
N.A
N.A
N.A
Cut Hole
100%
N.A
100%
*
N.A
Fillet Welds
100%
N.A
N.A
100%
Remarks
* Lamination
check before
cutting up to
100mm around
the cut hole.
Notes:
a) 1 joint of each welder’s production shall be radiographed.
b) Welder’s performance shall be closely monitored and records shall be available.
st
 Acceptance of welds shall be as per section 9 of API 1104 and SP 1177.
3.6.5
Repair Welding

Any repair identified shall be carried out with approved Repair WPS using qualified welders.

The welds identified for repair shall be recorded in the Daily repair list. This list shall be updated daily
to identify the repairs on the previous day production and also the status of pending repairs. A copy of
this report shall be given to the Pipeline Superintendent / Welding Inspector.

Single run repairs and root sealing runs shall not be permitted 150°C preheat shall be done for
materials SYMS>450N/mm2.

The total repair length shall not exceed 40% of total weld length. For partial penetration repairs, the
maximum length of single repair portion shall not exceed 30% of the total weld length. For full
penetration repairs, the maximum length of single repair portion shall not exceed 20% of total weld
length.

MPI and visual Inspection shall be done on the excavated groove to ensure that the defect is
completely removed.
Page 10 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
Rev. 0

The requirements of repair WPS such as parameters, time lapse between passes, preheat, interpass
temperature, pass sequence and the electrode weaving limitations shall be complied with approved
WPS.

A joint can be repaired once only. If the repair could not be removed during the first attempt, the joint
shall be cut and re-welded. However, at situations where it is practically difficult to meet this
requirement, a second attempt of repair may be done at the discretion of Company representative.
3.6.6
Quality Control.

Welding Inspector shall hold current certification to CSWIP, BGAS, PCN or AWS Standards.

Welding Inspectors shall be equipped with Welding Gauge (bridge-cam-gauge), Hi-Lo gauge, root gap
gauge, digital thermometer, clamp meter etc.

Temple stick (Thermal Crayons) for pre-heat assessment and inter pass temperature assessment will
be issued to welders.
3.6.7
Calibration of Equipment’s/Instruments.

All the welding machines shall be having valid calibration and the certificates shall be available for
verification.

