TotalSheetNos: 28

Name
Subcontractor's

PTELTD
DO,DSAL

Name
Company's

DolphinEnerqvLimited

Name
Contractor's

JGC MiddleEastFZE

ProjectName

DOLPHINProiect

PlantLocation

CITY.QATAR
RASLAFFANINDUSTRIAL

No.
Subcontract

Z -1430-60'l -2

PAINTINGWORKS(MC'2)
MECHANICAL&
SubcontractWorkPackage
FORSTEELU/G
METHOD
STATEMENT
& ERECTIOIN
PIPINGFABRIGATION
DocumentNo.withrevisionNo.
Subcontractor's
Rev.02
DOD-MST-Pl-020.
DOLPHIN Project
SUBCON.
No :

z- 1430- 601 -2

IWORKPACKAGE:

PURPOSE:
IISSUE

CLASS :

R E S U LC
TO D E :A , B .R . N .F

MECHANICALAND PAINTING

woRKs(MG-2)
)

NEXTSTATUS:
FA,Fl,FR,FC,AB(

RESUBI\'ISSION
DATE:

: ,
RESPoNSIBLE
DEPr./PERSoN

.''.

e ,p, J4
t
gd g,t'/t

REVTEWDATE

,Eil ,f ,("2;

Ar ApprcvedwithoutComment;B: Approvedwith MinorComment R: Approvedwith CommenlN: Not Approved F: Not

Subiectto Review
Appro\l or review here! nder shall not be construedto relieveVendor/ S ubcontraclorof his responsibilities
and iability
underlhe Contct.

JOBNO.
ContractorDOC.
NO.
CompanyDOC.
NO

Rev.

lssueDate

01

14.02.05

02

07.05.05

03

28.06.05

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0-3356-20
ORIG. I

NO.
SUBCONTRACT

v- |

1430-601-2
- M32
RL0-306012

Puroose/Descriotion
of Revision
Firstlssuefor Review/ comments

DELcomments
and
Incorporated
resubmitfor construction
Incorporated
and
JGC/DELcomments
resubmitfor construction

Comoanv Doc.No: RL0-3060

12-Nr!32-402
Rev.03

-2005

L
04-JU

Serial

RFV.

402

03

402

03

Prepared

Reviewed

Y.S.Rao

R.K.Sharma

S.S.Rao
S.S.Rao

S.Vijaya
Kumar
S.Vijaya

Ku<nar

it_v\\$,

Page 1 of 28

Approved
Alan
Shreeve
Alan
Shreeve
t Alan
^/Bhlbeve

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iirrrdl
* i lfH5D o d s Ia l
PROJECT

FACILITIES
ANDCOMPRESSION
: DOLPHIN
PROJECT
UPSTREAM

COMPANY

ENERGY
LTD.
: DOLPHIN

CONTRACTOR

: JGCMIDDLEEASTFZE

SUBCONTRACTOR: DODSALPTELTD.
JOBNUMBER

: 0-3356-20

METHODSTATEMENT
FOR
& EREGTION
U/G STEELPIPINGFABRICATION

DOCUMENT
NUMBER DOD-MST-PI-O2O
R E V I S I ON
NU M B E R

I S S U EN U M B E R

ISSUEDATE

28.06.05

Rev.
No

lssue
Date

06.02.05

1
2

Reasonfor lssue

For Approval,afterincorporating
JGC
Comments
and
Incorporated
DELcomments
07.05.05
resubmitfor construction
I n c o r p o r a t eJdG C / D E Lc o m m e 4 t s
28.06.05
and resubmitfor construction

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CompanyDoc.NorRL0-306012-l\,132-402
Rev.03

-2005

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Prepared Reviewed
Dodsal
Dodsal

Approved
Dodsal

RK
Sharma
S.Vilaya
KUmar
S.Vijaya

Alan
Shreeve
Alan
Shreeve
Alan
9ll rehve

Y.S.Rao
S.S.Rao
S.S.Rao

AUMAT

Approved
JGC

LW'..-\y 0[]d\,no
P a g e3 o f 2 8

1.0

PURPOSE

2,O

SCOPE

3.0

REFERENCE

4.0

DEFINITIONS

5.0

RESPONSIBILITIES

6.0

TOOLSANDEQUIPMENT

7.0

PROCEDURE

8.0

HEALTHSAFEWANDENVIRONMENT

9.0

ATTACHMENTS

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Page4 of 28

1.0

PURPOSE
to monitorand controlall
The purposeof this methodstatementis to provideguidelines
with
pipingto ensurethe compliance
of underground
activitiesrelatedto the installation
projectspecificaiionsand requirements.

