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METHOD STATEMENT FOR Rev : A

OXYGEN LINE FABRICATION Page : Page 1 of 13

Date : 21-Sep-2017

SABIC /GAS # 1100245

Project Title NITROGEN GENERATION UNIT PROJECT
Client E-TEC
Location GAS-YANBU

METHOD STATEMENT FOR OXYGEN LINE

FABRICATION
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Contents
1. OBJECTIVE: ...................................................................................................................................................... 3
2. SCOPE:............................................................................................................................................................. 3
3. REFERENCES .................................................................................................................................................... 3
3.1 Project drawings ..................................................................................................................................... 3
3.2 Project quality plan (PQP) ....................................................................................................................... 3
3.3 Codes and standards............................................................................................................................... 3
4. ABBRIVIATIONS/DEFINITIONS......................................................................................................................... 4
5. RESPONSIBILITIES ............................................................................................................................................ 4
6. PROCEDURE .................................................................................................................................................... 5
6.1 RECEIPT, STORAGE AND PRESERVATION OF PIPE RAW MATERIALS .......................................................... 5
6.2 SPOOL BREAKDOWN ............................................................................................................................... 5
6.3 PIPING FABRICATION .............................................................................................................................. 5
6.3.1 GENERAL ................................................................................................................................................. 5
6.3.2 Cutting and Beveling ............................................................................................................................... 6
6.4 WELDING................................................................................................................................................. 8
6.5 Inspection ............................................................................................................................................... 9
6.6 Material Identification .......................................................................................................................... 10
6.7 Positive Material Identification ............................................................................................................ 10
6.8 Storage and preservation ..................................................................................................................... 11
7. TOOLS & EQUIPMENTS ................................................................................................................................. 11
7.3 Execution .............................................................................................................................................. 11
7.4 HSE ........................................................................................................................................................ 12
7.5 Testing................................................................................................................................................... 12
8. HSE INSTRUCTIONS ....................................................................................................................................... 12
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1. OBJECTIVE:
This method statement shall provide SENDAN minimum requirement to carry out Fabrication of
OXYGEN Line piping spools at shop for GAS Nitrogen Generation Unit (NGU) Project at YANBU
Industrial City in Kingdom Of Saudi Arabia accordance with Project approved drawings, SABIC &
eTEC project specifications and Industrial codes.

2. SCOPE:
This Method Statement is applicable for the OXYGEN Line Piping fabrication activities, such as
Cutting, Grinding, Tack Welding, Full welding and NDT works shall performed at SENDAN
fabrication shop for the GAS-NGU Project. In the event of conflict between the procedure and
project specification later shall govern subject to e-TEC & PMT for the approval.

3. REFERENCES

3.1 Project drawings

3.1.1 Approved Project Drawings with IFC Stamped

3.1.2 Approved Piping Arrangement drawings
3.1.3 Approved P&ID.
3.1.4 Project Piping Layout drawings.

3.2 Project quality plan (PQP)

3.2.1 Inspection / Testing shall be in accordance with PQP

3.3 Codes and standards

ASME B31.3 Process Piping

PFI ES3 Fabrication Tolerances
PFI ES24 Pipe Bending tolerances
ASME Section V Non Destructive Testing
ASME 16.25 Butt-welded Ends
ASME 16.5 Pipe Flanges and Flanged Fittings
SNT-TC-1A Guidelines of American Society of NDT
P13-CO2 Fabrication and Erection
P14-T05 Non- Destruction Examination Requirement of Piping
P28-E01 Pipe Joints
Q01-T07 Material Identification Program
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P01 E15 Pressure Testing and Lay up Procedures

W02 F01 Welding-Safe Practices
W05 F02 Welding Requirements for On-Plot Piping
W01-F06 Storage of Welding Rods and Electrodes
4. ABBRIVIATIONS/DEFINITIONS
CL Client-e TEC
PM Project Manager
SM Site Manager
CM Construction Manager
PE PIPING ENGINEER
QA&QC Quality Assurance & Quality Control
QCI Quality Control Inspector
PQP Project Quality Plan
PPE Personal Protective Equipment
HSEP Health Safety & Environment Plan
HSE Health Safety & Environment

Company SABIC/GAS
Contractor eTEC
Sub-contractor SENDAN
Project Nitrogen Generation Unit Project (NGU)

5. RESPONSIBILITIES
5.1 It is overall responsibility of Project Manager/Site Manager to organize resources to perform
piping fabrication activities as per project specification, in compliance with quality, schedule
& HSE requirements.

5.2 It is the responsibility of Construction Manager that fabrication activities are executed
according to the relevant project specifications, in compliance with quality, schedule & HSE
requirements.

5.3 E-TEC is responsible to issue the Latest Approved for Construction drawings to SENDAN to
perform the fabrication activities.

