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EPC CONTRACTOR:
PROJECT:
30-99-90-1619
Rev.0
PAGE:
of
21
DATE:
03/08/2008
(ADCOP)
METHOD STATEMENT FOR PIPELIENE WELDING
30-99-90-1619
REVISION RECORD
REV
DATE
ORIGINATOR
REVIEWED
APPROVED
DOCUMENT No.:
30-99-90-1619
DESCRIPTION
DATE : 08/09/2008
10/08/2008
Dong Yingjun
Ye Xiaopeng
Zhang zhanhui
08/09/2008
Dong Yingjun
Sibi Peter
Zhang Min
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
CONTENTS
PAGE
1.0 INTRODUCTION............................................................................................................................................ 5
2.0 PURPOSE OF THIS DOCUMENT................................................................................................................ 5
3.0 DEFINITIONS AND ABBREVIATIONS......................................................................................................... 5
3.1 Definitions........................................................................................................................................5
3.2 Abbreviations....................................................................................................................................5
4.0 REFERENCES............................................................................................................................................... 6
4.1 Project Specificaion and Procedures .................................................................................................6
4.2 Other References.............................................................................................................................6
5.0 COMPLIANCE STATEMENT........................................................................................................................ 6
6.0 GENERAL...................................................................................................................................................... 7
6.1 APPROVAL / AUTHORISATION........................................................................................................7
6.2 DISTRIBUTION AND CONTROL .......................................................................................................7
7.0 ROLE AND RESPONSIBILITIES.................................................................................................................. 7
8.0 PROCEDURE................................................................................................................................................. 9
8.1 HSE Requirements...........................................................................................................................9
9.0 EQUIPMENTS.............................................................................................................................................. 10
10.0 PROCEDURE QUALIFICATION............................................................................................................... 10
11.0 WELDER QUALIFICATION....................................................................................................................... 11
12.0 METHODOLOGY FOR MAINLINE WELDING......................................................................................... 11
13.0 WELDING RETURN CIRCUIT.................................................................................................................. 12
13.1 Welding........................................................................................................................................12
13.2 Preheating....................................................................................................................................13
13.3 Root Run Process .........................................................................................................................13
13.4 Starting.........................................................................................................................................13
13.5 Closing.........................................................................................................................................13
13.6 Cleaning.......................................................................................................................................13
13.7 Removal of Clamp ........................................................................................................................13
13.8 Hot Pass.......................................................................................................................................14
13.9 Fill and Cap ..................................................................................................................................14
13.10 Cleaning and Restarting ..............................................................................................................14
13.11 Capping and Inspection ...............................................................................................................14
13.12 Subsequent Pipe Alignment ........................................................................................................14
13.13 Weather Protection .....................................................................................................................14
DOCUMENT TITLE
PROJECT:
DOCUMENT No.
30-99-90-1619
Description
30-99-90-1619-QP-01
30-99-90-1619-QCL-01
30-99-90-1619-QCL-02
30-99-90-1619-QCL-03
30-99-90-1619-QCL-04
30-99-90-1619-QCL-05
30-99-90-1619-QCL-06
30-99-90-1619-QCL-07
30-99-90-1619-QCL-08
30-99-90-1619-QCL-09
30-99-90-1619-QCL-10
30-99-90-1619-QCL-11
30-99-90-1619-QCL-12
Pages
DOCUMENT No.:
30-99-90-1619
Date/Rev.
6
1
1
1
1
1
1
1
1
1
1
1
1
DATE : 08/09/2008
1.0 INTRODUCTION
The United Arab Emirates (UAE)
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
API
FEED
IPS
MOT
MPS
MMBPD
PMC
PQP
PPE
QHSE
QA
QC
4.0 REFERENCES
4.1 Project Specifications and Procedures
Particular reference is made to the following project specifications:
30-78-12-0606 Specifications and Procedures
30-99-90-1642 Mainline Welding Procedure
30-99-90-1643 Pipe Weld and Cut-Out Procedure
30-99-90-1644 Pipeline Weld NDT Procedure
30-99-90-1650 Tie-in Procedure
4.2 Other References
30-99-90-1611 Project Quality Plan
30-99-90-1672 Project HSE Plan
5.0 COMPLIANCE STATEMENT
This document is in full compliance with the contract except for the following points.
Description of deviation
Approval date
- None -
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
6.0 GENERAL
6.1 Approval/Authorization
This document shall be issued, verified and approved by project members as described
in the Project Procedure 30-99-90-1619 REV.A
6.2 Distribution and Control
This document shall be distributed in a controlled manner by the Document Control Centre
according to the respective document control procedure PP 104 Engineering Document
Management.