2.O

SCOPE
anderectionof CS,
withprefabrication
associated
coversall activities
Thismethodstatement
of undergroundpipingat
sourwet servicesapplications
LTCSand SS materialsincluding
Facilities.
andCompression
DolphinProjectUpstream

3.0

REFERENCE

3.1

Documents
COMPANY/CONTRACTOR
.
.
.
.
.
o
.
.
o
o
.
o
.
o
o
.

:Pipingmaterialclasses
: SteelPiping Fabrication
pipingand equipment
:Weldingof pressurecontaining
2/
requirements
for
carbon
sfee/srn sourwet
:Metallurgical
HIC)
service(piping
and equipmentsubjectto SSCCand
requirements
for carbonsteelsin sourwet
:Metallurgical
GSPW622
and equipmentsubjectto SSCConly)
service(piping
:ProjectQualityPlan.
RL0-0000-GPG-00201/S-000-1139-001
:ConstructionHSEplan.
RL0-0000-FPG-50001/5-000-1654-001
:UnderGroundlnstallationNetworks
DOL-0000-CSP-00003/S-000-3116-001
for identification
of Piping
RL0-0000-LSP-00003
/ 5-000-1360-006 :Specification
matenal
:Material control procedure at site
RL0-0000-GPR-'10005
/ 5-000-1630-201
'
(construction
Phase)
RL0-0000-GPR-10101
/ 3-000-1670-101 :Qualitycontrol procedurefor welding
consumable
control.
RL0-0000-GMA-00101
/ 5-000-1676-001 :SiteweldingandNDEmanual.
RL0-0000-LPR-10002
/ 5-000-1676-002 :WPSfor Fieldpipingwork.
RL0-0000-LPR-10003
/ 5-000-1676-003 :WeldinoProcedure
Qualificationtest for
fieldpipingwon<.
qualificationtest for
RL0-0000-LPR-10004
/ 5-000-'1676-004 :Welderperformance
prprng.
Trero
for shopandfieldpiping
RL0-0000-LPR-10006
/ 3-000-1676-006 :PWHTProcedure

GS PW112
GSPVV171
GSPVV611
GSPW612

WOTK.

.
.
.

:QualityControlProcedurefor NDE/PWHT
conlrol
RL0-0000-LPR10009i 5-000-3160-001 :Construction Specification For Piping
Works.
:Construction
PunchListProcedure
RL0-0000-G
PR-10017/3-0001640-003
RL0-0000-LPR10016i 5-000-1676-008

Documents
SUBCONTRACTOR

5,2

.
.
.

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:ProjectQualityPlan
RL0-306012-402-201tV-1430-601-2-201
works
:MSTfor pipingprefabrication
RL0-306012-M32-4041V,1430-601-2-404
:QCPfor MaterialContro
RL0-306012-Q56-52O1V-1430-601-2-520

ComoanvDoc.No:RL0-306012l\,432-402
Rev.03

-2005

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Page 5 of 28

.
o
.
o
.
4.O

of equipmentand
:QCPfor Preservation
2-M33-549N-1430-601-2-549
RL0-30601
malenals
-1430-601-2-521:QCPfor Controlof WeldingConsumables
RL0-30601
2-Q56-521N
:MSTfor PostWeldHeatTreatment
RL0-30601
2-M32-4O3N-1430-601-2-403
:QCP for Wrappingand coatingof U/G
RL0-306012-M33-5504/-1430-601-2-550
Piping
Receiving
Inspection.
:QCPfor Material
RL0-306012-M33-525N-1430-601-2-525

DEFINITIONS
COMPANY
CONTRACTOR
SUBCONTRACTOR
SUPPLIER
t-J

SS
LTCS

: DolphinEnergyLimited
: JGCMiddleEastFZE
: DodsalPteLimited
: Supplier
andservicesto SUBCONTRACTOR
of products
:CarbonSteel
:Stainless
Steel
:Lowtemperature
CarbonSteel

RESPONSIBILITIES
5.'l

ConstructionManager
ConstructionManager shall be responsiblefor overall managementof all construction
activitiesat site.

5.2

PLANNING
Engineer
He shall be responsibleto prepare monthly and weekly schedu/esbased on over all project
plan and monitor progresson daily, weekly and monthly basis.

5.3

PIPINGEngineer
He shall be responsiblefor carryingout the all activitiesassociatedwith U/G pipingworks
includes prefabricationand erection in line with ihe schedule / targets given by the
Subcontractor's
ProjectControlsdepartment.Also responsiblefor planningand executionof
all U/G pipingactivities,includingbut not limited,to the Materials,Machinery,Manpower.
He will provide a list of materialsagainst each lsometricno, to the Material Controller
minimumtwo weeks in advanceof the plannedschedule. PipingEngineeris responsiblefor
expeditingthe missing materials,monitoringthe drawing revisionsand modificationsfor
meeting the productiontargets set by the project controls. They shall co-ordinateand
interfacewith CONTRACTORPipingSupervisors.