5.4 Piping Engineer will ensure that all the works are performed safely as per latest Approved for
Construction (IFC) drawings & specifications. He shall responsible to reflect necessary
construction data on drawing and submit to eTEC review prior to issue for construction.

5.5 SENDAN Piping Supervisor will ensure that all the piping fabrication is conducted in
accordance with this method statement and project specifications. He shall ensure all the tools
& relevant equipments shall calibrated with approved third party under eTEC supervision.

5.6 The Welding Supervisor will ensure the Piping welding work is accordance with Method
statement & Project Specifications. He shall ensure electrode, Baking & Holing calibrated with
approved third party.
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5.7 The Quality Control Inspector will ensure that all work is executed according to PQP and that
requirements of quality dossier are full filled. He shall arrange all inspections according to ITP
with eTEC QC department.

5.8 Safety officer shall ensure the fabrication activities performing as per the project HSE
specification and compliance.

6. PROCEDURE

6.1 RECEIPT, STORAGE AND PRESERVATION OF PIPE RAW MATERIALS

6.1.1 The All piping material received from client shall be off loaded in designated lay
down yard.

6.1.2 During offloading, pipes shall not be dropped on the transport. A crane and suitable
certified slings shall be used. Nylon slings will be used to handle SS and coated
piping & fittings.

6.1.3 The pipes shall be placed on concrete blocks with wooden packing in between.

6.1.4 The piping end covers shall be kept in place to prevent foreign particle entry into the
pipes.

6.1.5 All material shall come with color-coding as per size, material & schedule.

6.1.6 The piping material shall be segregated accordingly to facilitate location of the
items. SS, Low Temperature CS, CS and Galvanized pipe & fittings to be stored
separately.

6.2 SPOOL BREAKDOWN

6.2.1 The piping isometrics shall be marked into number of spools to facilitate the fabrication
& erection work.

6.2.2 Each spool shall be marked with a unique number.

6.2.3 Each joint on the isometric will be given a unique number preparing a welding map for
traceability. Separate numbering system will be followed for butt welds, fillet welds,
threaded joints, pipe supports directly attached to pipe, bolting points etc.

6.2.4 The details of piping isometric breakdown into spools and joints will be recorded for
reference.

6.3 PIPING FABRICATION

6.3.1 GENERAL
6.3.1.1 Material will be shifted from e-TEC to Sendan Lay down work shop as per relevant
piping isometric drawings.
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6.3.1.2 Carbon steel, low temperature carbon steel, stainless steel pipe fabrication work will
be done in separate areas.

6.3.1.3 Tools & equipment compatible with the material in fabrication shall be used.

6.3.1.4 The piping material is to be used in an appropriate and economical way.

6.3.1.5 All cuttings should be collected separately as per material code and place in order to
make best use of these.

6.3.1.6 Cuttings of other then alloyed material may be considered as waste up to maximum
1000mm, and should be stored separately

6.3.1.7 Pipes for socket weld joints shall be cut square.

6.3.1.8 Ensure all Welding Machines should be calibrated before using for fabrication/welding
works.

6.3.1.9 Inspection tools shall be calibrated & Using according to the project requirements.

6.3.1.10 Approved Electrodes should use for welding after inspection from Client

6.3.1.11 Electrode Baking & Holding Should be properly maintained as per ASME
requirements.

6.3.1.12 Unless otherwise specified, the dimensional tolerance of piping spools shall be
comply with PFI Standard ES-3.

6.3.2 Cutting and Beveling

6.3.2.1 Butt Joint

6.3.2.1.1 The pipes shall be cut as per dimensions mentioned in the isometric and all
pipe length shall be marked with the relevant spool No, as given in the
isometrics.

6.3.2.2 Based on spool break down of piping isometrics, pipe lengths shall be cut 100mm
extra length for pipe will be provided in spools for field adjustment.

6.3.2.3 The pipe ends for 2 inch & above shall be beveled as per approved WPS for the
piping class.
6.3.2.4 The cutting and beveling of pipes shall be done by mechanical means cold cutting
beveling machine/lathe machine, flame cutting or plasma/arc cutting, cutting shall
be acceptable provided the edges smooth.
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6.3.2.5 Cutting /Grinding wheels shall be suitable for the material (stainless steel and
Carbon steel) and not be mixed.

6.3.2.6 When torch cutting or arc cutting are used for alloy steel or stainless steel, after
grinding to sound metal a dye penetrate examination shall be performed to
eliminate the possibility of surface cracks.

6.3.2.7 The fit up of pipe ends, fittings & weld neck flanges shall be done to obtain uniform
root opening. The criterion given in related WPS shall be followed.

