Method Statement No : A008-MS-PIP-001 Issue: A6

Al RushaidConstruction Co., Ltd.

AL RUSHAID CONSTRUCTION CO. LTD.

Method Statement

Project – JUPC ETHYLENE PLANT PROJECT

Document Title:

METHOD STATEMENT FOR INSTALLATION OF PIPES AT PIPE RACK

APPROVED FOR CPL BY:

DISCIPLINE QA/QC SAFETY CM Rev

A6
ARCC/EE/ ISSUE STATUS

Revised as per UNITED

A6 ANDM 16-Nov-03 EVC / FPS MTMagno
Comment
Revised as per UNITED
A5 EMA / CAZ 20-Feb-03 EVC / FPS 20-Feb-03 MTMagno 21-Feb-03
Comments
Revised Incorporating ITP
A4 Items and UNITED EMA / CAZ 04-Feb-03 EVC / FPS 04-Feb-03 MTMagno 04-Feb-03
Comments
Revised as per UNITED
A3 EMA / CAZ 18-Jan-03 FPSawal 18-Jan-03 MTMagno 18-Jan-03
Comments
Revised as per CPL
A2 EMA / CAZ 29-Dec-02 FPSawal 29-Dec-02 MTMagno 29-Dec-02
Comments
Revised as per CPL
A1 EVCanoy 25-Dec-02 FPSawal 25-Dec-02 MTMagno 25-Dec-02
Comments
A0 Issued for Approval EVCanoy 10-Nov-02 FPSawal 10-Nov-02 MTMagno 10-Nov-02
Issue Date
Issue or Revision Description Origin By Date Checked By Date Approved By
Rev.

METHOD STATEMENT FOR INSTALLATION OF PIPES AT PIPE RACK Page 1 of 8

 Method Statement No : A008-MS-PIP-001 Issue: A6
Al RushaidConstruction Co., Ltd.

TABLE OF CONTENTS

Page
1 PURPOSE 3

2 SCOPE 3

3 REFERENCES 3

4 EQUIPMENT 3

5 MANPOWER 3

6 GENERAL PREPARATORY WORKS 4

7 WORK EXECUTION PROCEDURE 5

8 SAFETY CONSIDERATIONS 7

9 ATTACHMENTS 8

Notes:
1.0 The latest revised documents shall always be used.
2.0 Any conflict between this method statement and the CPL procedure, the CPL procedure
shall be followed

METHOD STATEMENT FOR INSTALLATION OF PIPES AT PIPE RACK Page 2 of 8

 Method Statement No : A008-MS-PIP-001 Issue: A6
Al RushaidConstruction Co., Ltd.

1.0 PURPOSE
This method statement will serve as a minimum guideline to carry out and complete the pipe
installation works at pipe racks.

2.0 SCOPE
This procedure will cover the random pipes & pipe spools installation at piperack.

3.0 REFERENCES
3.1 00-P-0036 Specification For Field Fabrication And Erection
3.2 00-P-0034 Specification for Acceptance Criteria - Flange Face
3.3 00-P-0031 Specification for Piping Traceability and Certification
3.4 00-W-0001 General Welding / NDE Specification for Pressure
Retaining Components
3.5 00-W-0003 General Welding / NDE Specifications for Piping,
Shop/Field Fabrication
3.6 00-Z-0004 Specification for Shop Preparation of Equipment and
Materials for Shipment
3.7 10-Z-0104 Positive Material Identification (PMI) Procedure (by
CPL)
3.8 ASME B 31.3 Process Piping
3.9 A008-ITP-P001 Inspection and Test Plan for
Installation of ASME B31.1 / B31.3 Piping (Site)
3.10 Relevant Project WPS
A6 3.11 A008-MS-PIP-011 Method Statement for Pressure Testing

4.0 EQUIPMENT
4.1 Mobile Cranes
4.2 Air Compressors
4.3 Welding Machines
4.4 Pneumatic Winch
4.5 Manlifts
4.6 Lifting Accessories
4.7 Rubber Lined Rollers
4.8 Hand Tools and Fixtures as required

5.0 MANPOWER
5.1 Field Superintendent
5.2 Field Supervisor

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 Method Statement No : A008-MS-PIP-001 Issue: A6
Al RushaidConstruction Co., Ltd.