5.4

Piping Foreman
He shall be responsiblefor fabricating fhe spoo/s as per the latest approved drawing as
identifiedby the piping engineer and also responsib/eto coordinate with igging foreman for
erection of fabricated prpe spoo/s. Ensure all personnel's working with him shall worn
necessaryPPE as per constructionHSEplan.

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P a g e6 o f 2 8

i-1'i_-_-'_''____-i
i - \
i -

. l

I-1=-r iOOdsal
I
g*r#{

5.5

Riggingforeman
for superviseall riggingactivitiesinvolvedin fabricationand erection
He shallbe responsible
of piping spoolsand ensureall personnel'sshall worn necessaryPPE as per construction
HSEplan.

5.6

Material Controller
MaterialControllershall be responsiblefor collectingmaterialsfrom the JGC ware
to the fabrication
areaand
house/JGC
designated
lay downareaand shiftingthe materials
shiftingthe fabricatedspoolsfrom the subcontractor'sfabricationarea to the erection site.

5.7

WeldingEngineer
control,Preparation
/
& inventory
for the selectionof consumables
He shallbe responsible
WelderPerformance,
of Welders& Monitoring
of WPS & PQR,Qualification
Qualification
TroubleShootingof all
on lsometricDrawings,
Markingthe WPS and NDE requiremenis
He shallalso
for theweldingpersonal.
trainingsections
weldingrelatedproblems,
conducting
in the
with Contractor's
WeldingEngineer/ Sr. WeldingInspector
coordinate
and interface
matersrelatedto Welding& selection
of Jointsfor NDT.

5.8

WeldingSuperintendent
/ WeldingForeman
for Job allocationand
He shall reportto the WeldingEngineerand shall be responsible
thatall
checking
monitoring
welders,controlandmonitorthe issueof WeldingConsumables,
preparation
parameters
weldvisualinspection
and
welding
confirms1othe WPS,conducting
repairsetc.,
of DailyWeldingProgress
Report,Attending

5.9

WeldingQC Inspector
confirming
He shallbe responsible
for the verification
and documentation
of all the materials
heat nos. on to the material
to the lsometricDrawings/ StandardDrawings,transferring
finalweldvisuals,
interpasstemperatures
traceability
records,checkingof fit-ups,preheats,
and preparation
of DWR,In process
witnessing
RF Padleaktesting,WeldVisualInspection
in theshop.
inspection
& surveillance
of allweldingactivities

5.10

NDE& PWHTGoordinator
He is the focal
all the NDE and PWHTactivities.
He shallbe responsible
for coordinating
pointfor requestingall the NDE and PWHT,flaggingand identification
of joints.He will
records,
and makethe listof spoolsclearedfor NDE.
updatethe NDTresultson traceability

5.11

HSEOfficer
for successful
implementation
of safetysystemsthrough
HSE officershall be responsible
different
traininoandinsoection.

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P a g e7 o l 2 8

\ t

j
Ih.-i..F, illodsal
l<
6,0

TOOLSAND EQUIPMENT
o
.
.
.
.
.
.
o
.
.

7.O

Cranesshallbe certifiedby thirdpafty

Fork lifts,Liftingbelts,Chainblocks,Tirfors,Slingsand other necessarytools and
tacklesfor rigging& materialhandlingoperations(Certifiedby thirdparTyif applicable)
and quarterlycolor-codedas per projectHSErequirement.
Pipestands,Pipeclamps,fixtures
(pencilgrinders)
Weldingandgrindingmachines
Electrodesbakingand holdingovenswith valid calibrationceftificates.
GascuttingandPlasmaCuttingmachines
Tools
PipeFittingand lnspection
Windorotectionhuts
to be fabricated
Handtoolssuitableto thematerial
tackles
with
fabrication
benches
andvices
Toolsand
PROCEDURE
SequenceOf Activities

7.1

Materialldentification
a. ldentifythe materialsrequiredfor fabricationof under ground pipingas per the
isometric
drawings.
approved
construction
fromthe JGGware house/lay
downareato fabrication
b. Collectand shiftthe materials
arealstores.Segregatethe materialsitem wise and colour codes for material
refer
specification
for identification
of pipingmaterials
identification
shallbe appendix-1,
Doc.No:RL0-0000-LSP-00003.
duringfabrication
of piping,
c. Millmarkingsshallbe verifiedwithmaterialtest certificate
beforecut the pipes to suit drawingdimensionsheat or chargenumbersshall be
transferredby hard stamping/tag
on cut piecesand duly recordedand get signedfrom
theconiracior
in thetraceabilitv
form.