Instruments such as Clamp Meter and Digital Thermometer shall be having valid calibration and the
calibration certificates shall be available for verification.
3.7
Electrode Control
3.7.1
Electrodes shall be supplied with the manufacturer’s batch certificates (Type 3.1B or equivalent)
complying with the requirements of SP 1177. Upon receipt at site, the electrodes shall be checked by
physical verification and the certificates shall be reviewed by QAQC for conformance to project specific
requirements.
3.7.2
Electrodes shall be stored in clean and dry conditions in accordance with the manufacturer's
recommendations and in a manner that shall prevent damage. Consumables shall remain in their
original containers, which contain the information of manufacturer’s name, brand name and the batch
number. Different classes of electrodes shall be segregated and stored separately. Storekeeper shall
issue the electrodes on first come first issue basis.
3.7.3
The welding foreman shall be responsible to collect correct electrodes (type and size as per WPS) and
shall ensure that the correct issue is made to each welder.
3.7.4
Electrodes which are wet, rusty or have damaged flux coating or which have been bent or unshaped or
have lost the identification shall not be used for the work.
3.7.5
Low hydrogen electrodes shall be stored and treated prior to use as specified by the manufacturer.
Electrode baking shall be carried out with layers of electrodes not more than 50mm high on each shelf
of the ovens. After baking, the electrodes to be stored in a holding oven at 140° -149º C from where
they shall be issued to heated quivers maintained at 70º C (Minimum).
3.7.6
Welders shall be issued an optimum quantity of electrodes that can be used within a shift. Electrodes
not used within the same working day shall be returned for re-baking. Re-baking is done to the original
baking temperature / time range and the re-baking is allowed once. Marking white dots at the bare end
of electrode shall identify re-baking. Re-baked electrodes shall be issued to welders on priority basis.
Any unused re baked electrodes shall be destroyed/ taken out from the fabrication yard.
Page 11 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
Rev. 0
3.8
Final Check
3.8.1
Spools should be cleaned thoroughly with compress air or rotary brushes to remove all sands, loose
rust and other foreign matters. Protection cover such as plastic caps, plywood should be used on
spool flange face and end of spool to avoid damages during handling period.
3.8.2
End caps shall be taped into the pipe spool to prevent from being removed during transportation and
storage.
3.8.3
After spool completion, Piping shop Engineer should check all relevant spool documentations and
markings (spool numbers, welding joint marked, welder number etc.) prior to delivery to painting spool
yard area.
3.9
Transportation and Storage
3.9.1
Fabricated spools from site prefabrication yard shall be transported to the site location by trailer or
cargo truck. Proper handling equipment (crane, forklift vehicles etc.) should be provided to maintain
and handle all site materials
4.
Organization Chart
Please refer appendix 1
5.
Responsibilities
Designation
5.1
Site Pre-Fabrication
Supervisor.
Responsibilities
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
Ensures correct implementation of the project
drawings, specifications and standards.
Ensures that Foremen and workforce are aware
of the nature of works to be carried out.
Ensures awareness of Hazard and Effect
Management.
Ensures the necessary labour and plant
resources are provided to carry out the work
with required safety standard and in efficient
manner.
Ensures required tools & tackles are available.
Supervises the workforce.
Ensures required tools & tackles are available.
Supervises the workforce.
Ensures that the joint numbers and spool
numbers are marked on Isometrics and clearly
marked on spools.
Is responsible for the safety of personnel
working under him.
Ensures calibrated instruments are used.
Ensures approved welding procedures are
available to cover the full work scope.
Ensures qualified welders only deployed for
welding work.
Ensures that approved WPSs are displayed
nearby location to the welder for reference.
Page 12 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
o)
p)
5.3
5.4
5.5
Welding Engineer
Welding
Foreman/Supervisor
Welding Inspector
a)
b)