5.3 Foreman Rigger

5.4 Foreman Piping
5.5 Rigger
5.6 Pipe Fitter
5.7 Permit Receiver
5.8 Fire Watcher
5.9 Scaffolder
5.10 Helper
5.11 Crane Operator
5.12 Welders
5.13 Mechanic Tender
5.14 Manlift Operator
5.15 Safety Engineer

6.0 GENERAL PREPARATORY WORKS

6.1 Pipe rack section(s) should first be turned over for pipe installation. Secure work transfer
form from structural group.
6.2 Leave out sections of steel structure should be clear of obstructions to position the crane.
Ground where the crane will be positioned shall be stabilized.
6.3 The delivered spools, random length, and other materials for erection shall be verified and
checked as follows;
6.3.1 Verify piping materials meet acceptance criteria as per Spec No. 00-Z-0004
Sect. 6.4.1, 6.4.2 and 6.4.3
6.3.2 Alloy materials must have the proper markings as per Spec. No. 00-P-0036
Sect. 6.1 para. 6.1.2. Related documents attesting PMI of the alloy materials
should also be available.
6.3.3 Review spool fabrication package and checked requirements for erection
including NDT, painting, heat treatment, cleaning, PMI documentation &
marking, etc.
6.3.4 Check material against ISO bill of materials and record as per Spec. No. 00-P-
0036 Sect. 10.1
6.4 Scaffolding and access to it are ready for use. Major pipe rack will be provided with mat
type scaffolds at elevations where most work will be done. Others will be scaffolded
individually at works location.
6.5 Manpower, equipment, tools and other logistics are ready and prepared for installation.
6.6 Provide working platform at leave out section(s) to do initial double ended welding of
random pipe to make 22 meter length(s) appropriate for pulling the pipe from roller to
roller
6.7 Lifeline to be provided for full length of working platform.

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 Method Statement No : A008-MS-PIP-001 Issue: A6
Al RushaidConstruction Co., Ltd.

7.0 WORK EXECUTION PROCEDURES

7.1 Pipes will be loaded using cranes into the ladder type loading rack at the end of the
piperack, see attached drawing for reference. The ladder type loading rack will first be
installed at elevation 0000 up to elevation 10.5000. Once the erection of pipes at this
level is complete additional ladder type loading rack will be installed for the next upper
elevation. Additional hanging scaffold with access walkway will be installed for fit-up
and full welding of pipe joints and supports not accessible by the hanging mat scaffold
(see attached Access Walkway Platform and Hanging Scaffold drawing for reference).
7.2 Install, align and fix the roller assemblies at rack beams. Rubber lined rollers will be
employed primarily to move random lengths along the racks.
7.3 Install an air winch complete with pull cable. The winch will be used to pull the pipes
from loading end, along the rollers, and to its final location.
7.4 Cranes will pick up the pipes either directly from trailers or from temporary lay down
nearby the pipe rack.
7.5 Pipes will be lifted by cranes using correct nylon slings and will be rig to position at
rollers in working platform.
7.6 Welding together of 5.5m random lengths to make 11m, can be done optionally at
ground level. 11m randoms can be welded together to make 22m length at working
platform.
7.7 Once the pipe is initially positioned at rollers (at two spans), hook the pipe to air winch
through a pull cable. A special hook attachment will be used so as not to damage bevel
at pipe ends.
7.8 While the pipe is being pulled, a watcher will check the travel of pipe such that it will
safely and correctly ride the succeeding rollers. A signaling system for safe execution
and control of pulling will be employed.
7.9 Once the length of pipe reaches its destination, it will be remove from rollers using
chain blocks.
7.10 Succeeding pipe lengths will be brought to its designated position as per steps 7.5 to
7.8.
7.11 Pipe spools such as expansion loops, branch take-offs, others will be placed directly in
position using cranes and/or chain blocks where required. Fit up and welding of spooled
pieces will be done in place utilizing the mat type scaffold or localized scaffold. Use of
scaffolds should be guided by United Jobsite Bulletin No. JB-100 Adjustable Pipe
Supports on Scaffolding.
7.12 For pipelines without attachments; a double-ended welding execution will be adopted-
i.e. the first two random length rigged to position will be fitted up and full welded
together. The succeeding lengths will be installed in the same manner. The double-
ended lengths are then welded together until the entire run is completed.
7.13 Prior to full welding works check the fitted-up spool / pipe joint for the following;
7.15.1 The surface clean as per Spec no. 00-W-0001 Sect. 2.5.3 item 2.5.3.1 and
2.5.3.4

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 Method Statement No : A008-MS-PIP-001 Issue: A6
Al RushaidConstruction Co., Ltd.