7.2

MaterialStorage
of bulkitems,e.g.bolts,nutsandwashersetc,will
a. All pipingMaterialwiththeexception
MaterialControlProcedure
at
in accordance
withcontraclor's
be storedand controlled
sitereferCompanyDoc.No:RL0-0000-GPR-10005.
Do notstoretogetherwith
to the itemclassification,
b. Materials
shallbe storedaccording
For sfainlesssteelspools/pipesand fittingsshallbe kept
differentitem classification.
withothermaterials.
separatelvto avoidcontamination
c. Pipe spoo/s sha// be stored area by area as per the PCWBS for easy access and
identificationof spoo/s.

7.3

Verificationof Trenching I Excavation

a. Trenching/ Excavationwill be done by othersfor all the U/G pipingworks. Afterreceipt
of trench handover document from Contractor, Subcontractorshould verify the

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i-:\
l e n i

Ef

r_---_--------_--.]i

iDodsal
i
lsE-

widthof trench,Slopes,
elevation,
for the Coordinates,
suitability
of Trench/Excavation
for safeworking.Any concerns
Beddingas perthe drawingsand trenchconfiguration
throughproperchannel.
willbe notifiedto Contractor,
7.4

Prefabricationof spools
approvedmethod
shall be carriedout as per the subcontractor's
a. Prefabrication
-1430-601
-2-404.
2-M32-404N
Doc.no:RL0-30601
for pipingprefabricaiion
statement
b. The spoolsrequestedby the Area PipingEngineerwill be deliveredto the location
andstacking
shallbe done
Unloading
/ PipingForeman.
advisedby the PipingEngineer
in such a way that, the commonaccessand roads are not blocked,until unless
The spoolsshallbe stackedto suitthe
informedand agreedby the CONTRACTOR.
materialwise, in particularavoidcontactof SS
erectionsequenceand segregated
sooolsto CS/LTCS.

7.5

Transportation
and placingof spools
a. The spoolsdeliveredto site are generallywrappingand coatedcondition.Hence,care
to avoid/minimize
damagesto the coatingduringloading,unloading
shallbe exercised
anderectionactivities.
b. If any damages occurred duing transpoftation and handling shall be notified to
contractor and damaged pipe/fifting shall be replaced with new pipe/fitting and welding
shallbe carried out accordingto the approved weldingprocedure.
c. The pipes/ PipingSpoolsduly coated/ Wrappedwill be placednearbythe excavation
withinthe range no closerthan 1.5M. The cranewill be kept at a safe distanceof 1.5
time'sminimumdepthof excavationdue to looseexcavatedsand/earth.The capacityof
the craneto be used will be identifieddependingon Pipedrameter/weight.
d. When there is no excavation is involved, piping can be placed directly on the
coordinatesof iis final location.
e. Liftingbelts shall be used to avoid damage to the Coatingof the pipingcomponents.
Steelropes/ Slingsare shallnot be used.
f.

7.6

Pipingcomponentswill be placedaboveground,usingwoodenDunn age or sand bags

to facilitateweldingand fit up operations.

Gleaningand protection of spools

a. Before field erection,Spools will be blown with compressedair to remove dirt and
debris, if any. lf the spool is not going to get erected immediatelyafter the
cleaningi
blowing,the ends wili be protectedwith the end caps or with a polyethylene
and any
sheet tightly tied with binding wire to avoid ingress of dirt/water/moisture
foreignob1ects.The open ends of the erectedspoolsshall be coveredimmediatelyto
avoidthe moistureingress.
b. Extracare shall be taken while erectingCS/LTCSand galvanizedspoo/sin the vicinity
of Stam/essSieel to avoid crosscontaminatlon.Wire rooe slinosshall not be used for
transportation
handling,
and erectionof SS spools.

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c. The flange faces shall be sealedwith light metal blinds/ plywoodor purpose
plasticcaps. Everycare shall be takento avoid damageto flange
manufactured
gasket-seating
facesduringthe courseof erection.lf any damageto the flangeface
by FQR.
to the CONTRACTOR
be
notified
shall
7.7