QA/QC Engineer
c)
d)
e)
f)
a)
Depute qualified welders for welding
b)
c)
d)
e)
Take care of preheat requirement
Control issue of electrodes
Supervise production welding
prepare daily welding report
a)
b)
Inspect fit up including material identification
Check welding consumables
c)
d)
e)
f)
Check welder qualification
Check preheat requirement
Examine weld visually
Prepare daily welding report for submission to
client.
Offer for NDT and check radiographs.
Recording welding parameters regularly
a)
b)
c)
d)
5.7
HSE
Manager
Adviser/
Ensures required PPE are available for
personnel working under him.
Ensures that the required lifting plans are
prepared and obtained approval well in
advance, and available at work place.
Preparation of PWPS and obtain approval.
Qualification of WPS/PQR as per approved
pWPS.
Obtain approval of PQR & WPS
Ensure all welders are qualified.
Monitor the weld repair rate
Training the welders, if required.
g)
h)
5.6
Rev. 0
a)
b)
c)
d)
e)
f)
g)
Maintain daily records and documentation
Control consumables.
Ensure that all NDT requirements are taken
care of as per specification
Prepare line history sheets, Pipe Book as
applicable
Report to HSE manager/Site construction
manager
Identify the hazards and ensure that the controls
are in place.
Ensure that the PPE is appropriate for the use
of employees with respect to the specified job
hazard
Interacts with the construction manager,
engineers, Supervisor, foremen and labors on
occupational health and hygienic issues.
Advise the plant supervisor regarding noted
defects in vehicle, plant/equipment and monitors
the close out of remedial measures.
Carryout and provide guidance for risk
assessment.
Ensure thatORPIC PTW procedure is complying
Page 13 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
6.
Rev. 0
Equipment
Welding Machines
Compressor
Grinding Machine
Line –up Clamp
Side boom
HF unit for GTAW Welding
7.
Documentation:
Qualified Welder List -
Form No : 150600-QPI-018
Daily Drying and Holding Control Record (Low Hydrogen Electrodes) - Form No : 150600-QPI-019
Welding Material Issue and Return Status - Form No : 150600-QPI-020
Fit-Up Inspection Report - Form No : 150600-QPI-021
Visual Inspection Report - Form No : 150600-QPI-022
Radiographic Examination Report- Form No : 150600-QPI-025
Ultrasonic Examination Report - Form No : 150600-QPI-026
Magnetic Particle Examination Report - Form No : 150600-QPI-027
Liquid Penetrant Examination Report - Form No : 150600-QPI-028
Welder Qualification Test for A/G Piping - Form No : 150600-QPI-035
Welder Identification Card - Form No : 150600-QPI-036
Material request slip –
Material return slip –
Material received record -
8.
Appendix:
Appendix -1– Project Organization Chart
Appendix – 2 - Risk Assessment for Grinding, Cutting & Welding.
Page 14 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
Rev. 0
APPENDIX – 1
(Project Organization Chart)
Page 15 of 16
PROJECT:- Pipe Work Package LPIC-EPC-3-NGL Extraction Unit with off-Site Works & Utilities (Fahud)
PROJECT ORGANISATION CHART
GENERAL MANAGER
N.I. VAHORA
CORP. QA/QC MANAGER
SANJEEVAN
SR. CONTRACTS MANAGER
NAVEEN CHANNA
CORP. HSE MANAGER
P.S. SOLANKI
LEAD QA ENGINEER
RASHEED
CORP. PLANNING
ENGINEER
ANIL VARGHESE
PROJECT MANAGER
ANIL SHRIVASTAVA
PRE-FABR @ COAST
C.R.JHON
DOCUMENT
CONTROLLER
COAST
CONSTRUCTION MANAGER
DHANESH
SITE QAQC ENGINEER
SATHISH
OFFICE ADMIN
NARESH KUMAR
PIPELINE SUPDT
PRAVIN PATEL
HSE MANAGER
SARAVANA BHAVAN
STORE KEEPER
SWARANJITH SINGH
HYDROTEST
ENGINEER
SARAVANAN
INSPECTORS
WELDING - N. RAVI
HSE ADVISOR
IMRAN
PAINT./COAT -SANMUGAM
NDT SUB CONT.
BY GS Engineering
HEAD OFFICE LOGISTICS
T.B.A.
TO BE ADVISED
FOREMAN MECH.
P.V. MURTHY
FOREMAN MECH.
DIDARUL
FOREMAN MECH.
(BENDING)
FOREMAN MECH.
(MADAN)
FOREMAN MECH.
(LOWERING &
TIE-IN) P.V.
FOREMAN MECH.
(PIPING)
FOREMAN (HYDRO TESTING CREW)
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ON
OFF-PLOT PIPING
Doc No. : F000-PI-MST-00001-00-GPST
Rev. 0
APPENDIX – 2
(Risk Assessment for Grinding, Cutting & Welding)
Page 16 of 16
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ONOFF PLOT WELDING
Doc No.:F000-PI-MST-00001-00-GPST
No
1
Activity
Transportation of
Material & Men
Hazard
Consequence
* Condition of vehicle
* Failure of brakes
* Tire Burst / Puncture
* Roll over in case of high
speed in graded road
*Absence of roll over bar
* improper roll over bar
*May lead to accident
* Physical condition of Driver