7.0 ROLE AND RESPONSIBILITIES
Construction Manager
The Construction Manager (s) in conjunction with Interface Coordinators, Permit Cocoordinators and Public Relation Officer are responsible for the implementation of the
work in accordance with safety regulations and also shall be responsible for ensuring all
required permits and approvals are in place prior to commencement of the Construction
works.
HSE Manager
The Site HSE manager monitors the work to ensure compliance with safety regulations
at site. He is responsible for preparation and implementation of all safety procedures
and practices for all activities as well as imparting training for supervisory, workmen for
execution of the works in a safe manner.
QC Manager
Site Quality control manager will be responsible for implementation of project quality
procedure and inspection of work as per Inspection and Test Plans.
Interface Coordinator
Interface coordinator will coordinate with ILF, CPECC, Highway contractors, other subcontractors and owners of all other utilities and facilities interfacing with new pipeline.
Arrange for meetings as required.
Survey Engineer
Survey Engineer shall be responsible for ensuring all construction survey activities to be
carried out in strict accordance with the approved procedures and safety requirements.
a) The Permit Co-coordinator (s) shall be responsible to coordinate all permits and
approval requirements before commencement and after completion of works at site,
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
Welding foreman
a) Shall be the team leader of welding crew and shall report to the pipeline
superintendent.
b) Welding foreman shall conduct the daily tool box talk.
c) From fit up stage to weld completion his close supervision is mandatory and he
shall control the job activities to achieve target production.
e) He shall ensure end caps are in place of the pipe string before leaving the site.
Pipeline superintendent.
a) Shall report to the construction manager and be responsible for supervision of the
job at site.
b) Shall be responsible for co-ordination with CPECC/ILF regarding activities at
site.
c) Shall have overall responsibility to ensure all necessary work permits, safety and
quality at site for the working group as well as the public and environment.
8.0 PROCEDURE
8.1
HSE Requirements
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
a) All personnel shall have attended HSE induction / awareness training programs
conducted in-house. This shall be documented adequately. Register shall be
maintained with Site HSE Manager.
b) NOC / Work permits shall be obtained from the concerned authorities prior to start
of the activity.
c) Work permits will be obtained from the concerned authorities. All permits passes
shall be issued prior to start of any excavation work.
d) Tool box talk shall be conducted before starting the work and all Hazards and safety
measures shall be discussed.
e) Warning tapes of red/white stripes shall be used to cordon off the area of operation
to prevent entry of unauthorized persons and vehicles
f)
Barricades shall be put up on either side of the area of operation at least 10 meters
away. The barricades shall have blinking lights on them to catch the attention of
driver as well as the users of the road to be crossed.
g) A clearly visible warning board stating "diversion" with arrow mark indicating the
direction of the diversion shall be placed at the point of diversion on both sides of
the area of operation.
h) Limits of the by-pass roads shall be clearly indicated by installing warning tapes,
distance boards, Traffic speed boards on either side of the by pass road.
i)
Necessary banks men or traffic regulators shall be deployed on both side of the area
of operation to control the traffic during the operation through the by-pass route /
tracks till the entire operation is completed and at least temporary restoration is done
on the crossing areas.
j)
It shall be ensured that only authorized personnel, for the operations and
inspections, shall be allowed to enter into the area of operation during the
excavation of the road and installation of the pipe.
k) If the operation is during night, the entire area of operation should be illuminated
well so that the workers and the supervisory personnel are safe within the area and
area is clearly visible for the possible users of the road. The diversion signs and the
by pass road shall be well illuminated.
l)
Not withstanding the above, any other measure, as demanded by the site conditions
and the climatic conditions at the time of operation shall be adopted to ensure safety
of the public property and the environment.
9.0EQUIPMENTS
The following instruments and equipments have been identified for the execution of
activities:
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
9.1
Instruments
9.2
Machineries
Excavator
PC400 or equivalent.
C594/60T
Dozer
Rock breaker
PC 400
Asphalt cutter
Grader
CAT 140G
Dump Truck
6x4
Front-end loader
CAT 950F
Water Tanker
6x4
Holiday Tester
0 To 25 KV
Hand Tools
Adequate nos. of equipment (of suitable type / capacity) in good working condition
will be deployed.
10.0 PROCEDURE QUALIFICATION
a)
b)
c)
d)
e)
f)
g)
h)
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
b)
c)
Check and ensure that all parameters as per WPS are followed during welding.
Monitor and record the actual parameters random by using a clamp meter.
Visually inspect all stages of each qualification and present the test coupons for
Companys approval.