Fieldinstallation
a 3D viewto be studiedto checkand ensurefor any interface
a. Priorto any installation,
with adjacent structures,piping or equipment.lncase if any such cases sha// be
for remedialaction.
informedthroughfield queryto contractor/company
traceability
recordsshall be
b . All pipingmaterialsshall be field run and fabrication,
for PipingPrefabrication.
MethodStatement
maintained
as perthe SUBCONTRACTOR
Heat numbers shall be transferredby means of hard punchingfor carbon steel
materialsthicknessabove 5 mm. For carbon steel materialsthtcknessless than or
eoualto 5 mm and all LTCS/SSmaterialsshallbe etchedwithelectricpencil.
and ensurethat
Erectionsequenceshallbe plannedaccordingto the spoolsavailability
thereis no inbrterence and difficultyof erectingthe remainingspoo/s,n later stage.
the Longseamsof pipeand
for staggering
e. Whilejoint fit up care shallbe exercised
weldsare offset
weldsthe longitudinal
fittingsin sucha way thatat the circumferential
from the top of the verticalpipecenterlinepreferably
30" left and 30' rightfor each
successive
element. The minimumdistancebetweenthe two long seamsshall be
whichever
is greater.
50mmor sixtimesthe pipewallthickness
butt ioints shallbe minimumof
The distancebetweeniwo successlvecircumferential
SAmmor one time diameterwhichever is oreater.
g. After completion
of the joint fit up, pipefitterwill makea box adjacentto the joint
markingthe Joint no., provisionfor Fit up & Weld Visualsign off from the welding
Inspector
andfor welderldentification
nos.
n . Pipe Fitter/ Pipingforemanwill checkthe fit up and advisethe areaweldinginspector
for clearance.Weldinginspectorchecksfit up, identification
of spool nos. and upon his
satisfactionclears the joint fit up and notes down the applicableWPS to be used for
weldingand preheattemperaiure,if required. There shall no be no stressplacedonto
equipmentnozzlesfrom piping. No pipe springingallowed.
All valves, strainersand inline items shall be installed as per /atesf approved drawing
and ensure the actual flow direction of the svstem and valves marked flow direction
shallbe the same direction.
J.

All bolts and nuts shall be protectedwith anti seize compoundto prevent corrosion.

k . All pipingflangeboltsare to be tightened

/torqueas applicable
and torquevaluesshall

be as per the projectspec. Bolt tighteningsequenceshall be followed,as per the boll

procedure
tightening
willbe submitted
separalely.
L

Dimensional
tolerances
of companydoc.no:RLOshallbe followedas per attachment-1
0000-LPR10009.411
angulardimensionsof bendsand branchesshall be maintained
within11 deoree.

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l'8
- l iDodsel
I
lugsandstrongbacksandtackweldsusedduringfifup
Allthetemporary
attachments,
and shallbe weldedby
with
weldingprocedure
shallbe madein accordance approved
the qualifiedwelder's. Upon/duringcompletionof welding, all the temporary
attachments
shall be removedby using grindingand groundflush with the base
penetrant
test.
followedby Magneticparticle/dye
visually
material,
andinspected
n. Pipe suppotisinstallationand welding shall be done as per the approvedisometric

drawingsand painting of the sameshall be done accordingto the proiectpainting

referDoc.No:RL0-0000-WSP-02005.
soecification
o. After line is mechanicallycompletedand prior to test pack submlsslon,line shallbe
thoroughlycheckedwith latestapproveddrawingand any changesof dimensions,
rerouting& additionalweldjoints shallbe markedon drawingand submitfinal as built
panv.
drawinq to the contractor/com
7.8

Weldingconsumablecontrol
controlshallbe followedas per the approvedQCPfor controlof
a. Weldingconsumable
weldingconsumables
referDoc.No:RL0-306012-Q56-521.
b- All backingand holdingoven shall be equippedwith thermostatand havingvalid
LowhydrogenElectrodes
shallbe backedat a temperature
300'
calibration
certificate.
recommendation.
After2 hoursof
C to 350'Cfor 2 hoursor as oer the manufactures
backing,the sameshallbe shiftedto holdingovenand maintaina temperaturel50"C
priorto issue.
from holdingovensonlyand carrying
c. Weldingelectrode
shallbe issuedfor production
the electrodes
to field by portableovens/quivers
maintained
at a temperature
70'C to
100'C.Un usedelectrodes
shallbe returnto storedby the end of shiftand shallbe
Maximumnumberof times
rebakedas per the manufacturer's
recommendation.
electrodes
canbe bakedshallnotexceedthreetimes.

7.9

Welding
a. Allweldsincluding
weldrepairsshallbe supported
by the relevantWPS.All theWPS's
shall be supported by PQR's and shall be qualified in the presence of
COMPANY/CONTRACTOR
accordingto the ASME Sec.lX and relevantproject
soecifications.
b. All the relevantand latest approvedWPS's copy will be availablewith welding
foremaniwelding
superintendent
and it will be displayednearthe weld arealwelding
consumable
controlstorelocatedat site.
c. Dailytoolboxtalksshallbe conducted
by the weldingforeman/welding
superintendent
Theweldershallstrictly
andexplainto the welder'sto followthe weldingrequirements.
adhereto the WPS, and shall be monitoredby the WeldingInspectorAlVelding
Superiniendent.
d. Beforestartwelding,
checkthelointfor cleanliness
to ensurethatthe jointandjoint
bothsidesof basematerial
at least25mmshallbe cleanandfreefrompaint,oil,dirt,
scale,oxidesandothermaterials
detrimental
to welding.