*Failure to stick to
maintenance schedule
*Over turn
*Over turn while negotiating
corners, falls of load from
vehicle.
* Over speeding
*.Towing of vehicles in case
of break down.
*Drinking alcohol and driving.
*Heat stress.
*Attitude
*lack of training
* Over loading
* Inflammable materials.
*Un secured loads
*Mishandling
*Road& ROW condition
* Exposure to
Smoke/Dust/Fog
*Contact with O H Lines
*Contact with Third parties.
*Contact with Live stock
*Movements of heavy plant
* Hitting / Collision
* Equipments being driven by
untrained personnel.
*Loss of control /Collision,
overturning
*Crash
* Rollover
* Accidents
* Personal Injury
* Property Damage
* Fatality
* Third party
damage
*Hitting OHL
* Electrocution
* Fire
*Loss of assets
L
3
S
3
Effect
A/P
Risk
Rating
12A/P
Rev. 0
FIT UP
Control Measure
*Conduct Tool Box Talk
*Valid ROP Driving license or all Drivers. *Preventive
& proper maintenance for all vehicles
*.RAS Certification of vehicle.
*Daily inspection checklist for all vehicles.
*Daily vehicle checks by driver
Weekly inspections by HSE Advisor.
* Servicing by mechanic.
*All light vehicles to be fitted with roll over bars.
*Tool Box Talk by Journey manager
*Driver shall be minimum of 21 years old.
*Disciplinary action.
*Both the vehicles (the vehicle used for towing & the
vehicle being towed) to be selected properly Proper
rigging. Hazard Light to be switched on while towing
*Monitoring by plant supervisors
*Secure load properly
*Maximum permitted load not to be exceeded
* Hazardous material Follow Proper procedures and
inspection
* Follow Road safety regulations/signs
Material Safety Data Sheets
* Trained personnel to handle
*Erection of goal posts at safe distance and height
*Driver to switch on dipped lights & high intensity lights
* Reduce speed to suit the visibility
*Follow Dust Code
Drive with dipped light
* Driver not to overtake in dust.
* Trained and certified operators to be kept on the
plant / equipment
L
S
Residual
Risk
2
1
2
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ONOFF PLOT WELDING
Doc No.:F000-PI-MST-00001-00-GPST
2
Lifting operation
With Crane & Side
Boom (Offloading,
handling & alignment
of pipes or fittings on
location.
( Whenever Applicable)
*Fall of objects / swinging
load – struck by crane,
*overloading
* Collapse
* Dropping of loads, Caught
in between /Fall/Hit
*Failure of lifting equipment,
* low visibility
* Bad Weather
(Rain/Fog/High Wind)
* Poor visibility and high wind
lead to topple of boom
* uneven surface
* Crane toppling
*poor condition of lifting
gears,
*Loose lifting tackles
*Brake/ cut slip/dropping load
*Incorrect rigging / slinging
and lifting practices
* poor knowledge
*Lifting operation in
congested area
* Hit with other objects /
personnel
*Overhead Power Lines
* Contact with Electricity
* Operator Fatigue /Health
/Attitude
* Loss of concentration lead
to collapse / overturning of
crane
*Miss understanding
Communication between
Crane opt and Riggers
*Personnel injury
*Fall/ Cut/hit Injury
*Topple of crane
* Asset damage
* Fatality
*Electrocution
*fire
3
3
A/P
12A/P
Rev. 0
FIT UP
*Conduct Tool Box Talk
* Obtain a Lifting work permit
* Required Proper signal by trained banks man,
trained riggers, Tag lines, warning signs& barriers
*Ensure proper maintenance and lifting equipment &
certified by third party
* Inspect equipment and tools wire rope, chains slings,
and lifting tools, Sidebar and lifting equipment.
*Ensure SWL & all safety devices are working on
crane.
* Ensure daily operator check list.
* Ensure operator certification
* Proper signals by competent banks man,
Supervision.
* Checking and assessing soil condition, Compaction
and additional load spreader shall be used underneath
outriggers, extended out riggers fully.
* Lifting plan, calculate and ensure load is within limit
and safe to lift, Crane to be fitted with over load alarm,
S.W.L & date of next inspection shall be clearly
marked on crane boom. Operator shall be trained &
physically fit. Barricade the area and restrict
unauthorized entries, Do not walk / stand under
suspended load, Check wind flow.
* Verify that the only the authorized personnel are one
is allowed to carry out the lifting operation and only
one person is allowed to direct the operation and that
the lifting operations is within the sight of the operator.
* All lifting tackles to be inspected and certified by third
party. Physically inspect for wear & tear before every
