GSE

GULF SPIC ENGINEERING L. L. C

METHOD STATEMENT
FOR
ABOVEGROUND PIPING
Doc No: GSE/MS/AGP-002 REV 1

PROJECT: AL-AWEER GAS TURBINE POWER STATION H PHASE III

GSE

GULF SPIC ENGINEERING L. L. C

METHOD STATEMENT FOR AG PIPING

PREPARED By

GULF SPIC
ENGINEERING L. L. C

REVIEWED By

APPROVED By

SIEMENS/ETA

MMD/DEWA

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METHOD STATEMENT FOR AG PIPING

CONTENTS
Sl No

DESCRIPTION

PAGE No

DEFINITIONS

INTRODUCTIONS

SCOPE OF WORK

REFERENCE

RESPONSIBILITIES

4.1

PIPING ENGINEER

4.2

MATERIAL CONTROLLER

4.3

QC ENGINEER

4.4

SAFETY ENGINEER

HSE CONTROL

WORK SCHEDULE

EXECUTION PLAN

7.1

MATERIAL RECEIVING AND HANDLING

7.2

PRE-FABRICATION & INSTALLATION OF PIPILINE

7.3

HYDROTEST

13

7.4

EQUIPMENT TOOLS & TACKLES

14

7.5

MANPOWER

15

8.

JOB SAFETY ANALYSIS

15

9.

DOCUMENTS ATTACHEMENT

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METHOD STATEMENT FOR AG PIPING

I.

DEFINITIONS
GSE

GULF SPIC ENGINEERING L. L. C

SIEMENS/ETA-

SIEMENS/ETA CONSORTIUM

DEWA

DUBAI ELECTRICITY & WATER AUTHORITY

QA

QUALITY ASSURANCE

QC

QUALITY CONTROL

AG

ABOVE GROUND

HSE

HEALTH SAFETY & ENVIRONMENT

ASME

AMERICAN SOCIETY OF MECHANICAL ENGINEERS

WPS

WELDING PROCEDURE SPECIFICATION

PQR

PROCEDURE QUALIFICATION RECORD

NDE

NON-DESTRUCTIVE EXAMINATION

PWHT

POST WELD HEAT TREATMENT

SS

STAINLESS STEEL

CS

CARBON STEEL

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METHOD STATEMENT FOR AG PIPING

1.0

INTRODUCTION
This method statement is intended to outline the method and sequence of work
execution which will be followed for FABRICATION, ERECTION, COMMISSIONING &
TESTING of aboveground piping of AL-AWEER GAS TURBINE POWER STATION H
PHASE III.

2.0

SCOPE OF WORK
The activities includes but not limited to receiving of pipes and fittings from
ETA/SIEMENS, transporting to site, installation of piping, fabrication & welding,
NDE, and leak test as per project specifications for the following piping systems
(not limited to)

FUEL GAS PIPING

FUEL OIL PIPING

INSTRUMENT AIR PIPING

SERVICE AIR PIPING

FIN FAN COOLER SYSTEM

LUBE OIL SYSTEM

It shall be our responsibility to ensure all the requirements as per SIEMENS/ETA

approved drawings, DEWA specifications and international standards.

3.0

REFERENCE DOCUMENTS
ASME B 31.1
ASME B 31.3
DEWA PROJECT SPECIFICATION G5.1, G5.5 & G5.6

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METHOD STATEMENT FOR AG PIPING

4.0

RESPONSIBILITIES
SITE ORGANISATION CHART AS FOLLOWS
SITE
MANAGER

PIPING
ENGINEER

4.1

QA/QC
ENGINEER

MATERIAL
CONTROLLE
R

SAFETY
ENGINEER

PIPING ENGINEER
He shall be responsible for carrying out all the activities associated with AG
piping works including prefabrication

and erection. He will have the

responsibility of timely execution of project activities in line with the project

schedule. He will plan for activities related to AG piping including but not limited
to materials, machinery, and manpower.
He is also responsible for expediting missing materials, monitoring drawing
revisions and modifications for meeting the project targets.
4.2

MATERIAL CONTROLLER
Material controller is responsible for collecting materials from warehouse
designated lay down area and shifting the same to the fabrication area and
shifting fabricated spools from the fabrication area to the erection site.

4.3

QC ENGINEER
He is responsible for preparation of WPS / PQR, welder performance
qualification, selection and control of welding consumables & NDE requirements.
He will be in-charge for verification & documentation of all relevant drawings
and reports; material, welding and welder traceability on job and all stage
inspection as per approved ITP. QUALITY ASSURANCE is ensured at all levels of

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fabrication, erection commissioning process through phased flow and execution

of procedures.
4.4

SAFETY ENGINEER

Reports to the HSE In charge.

Implements the project safety plan.

Conducts safety awareness training for site personnel

Monitors the site to ensure safe working practices.

Ensure all tools & tackles, heavy equipments and machinery do comply
with the safety requirements of the project.