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Aada

11 ^f )9,

Before welding,ensureearthingis properlyconnectedto the iob to prevent loss of

amperageand arc strikes.
f.

To avoiddamageto the existingCoating/ Wrappingdue to the weldingand related

suchas weldspatter,grindingetc.,adjacentareasat weldjointwillbe mvered
activities
withfireproofprotectivecovering/ fire blankets.
WeldingForemanwill allocatea qualifiedwelder (approvedby CONTRACTOR,
for
identifiedby welder lD card) for performingthe weldingand also responsible
wind shields,damsand backpurging
arranging
the requiredfillerwire & electrodes,
wiih the approved
of ihe joint in accordance
whileweldingstainlesssteel,preheating
WPS.

after attainingthe preheatingtemperature,

n . In case the joint requirespreheating,
Weldingforemanshall be checkedpreheatand ensure preheatshall be as per
indicating
approved
WPS. EachWelderhas beenprovidedwith a set of Temperature
Crayon,and welder shall be responsibleto check and maintainthe inter pass
temoeratures.

t_

Weatherconditions
becometoo severe,like blowingwindstronglyand rain is falling,
fromthewindor rain.No
weldingshallbe stoppedunlessprovidedadequateshielding
Any moistureon surfacesto be
weldingshallbe carriedout on wet basematerials.
to 50oCpriorto welding.
weldedshallbe removedby preheating
time to
afterpurgingwithallowingsufficieni
Weldingof SS jointsshallbe commenced
withapprovedwelding
air and backingshallbe in accordance
displacethe entrapped
oroceoure.
the next passthe joint shallbe
Aftercompletion
of eachpassand beforedepositing
purging
till the end
The
shallbe continued
cleanedof slag,poresor any irregularities.
of hotpasswhileweldingStainless
Steel.
quiversshallbe alwayspluggedand the covershallbe keptclosed. lf
The electrode
shallapproachthe welding
the weldershaveany problemwith the joint / electrodes
needed
action
or
clarification.
Foremen
or WeldingInspector
for

m . Aftercompleting
thejointthe welderlD Numbershallbe enteredon thespaceprovided

adjacentto the joint. Dependson the sizeof the joint 1 or morewelderscan welda
joint.Theareaperformed
But,alwayscareshall
by eachwelderwillbe clearlyidentified
be takento engageminlmumnumberof welderson a singlejoint. lf morethan one
welderis used to completea.loint, all welderslD's are to be confirmedon QC
documentation.

n . Ensure Joint shall not be moved/lifted until welding at least 2 passes or 1/3'" of wall
thickness is completed, some critical applications lifting of joint with out complete
welding shall be notified to contractor/company.
o. At the end of each shifl weldingforemanshall preparea list of all the jointswhose
weldinghas beencompleted
and submitto theWeldingQC Inspector

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P a g e1 2 o f 2 8

7.10

VisualInspectionand NDT
will inspectall weldjointsvisuallybothcappingand rootwherever
a. Weldinginspector
to
He will verifyall ihe detailsconfirming
to meetihe projectrequirements.
accessible
to thejoint.
themarkings
adjacent
of acceptance,
the lisiwillbe given10ihe Contractor's
b. Afterinspection
and con{irmation
inspectorcompleteshis
Inspectorfor inspection/ review. Once the Contractor's
inspectionthe signed DWR, copies shall be distributedto the ProjectControls
Weldingengineer.
andContractor's
fieldNDE& PWHTcoordinator
department,
the flaggingand identification
of weldjointswith
organizes
c. NDEand PWHTcoordinator
jointly
for
off
as
acknowledgement
The NDErequests
shallbe
signed
NDESUPPLIER.
joini
for availability
of accessand lightingfor carrying
witnessing
the
and confirmation
outthe NDEactivities.
will receivethe NDE reportsand PWHTchartsfrom the
d. NDE & PWHTCoordinator
NDESUPPLIER
and PWHTsupervisor
respectively.He will reviewthe PWHTChart
for reviewandsignature.
andaftersigningsubmitto the CONfRACTOR
e. The signedPWHTChartwill be retainedby the CONTMCTORand a copyshallbe
issuedto the SUBCONTRAGTOR
for reference.The NDE & PWHTchartswill be
recordson
issuedto the site QA"/QC
Engineerfor updatinginto the fieldtraceability
by the NDE/PWHTCoordinator.
dailybasisanda mastercopyshallbe maintained
NDT,NDTcoordinator
willreleasethejoints
f. Aftercompletion
of PWHTand Necessary
will be submitted
for testing.Testingwill be carriedout as perthe approvedprocedure
separately.
g. Arc strikes outside weld bevels shall be avoided, if any occur, the deposit shall be
carefully removed by grinding and the area shall be 100% examined by magnetic
particle test (on magnetic materials)or dye penetrant test (on non magnetic materials).
All repairs shallbe done accordingto the approved weldingprocedure.