6.3.2.8 The joint should be free of grease, oil, scales, rust or other foreign material.

6.3.2.9 The primer paint coat on pipe & fitting ends shall be removed prior to bevel end
preparation.

6.3.2.10 The pipes shall be tack welded by a qualified welder. If the pipes are of
different thickness, the larger thickness will be tapered in compliance with standard
to match the smaller thickness.

6.3.2.11 The adjacent section of longitudinally welded pipes that are to be joined by butt
welds shall have longitudinal weld seams positioned such that they are at least 30
apart from horizontal centerline. The fabricator will also not locate longitudinal weld
seams on top or bottom of the pipe so that branch connections are not located on
the seam.

6.3.2.12 Reinforcement pads shall be fabricated only if required in the isometric. The
material for reinforcement pad shall be same as that for the pipe unless otherwise
authorized by Client. The size & thickness of pad will be as specified in the
isometric. It is preferable that the pad shape is circular; however, the pad size may
be altered provided equivalent cross-sectioned area is maintained as per ASME
requirement. The pad shall have a 1/8 NPT vent hole, drilled & tapped to NPT
prior to installation of reinforcement pad.

6.3.2.13 The Flanges indicated on isometric to be supplied loose should be tack welded
with the pipe. Full welding shall be made after site checking.

6.3.3 Socket Joint

6.3.3.1 The pipe for welded sockets joint shall be ground to remove burrs due to cutting. A
gap between end of pipe & bottom of socket will be maintained as per Project
Specifications.
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6.3.4 Threaded Joint

6.3.4.1 In case of threaded pipes (for utilities piping only) screw threads shall be
concentric with axis of pipes with no burrs or stripping. The threading dies shall be
sharp & properly designated for the piping material.

6.3.4.2 All pipe threads shall be taper-pipe threads in accordance with ASME B1.20.1

6.3.4.3 Teflon tape shall be used for all threaded joints, except instrument air, where the
design temperature is 200 deg.C or below. Other acceptable materials for thread
lubrication are the following. a. Teflon paste - Threaded joints to 200 deg C b.
Copper paste - Threaded joints 200 deg.C to 620 deg.C.

6.3.5 Material Traceability

6.3.5.1 Material traceability shall be according to the Method Statement of material

traceability.

6.4 WELDING

6.4.1 All welding work will be according to approved WPS and B31.3 and only qualified
welders shall be employed.

6.4.2 Heat treatment will be indicated on WPS, where required.

6.4.3 Electrode baking and holding shall be properly maintained as per ASME requirements.

6.4.4 The welding work piece will be shielded against high winds and rain. The wind speed
exceeding 10 m/sec and 3 m/sec for SMAW & GTAW respectively.

6.4.5 The weld surface shall be cleaned with wire brush or grinding prior to welding
operations to give a surface free from rust, scale or mill coating.

6.4.6 Root pass welding shall be done by GTAW process with argon backing purge.

6.4.7 Between each layer of welding any cracks, pores or welding spatters shall be removed
by grinding the surface before application of next layer.

6.4.8 The appearance of finished welds shall conform to ASME B31.3 code & WPS and
shall exclude any under cuts, spatters, and cracks.

6.4.9 All branch connections shall be joined to headers with full penetration welding. The
bore side shall be ground smooth, free from cracks.
6.4.10 For flange to pipe connections if welding shrinkages can lead to misalignment, two
similar flanges shall be joined by inserting a temporary gasket and then welded.
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6.4.11 For socket welding the pipe ends shall be cut straight.

6.4.12 The distance between centerlines of adjacent girth butt welds and staggering of
longitudinally welded pipe for making butt weld shall be according to project
specification.

6.4.13 Preheating shall be done in accordance with the welding requirement related to each
class of piping base metal material.

6.4.14 Welding shall be performed to ensure complete fusion of the weld deposit and the
base metal in order to obtain homogeneous bound over the entire cross section area
of the weld.

6.4.15 Welding current and polarities shall comply with the instructions given by the
manufacturer of the filler metal.

6.4.16 Number of layers shall never be less than two.

6.4.17 Proper protection shall be done while performing welding activity.

6.4.18 Only approved electrode shall be used and electrode issuing & receiving log sheet
should be maintained every day by store.

6.4.19 Adjustable Stand Support should be used for the pipe welding with the maximum
distance of 1 meter above the ground level.

6.4.20 Extra care shall be taken for the cleaning of pipe spools.

6.4.21 Passivation should be done for Stainless Steel Piping.

6.5 Inspection

6.5.1 The fabricated pipe spool shall be checked against project drawings to verify its
compliance.

6.5.2 The dimensions, angle and direction of spool and allowances for field welding shall be
according to the ASME B.31.3 (chapter V).

6.5.3 Material, Fit-up & Welding Inspection should be done as per SES
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6.5.4 NDE shall be performed as per ASME section V after PWHT if specified on isometric
drawings or project specifications.