7.15.2 The weld joint, bevel angle, root opening and alignment is in accordance
with Spec. no. 00-W-0001 Sect. 2.5.2 and approved WPS.
7.15.3 The flange face free from damage and scratches. Refer to Table 1 of Spec.
00-P-0034 for the acceptance criteria.
7.15.4 The weld seam is staggered as per Spec. No. 00-P-0036 Sect. 10.5
7.15.5 The 6mm vent hole in reinforcing pad is provided as per Spec. No. 00-P-
0036 Sect. 9.3.3 para. (c).
7.15.6 The gap for socket welding is in accordance with the Spec. No. 00-P-0036
Sect. 10.6
7.15.7 The welding consumables to be used is in accordance with the approved
WPS and Spec. No. 00-W-0001 Sect. 2.4.1 & 2.4.2.
7.14 Submit request for inspection of the fitted spool / pipe.
7.15 When the fit-up is accepted proceed full welding of the pipe / spool. Welding process
used shall be as per approved WPS and the welder is qualified for the said WPS and
documents such as WPS and WPQR should be made available as per Spec. No. 00-
W-0001 Sect. 2.2 and 2.3 and hanged on the work area.
7.16 During the welding process the in-process inspection will be done verifying the following
items;
7.16.1 The Welding consumables used is in accordance with the approved WPS and
Spec. No. 00-W-0001 Sect. 2.4.1. & 2.4.2.
7.16.2 The required pre-heating / inter-pass temperature requirements is done as per
approved WPS and Spec. No. 00-P-0036 Sect. 9.1.3.
7.16.3 Purged requirement, as applicable, is being maintained as per approved WPS
and Spec. No. 00-W-0001 Sect. 2.5.8 para. 2.5.8.2 (b).
7.17 When the welding is completed visual inspection will be done checking the following
items, as applicable;
7.17.1 Inside surface of orifice flanges welded joints is ground or machined smooth as
per Spec. No. 00-P-0036 Sect. 10.4.
7.17.2 Threaded joints checked for fit and roundness as per Spec. No. 00-P-0036
Sect. 10.7
7.17.3 Weld surface reinforcement in accordance with ASME B31.3 Table 341.3.2
7.17.4 Dimension of fillet weld in accordance with ASME B31.3 Figure 328.5.2B and
328.5.4D.
7.17.5 The root pass in accordance with ASME B31.3 Table 341.3.2 and Spec. No.
00-P-0036 Sect. 10.8
7.17.6 Arc strikes in areas in areas not covered by the finished weld is ground as per
Spec. No. 00-W-0001 Sect. 2.5.5 para. 2.5.5.4.
7.17.7 Temporary materials used are already removed as per Spec. No. 00-W-0001
Section 2.5.5 para. 2.5.5.4.
7.17.8 Cleanliness of pipe shall be maintained as per Spec. No. 00-W-0001 Sect.
2.7.1 para. 2.7.1.2. The weld spatter, slag, flux, and other foreign materials
are removed.

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 Method Statement No : A008-MS-PIP-001 Issue: A6
Al RushaidConstruction Co., Ltd.