7 .11

Repairs Management
a. Once a repair is identified,for joints sizes below 2" NPS the full joint will be cut and rewelded. For all other sizesbased on the extent of repair, the Welding Superinlendent
shalldecide whetherjoint is to be repaired locally or the joint is to be cut and re-welded.
For localized locations the repair shall be marked from lhe tracers given by the NDE
co-ordinator.
b. Thejoint will be excavated by grinding and excavatedportion shall be sufficientlydeep
and long to remove the defect. The width and profile of excavatedportion shall have an
adequate accessfor rewelding.
c. After repair removal shall be followed by MT/PT to ensure the defect is completely
removed and re-welded as per the approved repair weldtngprocedure and necessary
NDE & PWHT shall be performed. The information regarding the obseNation on the
repair shall be recorded as found / not found and given to the welding engineer for his
review and records.

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P a g e1 3 o f 2 8

7.12 Reportingand DataManagement:

NDE SUPPLIERshallmaintaina database,whichcan provideall necessaryqualityrepofts
and informationfor maintainingthe Quality.
Thelnputfor the Date Baseis:
.
Jointsmarkedup Isometricsfor creatingthe basic data.
.
Daily WeldingRepofts
.
Lrsfof SpoolsReleasedfor NDE
c
AIINDERequests
.
All NDErepofts
.
Lisfof SpoolsReleasedfor Painting
TheOutputobtainedfromthe Data Base
.
.
o
.
.
.
.
.
.

WeeklyWelderPerformanceReports
Sfafusof TracersMarking
LineC/asswlse NDEsummaryandcoverage
WelderWiseNDEcoveragefor Randomradiographyjoints
No. of Jointsweldedand No.of Jointsbalancefor weldinq
No-of Jointsbalancefor Radiography
No. of Jointsbalancefor PWHT
No-of Jointsbalancefor RT repair
Sfafusof Spoo/sunderfabrication,
underNDEclearanceor underPainting.
Statusfor the same shallbe submittedto contractorQC departmenton weeklvbasis.

8.0

HEALTHSAFETYAND ENVIRONMENT
1- Tool Box Talks shall be conductedbefore the commencementof new activity and
everydaymorningdetailingthe risksinvolvedin the activitiesgoingto be carriedout.
2. Before commencementof work SafeActivity Pre-Check (SAP) sheefs sha// be filled as
attached.
3. All personnel'sshall worn necessaryPPE all times during the work.
4. Ensure all lifting equipment and accessories shall be cerlified for their capacity, validity
and quafterlycolor coded as per constructionHSE plan5. All electrical equipment shall be inspected and properly earthed by a qualified
electricianand quarterly color-codedas per constructionHSEplan.
6. The excavatedtrenchareawill be barricadedat least2M back,with safetyribbonwith a
billboard
dispaying"DeepExcavation".
At night,blinkingights& safetytripodwill also
be displayed
aroundthe excavation
area,wheneverrequired.Hardbarricading
shallbe
providedfor excavationbeyond2-meterdepth.
7. Proper rigging studies shall be done on case-lo-casebasis for exact crane positioning
and safe liftind oDeration.

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Page 14 of 28

8. ln case of any emergencyduring installationof piping in trench,piping foreman will lead

the team for emergencyevacuation.

9.0

ATTAGHMENTS
Tolerances
1. Attachment-1
, Dimensional
Piping
lnstallationand Testing
2. SWMSfor UnderGround
(SAP)
sheet
3. SafeActivityPre check

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P a g e1 5 o f 2 8

f:\

"4

SIOI']ALTOLERANCES
DIi\4EI'I

LocationalTolefan:': .
{ 1 ) Nlaxlntir:,r.."!r:.,Y3ble
m a x . r : l i r ! r : ;l i I L qi n . )
For"lake-oul posllic'1"ol oriilceflow meier
connecllon
.max. 11.5 mni (1/6 in-)

(2) Allowarii i 'l ri:in.ie iil Length... as per

above 1 in pi:i-.cipi4,hi'r,'iYer' may be
'Opiional'where ttreii, is ar{ aliowence for
adiustment.