6.5.5 Hardness test (HT) shall be performed according to requirement.

6.5.6 The acceptance criteria for Visual inspection shall be done according to the ASME
B.31.3. (Chapter VI).

6.5.7 Visible small transverse cracks & star cracks of limited thickness shall be removed by
grinding & repaired by welding. However circumferential cracks shall result in weld
rejection. The defective material will be cut out & re-welding preformed.

6.5.8 Butt welds shall be Radiographed (RT) and Dye penetrant test for socket welds as
per line class requirement.

6.5.9 NDE tests shall be performed & recorded as per Project Welding Specifications.

6.5.10 The NDE result shall be interpreted by qualified inspectors (level II).

6.5.11 Branch connections shall be examined by dye penetration or Magnetic particle or

Ultrasonic methods.

6.5.12 All welding records for each joint shall be maintained throughout the fabrication work.

6.5.13 Low temperature carbon steel material traceability shall be maintained throughout the
fabrication work such that location & heat numbers of all welded pressure retaining
pipe component is maintained. Permanent marker will transfer the heat number to all
pieces cut from main pipe.

6.6 Material Identification

6.6.1 Each fabricated spool shall be clearly marked with a number. This number shall
include line number & spool number as shown on the piping isometric. For piping up to
diameter 6 inch it will be hard marked on to a steel plate 2x 3x 1/16 inch, which shall
be securely wired to the pipe. However for piping greater than 6 inch diameter the
number will mark on inside of the pipe using a permanent marker.

6.7 Positive Material Identification

6.7.1 Marking
All pipe and fittings shall have the material specification and grade stamped, stenciled,
or otherwise marked.
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6.7.2 Alloy Testing

Materials must not get mixed up at any time, from manufacturing to installation. Alloy
testing is prescribed in SES Q01-T07.

6.8 Storage and preservation

6.8.1 The pipe spool complete in all respect shall be stored separately.

6.8.2 All spools shall have their identification/piece number clearly designated on each
spool.

6.8.3 The spool will be cleaned in an inclined position by tapping so that all foreign materials
are removed.

6.8.4 The spool shall be placed on wooden baton to avoid direct contact with soil.

6.8.5 The open ends shall be covered by polyethene sheets or end caps. In case of flanged
spools the same shall be covered by securely tied wooden blanks to avoid foreign
material entering the pipes.

6.8.6 The spool shall be handled using nylon lifting slings.

6.8.7 Alloy / SS to be stored separate form CS.

6.8.8 Piping material to be preserved as per SABIC approved preservation procedure.

6.8.9 Identification Tag material for SS pipe spool shall be of stainless steel.

7. TOOLS & EQUIPMENTS

7.3 Execution

7.3.1 Hand Tools

7.3.2 Cutting, Beveling & Grinding Machines
7.3.3 Cranes (Mobile)
7.3.4 Welding Diesel Generator
7.3.5 Hack Saw
7.3.6 Trailer
7.3.7 Welding Set
7.3.8 Cutting Set
7.3.9 Magnetic Drill
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7.4 HSE

7.4.1 Safety helmet

7.4.2 Safety belt
7.4.3 Safety Goggles
7.4.4 Gloves
7.4.5 Safety Shoes
7.4.6 Welders Helmet
7.4.7 Ear Plugs/Muffs (if required)
7.4.8 Dust mask (If required)

7.5 Testing

7.5.1 Radiography
7.5.2 Ultrasonic Testing
7.5.3 Magnetic Particle Testing
7.5.4 Positive material identification.
7.5.5 Dye Penetrant
7.5.6 Hardness test

8. HSE INSTRUCTIONS
8.1 During execution of the job all measure shall be adopted to ensure safe working.

8.2 Client site management system (latest revision) will be implemented.

8.3 All personnel involved will use necessary PPE as required.

8.4 The workers will be made aware of HSE requirements related to this activity through daily,
weekly and monthly toolbox and HSE talks.

8.5 HSE notice board will be installed.

8.6 All equipment will be inspected by HSE (SENDAN) prior to use.

8.7 During transportation of pipes and other fittings, the material shell be properly supported
and tied on the Trailer.

8.8 Ensure that pipes are properly wedged or blocked to avoid rolling.

8.9 Correct rigging procedure should be observed.

8.10 Properly insulated and nonconductive tools should be used for electric work.

8.11 Access and good housekeeping should be maintained in all fabrication areas.
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8.12 Fire extinguisher should be available in all working areas.

8.13 Proper storage, handling and use of gas cylinders will be observed.

8.14 All cylinders shall be kept in trolleys and in an upright position.

8.15 Wild and domestic life should not be harassed.

8.16 Welding sets should be checked and maintained regularly for wear and tear.

8.17 Waste Management should be strictly followed to keep the job site neat and clean.

8.18 Never monkey with electric cables and appliances.