7.18 The welder’s ID, weld no., and line no. will be marked with metal marker on the pipe
next to the weld. In addition the heat no. will be marked with low stress die stamp.
A6 7.19 For Golden joint, welding shall be as per A008-MS-PIP-011, Method Statement for
Pressure Testing.
7.20 The completed weld will be subjected to the required NDE as per Spec. No. 00-W-0003
Sect. 2.4. PMI as required shall be conducted in accordance with Spec. No. 10-Z-0104
Section 5.0, 5.2 and Table 1,2,& 3. “AV” shall be marked on the longitudinal surface of
the pipe 75mm away from the weld joints to denotes PMI acceptance. Hardness test as
required on some joints shall also be conducted and in accordance with Spec. No. 00-
W-0001 Sect. 2.6 and Spec. No. 00-P-0036 Sect. Sect. 11.7. Note that hardness test on
some joints requiring PWHT shall be done after the completion of PWHT.
7.21 Rejected weld will be repaired and will again undergo visual inspection as per item 7.17
above and required NDE as per item 7.19 above.
7.22 PWHT as required on some weld will be done after the weld pass the NDE
requirements.
7.23 Tightening of bolts shall be done in sequence to produce even compression and
uniform bolt loads as required in Spec. No. 00-P-0036 Sect. 10.3.2. Torque wrench use
shall be calibrated daily as required in Spec. No. 00-P-0036 Sect. 10.3.4. When using
stud tensioner the manufacturer procedure must be followed as specified in Spec. No.
00-P-0036 Sect. 10.3.6. The bolt used shall be checked for conformance with the
specifications.
7.24 For pipelines with shoes, saddles, others; these attachments will be tacked welded to
the pipe after being rigged to position. Shoes and saddle shall be positioned such that it
will align and rest properly at beams or supports. Prior to full welding the alignment,
location, and orientation must be checked and verified with the IFC drawings. The
supports used should be in accordance with the IFC drawing. PMI, if required, for
supports directly weld to alloy pipes shall also be conducted.
7.25 Pipe stoppers and guides will be full welded and painted while still accessible.
7.26 At interconnecting pipe racks, the same roller system will be utilized where new steel
works is installed and when there are no obstructions. Other areas will utilize cranes or
manual rigging method (sticking-out method) to directly install the spools and straight
lengths into position (see attached drawing for reference).
7.27 Prior to closure of piping sections, full compliance with cleanliness inspections and
documentation shall be insured in accordance with Spec. No. 00-P0036 Section 12
para. 12.2 and 12.3.

8 SAFETY PRECAUTIONS
8.1 Obtain the approval of the work permit from the concerned CPL/JUPC Department
before starting any work.
8.2 Fire Watcher with Fire Extinguisher shall be at work area whenever there is hot work.
8.3 All electrical tools shall be checked and color coded.

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 Method Statement No : A008-MS-PIP-001 Issue: A6
Al RushaidConstruction Co., Ltd.

8.4 Continuous monitoring and inspection shall be implemented to detect and correct unsafe
practices while performing the work activities.
8.5 Provide warning sign and sufficient barricade on working area and only assigned
personnel will be allowed in the area.
8.6 Welding location shall be enclosed with wind barrier and provided with non-asbestos fire
blanket to prevent spread of any welding sparks.
8.7 Safety Officer shall monitor the work activities to help and to protect all assigned workers
against exposure to safety hazards. He shall ensure that Personnel Protection
Equipment (PPE’s) are supplied and used and comply with CPL/JUPC applicable
general instruction and standards.
8.8 Safety harness with double lanyards shall be used all the time when working at elevated
temporary platforms.
8.9 Manlift users shall be trained and certified to operate and use the equipment.

9 ATTACHMENTS

A Installation Using Rollers 1 sht

B Pipe Roller Sketch 1 sht
C Pipe Clamp Details 1 sht
D Scaffolding Plan for Main Piperack Pipeloading 3 sht
E Design Calculation of Scaffold for Main Pipe Loading at Piperack 30 sht
F Access Walkway Platform and Hanging Scaffold 6 sht
Deleted, Incorporated in
G Design Calculation of Access Tower Scaffold 8 sht A008-MS-SCAFF-001
H Typical Elevation of Tubular Truss for Piperack 1 sht
I Design Calculation Tubular Truss 12 sht
J Typical Scaffold Connection Detail 1 sht Deleted, Incorporated in
K Design Calculation Sheet for Coupler and Vertical Tube 1 sht A008-MS-SCAFF-001

L Typical Installation using Sticking-out Method 2 sht

M Indicative Crane Position for Piping Erection 2 sht
N Job Hazards and Risk Analysis 4 sht
O A008-ITP-P001 - Inspection and Test Plan for Installation of 18 sht
Piping (Site)

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