The following records shall be compiled and submitted for Client approval:
a)
b)
c)
d)
Welders shall be issued with qualification cards identifying the WPS numbers that he
can be allowed to weld; Essential variables for the welder qualification shall be as per
API 1104.
11.2 Welders qualified on tie-in welding can be used for fill and cap on mainline welds.
Each welder shall be assigned a unique ID number. The numbers once assigned to a
particular welder shall not be reused for any other welder under any circumstances.
12.0 METHODOLOGY FOR MAINLINE WELDING
12.1 Cleaning of Pipe, Beveling Inspection & Clearing
a)
Each length of pipe shall be thoroughly examined internally and externally to make
sure it is free from visual defects, corrosion, dirt or foreign matter.
b) Each pipe length shall be adequately swabbed to remove foreign matter and pulled
through proper to ensure it is free from dirt before lineup. While using pull through
proper care should be expressed to avoid damage of coating before welding,
c) All rust and foreign matter shall be removed from the beveled ends by poweroperated tools. This shall be affected inside and outside and for a minimum distance
of 25mm from the edge of the weld bevel.
d) On pipes, which have been cut back, a zone extending 25mm back from the new
bevel, shall be ultrasonically tested to the requirement of the line pipe specifications to
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
ensure freedom from laminations. The new bevel shall be 100% visual / MPI tested.
A report shall be written for all testing and records.
12.2 Alignment, Fit up
a) Pipes shall be checked for correct thickness, dia. and spec. with respect to the
approved alignment sheets.
b) Before Welding, the pipes shall be checked to confirm that the inside is clean and
free of any objects. The supports shall be strong enough to support the line pipes.
Sand bags are suggested as supports.
12.3 The root gap shall be checked accurately and shall be as per qualified WPS.
a) Longitudinally or spirally welded pipes ,a minimum distance of 10 inches (254 mm)
between each longitudinal and spiral weld shall be maintained in lining-up pipes and
these weld seams shall be located in the top half of the pipe (120) Particular
relaxation in case of welding pipe to bend or bend to bend shall be subject to
approval.
b) For pipe of same nominal wall thickness the off set shall not exceed 3 mm. The
offset may be checked from outside by dial gauge.
12.4 Alignment and fit-up shall be checked before welding.
Before starting of welding works Welding engineer shall submit batch Certificates of the
electrodes for review by ILF/TPI. Only approved batch of electrodes /filler wires shall be
used at site.
13.0 WELDING RETURN CIRCUIT
Earthling clamp shall be used and the power connection on line pipe cant make arc
strike.
13.1 Welding
Welding shall be done as per the approved welding procedure specifications (WPS).
Only qualified welders shall be engaged and each welder shall bear an identity card
during welding operation. Weld box shall be used to meet the requirement of
identifications.
13.2 Preheating
Pipe shall be heated using the method as per WPS required Preheat temperature shall
be maintained prior to commencement of root run and subsequent runs. The burners
shall be equally spaced, so as to ensure uniform heating all around the joint. The
temperature shall be checked by calibrated temperature crayons and digital pyrometers.
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
down.
b) Arc strikes outside the bevel surface shall not be permitted. If any such arc strikes
are caused accidentally, such areas shall be repaired as per the method approved by
ILF. The skids used in during welding shall be removed only, after completion of full
welding.
13.10 Cleaning and Restarting
Every pass shall be cleaned by power-brush, grinding machine and chisel, starting and
finishing point shall be staggered for every pass.
13.11 Capping and Inspection
Capping shall be max 1.6 mm over the surface of the pipe. Spatters shall be removed
and cleaning shall be done by power brush and any remedial grinding necessary, shall
be performed limited to dressing.
13.12 Subsequent Pipe Alignment
Further, joints shall be welded in the same manner as explained above.
13.13 Weather Protection
Wind shelter shall be provided to cover the welders and joint during welding, if
necessary to protect against rain/drizzling/wind.
13.14 Visual Examination
a) All finished welds shall be visually inspected for excessive reinforcement, concavity
of welds, shrinkage, cracks, undercuts, dimensions of weld surface porosity and
other surface defects. If any such defects are noticed they shall be rectified.
b) Night Caps to be welded after completion of main line section as per ILF
specification.