(3) Ma::iii r;r,' i l',,izontalOif-seiof

'trranehes',

e t c .r , " r a : .l : ' : r r ; l i 1 / 3 i n . )

[4aximum ali!'wable rolaii'trnoi ]'i.r,r!:: -qrii

in )
Hcie .max. i1.5mm('1116

{5)

lnciinalitir!,i -iairil, i.l3ximum.-.. 114

degree i1:2i.'0)o,'lr r'rnilr'8 itt.),vrhicheveris
smaller

( 6 ) Maxi|rr';:r AiicwableAngleTolerance
ee { as pef pafa.7.3 of GSPW
lv4ar ! r ,:1,,.,,,
17i)

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P a g e1 6 o f 2 8

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.>..:

(SAP)SHEET I @,1C0ilimrefasr]ll
PRE-CHECK
SAFEACTIVITY
Date:

Company;
Location:

Foreman (print nameli

Task Descriotion:

POINTLOCATION:
MUSTER
/ ASSEMBLY
priorto workcommenclng).
mustbe performed
PLACEOFWORKTIDY?- YESor NO (lf "NO"housekeeping
tS YOURDESIGNATED

KeyTask RelaFdHazards
NO

r4l

Excavalions
Access Only
Plant & Equipment

Electrical

::r:=--=j-::-!(ey:EGnenf ative Contro!,ltrleasures.:- .. .

Confined Soaces
lsolations

Lock Out,/Taq Out

Hot work
Instrumentation
Pre / Commissioning / START-UP
SHORED
/ SLOPED
/ BENCHED

F I R EE X T I N G U I S H E R

LADDERSPROVIDED

FIRE BLANKET

BURIEDSERVICESIDENTIFIED

CYL]NDERS
U P R I G H T& S E C U R E D

VEHICLE
STOPBARRIERS
/ BOARDS

COIi,4BUSTIBLES
REIT,4OVED

EXCAVATIONINSPECTED

FIRE WATCH (SafetyPasspodcheck)

SPECIALPPE (VISORS,GLOVFS,elc)

NO
STANDBY I\,,IAN

EMERGENCYCOMMUNICATIONS

VENTILATION

WORK BELOW RESTRICTED

PERMITto WORK

BARRIERS
/ SIGNS
POSTED

GAS TEST COI\TIPLETED

FLAMEARRESTORSF]TTED

TALLYBOARDor similar

WELDINGCABLESIN GOODCONDITON

E[,4ERGENCY
ACCESS

CHEMTALS

coi\,4t\,4uNtcATtoNs

MSDS REVIEWED/ AVAILABLE

SAFETYHARNESSES

SKIN / EYE / THROAT IRRITANT

S U T A B L E( E x . )L I G H T I N G

SHOWERoI EYEWASHAVAILABLE

N/A

CONTAINERSLABELLEDPROPERLY

lNSPECTIONSCAFTAGPOSITIONED& IN DATE

S I G N SP O S T E D

S A F EA C C E S S/ E G R E S SP R O V ] D E D

R SK ASSESSMENTCONDUCTED

TOEBOARDS.KICKPLATESIN ORDER

HMARDS CONl[IUNiCATED

H A N D R AL S S E C U R E D

GROUNDING

HARNESS& LANYARDSINSPECTED

CONTA NI\,4ENT
REQUIRED/ PROV DED

S T A T I CL I N E S- T I E O F F P O i N T S

ABSORBENTAVA LABLE /N S/7U.

YES

NO

'ol

N/A

P L A N T& E Q U I P I \ 4 E NN
TSPECTED

T O O L S .A P P L L A N C E S
NSPECTED

L I F T I N GG E A R .R G G N G N S P E C T E D& C E R T S

DEFECTSREPORTED

BANKS[']AN
/ C O I \ 4 P E T E NPTE R S O NI D E N T I F I E D

PORTABLE
APPLIANCES
INSPECTED

L I F T I N GP L A N/ C A L C S& M I S C N E C K E D

EXTENSiON
C A B L EC H E C K E D8
TAGGED

OPERATOR
CERTIFIED

OPERATORS
C E R T I FE D

C A B L E SH
, OSES NSPECTED

P P E R E Q U I R E [ ' ] E N T] D
S E N T I FE D

F L A G M E NT R A I N E D] P O S I T ] O N E D

G U A R D SP O S I T I O N E D

_
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C o m o a n vD o c . N o : R L 0 - 3 0 620- M
1 3 2 - 4 0R
2 ev03

-2005

L
04-JU

. N/A:

SPECIALPPE AVAILABLEAS PER NTISDS

SCAFFOLDINSPECTED

PLANT& EQUIPMENT

I YEs

D)^^

)7 ^f )A

_
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CompanyDoc.No:RL0 306012-l\132-402
Rev.03

-2005

L
04-JU

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