operation, Trained personnel to select the proper
tackles as per load requirements
* Lifting Equipments / tackles are to be color coded
* Uses tag lines wears
*Avoid crane operation near over head line, Use side
boom
* Required Goal post
*Required Overhead Clearance
* Required Competent Electrical Person
* Operator must be medically fit /Ensure sufficient rest
and physically fit
* Stop lifting operation when visibility is poor and
during high wind. Lower the load to ground level and
secure the crane.
∗Ensure controlled supervision. Ensure correct
2
1
2
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ONOFF PLOT WELDING
Doc No.:F000-PI-MST-00001-00-GPST
3
Hot Work (Cutting,
Grinding, Welding)
*Fire
* Explosion
*Burn
*Extreme Head
*Defective welding equipment
*Electric shock
*Welding spatter
* Hitting personnel / contact
with combustible
*Welding fumes
*Flying particles
*Personnel injury,
*Hand & Fingers,
Eye Injuries,
*Fatality,
*Asset damage.
Personnel health
effect (Breathing
problems, Eye
irritation, Asthma)
*Shock/Burn
*Noise induced
Rev. 0
FIT UP
handling to prevent rolling of pipes.
*Ensure pipes are stacked on skid / sand bags with
proper padding. Insert wooden wedges to avoid
rolling pipes.
*Ensure pipes are stacked at safe distance (Minimum
02 meter) from edge of excavation.
*Ensure all personnel maintain safe distance during
unloading and stacking of pipes.
*Ensure no part of body comes under the pipes. Keep
body parts clear from pinch points.
*Ensure use of PPE such as hard hat, safety glasses,
cotton hand gloves and safety shoes.
*Ensure proper verbal communication between crane
operator, banks man and team.
*Ensure cold drinking water available at site and
people drink plenty of water
*Reduce exposure limit by taking frequent breaks.
*Ensure vehicle with A/C available at site
*Wear ear plug / ear muff at noisy area
Ensure water sprinkling at work location
*Lifting of the tack welded joints to be minimized.
*If Lifting is unavoidable it shall be carefully done and
shall be placed on temporary pipe supports or wooden
skids for welding.
*Obtain a hot work permit
*Conduct tool box talk prior to start the job.
*Mandatory PPE required at all times, PPE (Welding
screen, Leather apron, Cotton coverall, Leather hand
gloves, Hand sleeve and leg sleeve, Safety Shoes),
Full face shield / double eye protection when grinding,
including suitable hearing protection.
* SWP procedures to be followed at all times.
* Only Competitive & Qualified welders with valid
identify cards shall be used for this task.
*Follow safe working practices andprocedures
*Calibration certificates for equipment and instrument
shall be available at site.
* All equipment must be inspected prior to use.
*All equipment, Leads & Hoses shall be checked prior
to use.
* All the portable instruments including angle grinder,
pencil grinders shall be inspected and tested
periodically.
*Abrasive wheels, guards on the machine also to be
checked.
*Proper Earthing of welding equipment, clamps &
rods. Use appliance tested electrical equipment.
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ONOFF PLOT WELDING
Doc No.:F000-PI-MST-00001-00-GPST
* Hot work in oxygen deficient
atmosphere Welding Arc
* Rotating parts (Grinding
wheel)
*Hydrocarbon leakages
during hot work
Live Electric Cable
(Grinding)
* Improper handling, loading /
unloading storage and
transporting gas cylinders.
*Miss handling. Rolling /
hitting/explosion
* Improper electric tools /
damaged cables / hoses.
* Contact with electricity
* Noise & vibration
* Poor housekeeping.
* Trip / slips / falls
hearing loss
Vibration white
fingers
* Hitting personnel /
contact with
combustible
* Electrical Shock
* Fire
* Asset Damaged
2
4
A/P
8A/P
Rev. 0
FIT UP
*Proper Tools with Right RPM Disc
*Fire Watch, Fire blankets and extinguishers available
on site at all times
* Provide guard for protection against flying particles.
* Keep fire protection equipment ready.
Check them for readiness
*Removal of all debris and flammables prior to hot
work.
* Welding shall be carried out when the weather or
degree of protection permits satisfactory at site.
* Electrodes which are wet, rusty, have damaged flux
coating, have been bent, unshaped, or have lost the
identification shall not to be used for this work.
*Good supervision (including HES)
*Good communication at all times
*Awareness of potential pinch points (Hand Gloves)