14.0 FOR TIE-IN WELDING
14.1 METHODOLOGY
a) Field welding of pipelines TIE-IN joints shall be done by method as approved WPS
after qualification.
b) Qualified welding procedures shall be used for welding of TIE-IN joints after due
approval from ILF/IPIC.
c) Only ILF/IPIC approved brands of welding consumables as specified for each run in
the WPS shall be used.
d) A TIE-IN pit of suitable length, depth and width shall be cut to enable to work freely
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
inside the trench. Proper care shall be taken so as not to allow pit to collapse or pit
wall caving in. Necessary supports shall be used wherever required.
e) In connecting pipes, special items, fittings on joints of differing material thickness as
supplied transition piece with 1:4 taper shall be used and the welds shall be
subjected to Radiographic and Ultrasonic examination.
f) Cut pipe ends shall be examined wherever for laminations by Ultrasonic over
distance of 25 mm minimum. Defective pipe length shall be cut back until laminated
section is removed and re-beveled For pipe which have been cut, Pipe no., Heat no.,
Coating yard no., Balance length has to be transferred on to remaining pipe length.
g) Alignment of the TIE-IN joint shall be done using external clamp capable of removing
offset and misalignment shall be minimized.
h) Seam orientation of welded pipe shall be selected to ensure that the longitudinal
welds shall be staggered in the top 120 of the pipeline or 254 mm. which ever is the
less and shall be positioned in the upper half of the pipe. In case the seams come
closer than as defined above, a pup piece of minimum 2.0 m shall be used. For pipes
of same wall thickness.
i) TIE-IN shall be done in such a way as to leave minimum stress in the pipe. If any pup
end is required for TIE-IN, the minimum length shall not be less than 750 mm.
j) TIE-IN joint welding including necessary cutting, beveling, grinding and line up etc
shall be carried out as per this procedure and approved WPS.
k) The new field bevels shall be examined visually before offering for MPI and ultrasonic
testing. All reports of TIE-IN along with NDT reports shall be prepare. Cleaning,
Priming, coating and other activities shall be performed as per approved procedures.
l) The root gap shall be accurately checked and shall conform to the qualified welding
procedure. All spaces between bars or at least 50% of first pass shall be welded
before the clamp is released and pipe remaining adequately supported on each side
of the joint.
m) Segments thus welded shall be equally spaced around the circumference of the pipe.
Slag etc. shall be cleaned off and the ends of the pass shall be prepared by grinding,
so as to ensure continuity of the weld bead.
n) Qualified welders shall carry out welding. While welding is in progress, care shall be
taken to avoid any kind of movement of the components / pipe, shocks vibration and
stresses to prevent occurrence of weld cracks.
o) Electrode starting and finishing points shall be staggered from pass to pass.
p) Arc strikes outside the bevel on the pipe surface shall not be permitted. Accidental
arc strikes shall be repaired as method approved by CLIENT.
q) All finished welds shall be visually inspected for parallel and axial alignment of the
work, welds, surface porosity and other surface defects.
r) Parts being welded and the welds shall be protected by windshields made of metallic
frame covered by Canvas, whenever necessary, to protect from rain and strong
winds.
s) The completed welds shall be covered with asbestos cloth covered by GI sheets,
whenever necessary, to protect from bad weather conditions.
t) For TIE-IN of adjacent sections of pipeline already pressure tested also called golden
joints and for final joints, a single length pup or off cuts, which have been
DOCUMENT TITLE METHOD STATEMENT FOR PIPELINE WELDING
PROJECT:
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
Mainline welds
NDT
100 % Visual Inspection
100 % RT for manual and 100% automatic UT for
semi/automatic welding or as per specification No:
30.78.12.0605.
30 % UT
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
100 % RT
100 % UT
100 % Visual Inspection
Repair welds
Arc Strikes
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
n)
o)
If cut out / Re-weld requires to be made in Transition joint, the joint shall be
numbered as follows. Example: K0 T40 TR-RW1
Weld Joints made after hydro test shall be numbered as K0 GT 40.
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008
Welding Machines
DG sets
Prime Movers
Internal Camp
External clamps
Compressors
Grinding Machines
Description
30-99-90-1619-QP-01
30-99-90-1619-QCL-01
DOCUMENT No.:
30-99-90-1619
Pages
Date/Rev.
6
1
Project No: E30153
Page 20 of 21
Rev.0
DATE : 08/09/2008
30-99-90-1619-QCL-02
30-99-90-1619-QCL-03
30-99-90-1619-QCL-04
30-99-90-1619-QCL-05
30-99-90-1619-QCL-06
30-99-90-1619-QCL-07
Qualification Range
30-99-90-1619-QCL-08
30-99-90-1619-QCL-09
30-99-90-1619-QCL-10
30-99-90-1619-QCL-11
NDT Request
30-99-90-1619-QCL-12
To
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Note: In case of any conflict between the requirements of this procedure and ILF Specification the
later shall govern, until and unless specific intention is meant.
DOCUMENT No.:
30-99-90-1619
DATE : 08/09/2008