*Ensure welding hut would be provided with proper
shaded tarpaulins and hot work activities take place in
site it.
*Only competent welder will do the welding activities.
*Don’t put combustible material, gas or liquid form
burning material near the welding activities.
*Erect barriers and sign boards
*Restrict unauthorized entry, Welding booth,
*Reduce exposure limit by frequent breaks or
changing person.
*Ensure enough ventilation by providing one side
opened welding booth to disperse fumes from welding
area.
*Ensure use of welding screen by *welder and crew
members to use black safety glasses.
Perform gas test and continues monitoring.
*PTW in force. Stop hot work if explosive gas is
present.
*Do not use multiple connections from one socket.
* Avoid any illegal cable splicing
*Ensure proper cable management
* Power tools must be equipped with dead man switch
*Prior to use conduct physical
Inspection of grinding machine,
electrical cord and
sockets for its
operational condition.
*Ensure guard available on rotating parts of machine.
*Prior to use inspect the grinding wheel, wheel guard,
tool rest.
*Remove unwanted personnel
Use ear plugs
2
1
2
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ONOFF PLOT WELDING
Doc No.:F000-PI-MST-00001-00-GPST
4
Heat stress
Environmental issues
5
*Extreme
Heat
*Heat stress
* Work in hot
environment at levels in
excess of the
standards.
*Personnel Health
effect
*Nausea
*Giddiness
*Heat Stroke
*Noise
* Loss of hearing
*Dust
*Breathing
Problems
*Biological hazards
* Snake bite
* scorpion sting
*Personnel Health
effect
*Fatality
*Deafness
*Permanent hearing
loss disability
2
3
P
6P
2
3
P
6P
Rev. 0
FIT UP
Cordon of area
* Store Gas cylinders in upright position. Load &
unload gas cylinders properly. Transport them in
trolleys secured with chain.
*Proper handling of compressed gas cylinders must be
observed.*
*Ensure cylinders are secured on gas
Trolley in upright position and chained.
*Gas cylinders are kept at safe distance from hot work
location
Handling of cylinder and cutting by competent
personnel. Do not drag /roll /slide cylinders on ground
*SHOC card should be available according
* Have proper inspection schedules for Electric tools
and cables & If any, rectify immediately.
* Maintain Good Housekeeping.
*Ensure adequate drinking water is available.
*Shaded area to be provided.
*. Ensure Air-conditioned Welfare Facility including Cool
drinking water,
*Frequent break should be provide
*Ensure cold drinking water available at site and
people drink plenty of water
*Reduce exposure limit by taking frequent breaks.
*Ensure vehicle with A/C available at site
* Follow the PTW system.
*Have access to shade work managed to reduce the
potential ill effects
*. Conduct noise monitoring in the area and for the
equipment before induction.
*Appropriate Ear protection
*Wear ear plug / ear muff at noisy area ( if>80 dBA).
* Ensure water sprinkling at work location to reduce
dust formation.
*. Ensure all personnel use PPE (Dust mask,
Balaclava, Hard hat, Safety glasses etc.)
* Stop working in heavy wind & dusty atmosphere.
*. Standby Emergency Vehicle + presence of advance
first aider
* Be vigilant for snakes and other reptiles.
2
1
2
2
1
2
LIWA PLASTICS INDUSTRIES COMPLEX
METHOD STATEMENT FOR FIT UP & WELDING ONOFF PLOT WELDING
Doc No.:F000-PI-MST-00001-00-GPST
*Loose soil,
6
Erection of Platform
*uneven ground
*Unsafe working platform
* Tilting or tripping of scaffold
* Scaffold materials of poor
quality
* Collapse of scaffold
* Scaffold
erection/dismantling by nonqualified persons
* Gaps between planks and
absence of toe-boards
* Falling of tools and
materials
*Poor House-keeping
*Slips/Trips /Falls
*Personnel Injury
*Asset damage
* Damage to
equipment
3
3
A/P
9A/P
Rev. 0
FIT UP
* Ensure the ground is level and firm. *Use base plates
and sole plates
* Ensure all the materials used are without damage
and conform to quality standards
* Means of access and egress should be only through
small ladders or steps
* All scaffolders should be experienced and trained. A
trained scaffold supervisor should supervise the job
and inspect and certify before use.
* Make sure there is no gap between the planks.
Provide toe board
* Guard rails and mid rails should be in place. Safety
harness should be used
*Housekeeping should be carried out in the area
before and after the task. Stack the material properly.
Provide safe passage way.
2
1
2