5.0

Prepares daily, monthly safety reports.

HSE (HEALTH SAFETY ENVIRONMENT) CONTROL

GULF SPIC ENGINEERING L. L. C will engage qualified safety personnel who
ensure that carbon steel piping works are carried out as per the CONSTRUCTION
HEALTH PLAN which is enclosed with this document.
Only the Mott approved Construction HSE plan will be implemented. All persons
involved will use necessary PPE and will be made aware of all the safety
requirements on job.
Work permit at site for the field jobs will be acquired and will be made available
at site.

6.0

WORK SCHEDULE
From the master schedule, related sections of piping works shall be extracted
and be used as the timeframe. Work sequence shall be followed while executing
the different activities involved.

7.0

EXECUTION PLAN

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7.1
7.1.1

MATERIAL RECEIVING AND HANDLING

The receipt of materials at stores is inspected by the QC Engineer for relevant
TCs and visually checked for damages. A MATERIAL INSPECTION REPORT will be
prepared and submitted to the SIEMENS/ETA. Any discrepancies in the incoming
material

inspection

will

be

identified

in

the

report

and

concerned

documentation shall be made to regularize it.

7.1.2

Material controller ensures only accepted materials are issued to the concerned
Piping Engineer.

7.1.3

Piping Engineer shall identify the list of material as per the approved drawings.
He prepares a material requisition and submits to stores via MATERIAL ISSUE
VOUCHER for drawing the materials.

7.1.4

Any discrepancies in the Isometric drawings shall be referred back to

SIEMENS/ETA, (after checking in the P & ID, Layout drawings) whom shall revert
with necessary documentation to get written notice or field revised drawings.

7.1.5

Piping Engineer will ensure proper handling of materials at all stages of

fabrication, erection commissioning. All pipes are fixed with end caps closed
until it is ready for fabrication/installation to avoid sediments going inside.

7.2
7.2.1

PRE-FABRICATION & INSTALLATION OF PIPELINE

Pre-fabrication of the pipes and spools will be identified as per LAYOUT & ISO
drawings. Doubling of pipes will be carried out at a suitable identified location
(offsite). The work front shall be made available by SIEMENS/ETA to cater the
desired work progress as per the project schedule.

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7.2.2

The piping engineer on referring the P&ID and ISO drawings will identify the
scope for pre-fabrication & doubling of pipes. SIEMENS/ETA shall also decide on
the scope for pre-fabrication.

7.2.3

The priorities for pre-fabrication of pipes, spools will be identified based on the
overall project schedule. SIEMENS/ETA shall also advice on the priorities of the
piping systems to be made ready for erection.

7.2.4

Welder Performance Qualification will be carried out as per approved WPS/PQR

and the same will be witnessed by SIEMENS/ETA. Each welder will be provided
with identification no.s for traceability of welders on job.

7.2.5

Welding of the pipes will be carried out as per the approved WPS by qualified
welders. The joint design will be ensured for compliance with WPS checking the
edge preparation, root gap, bevel angle, land etc. Preheat of weld joint will be
done at applicable areas which will be identified based on project
specifications/codes & standards.

7.2.6

The fitup of connected fittings with the pipe will be given additional concern to
have a proper orientation as depicted in the ISO drawing for matching with the
connected pipings at site.

7.2.7

The welding consumables will be under the control of QC Engineer. The

electrode selection as per WPS, baking of electrodes wherever required by
calibrated baking ovens, portable holding ovens issued for welders on job,
calibration of welding machines and electrode baking record will be maintained
and ensured by the QC engineer for clients review.

7.2.8

The NDE for the pre-fabricated pipes will be carried out based on the
segregation made on piping class and Project Specifications. The scope for RT
(decided based on pressure rating as per project technical specifications) will

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be identified at site and the same will be ensured for its compliance (as test
reports).
7.2.9

PWHT for the required pipe weld joints will be identified based on the Project
Specifications G5.6 /applicable codes and standards (ASME B31.1). Before
PWHT, all the required Non-Destructive Examinations will be carried out in the
piping weld joints and the same will be compiled as NDE records.

7.2.10 The stage inspection to be carried out during welding as prescribed in the
approved I&TP will be executed and all the responsible participating parties
will be called during inspection. The following inspection reports will be
maintained and be concurred from SIEMENS/ETA after successful completion of
subsequent stages,

Fitup and Alignment Inspection Report

Welding Visual Inspection Report

RT report

Post Weld Heat Treatment Record

7.2.11 The joint reference will be identified near the weld joint where the details
including weld joint no., welder no., line ISO no. etc., will be transferred by
suitable means (via., permanent paint markers or direct hard punching on
surface). Such joint references will be retained till the final pressure test.
7.2.12 The routing of the pipes on steel columns, sleeper bays will be studied by the
piping engineer. This feasibility study will include

Space adequacy for positioning of lifting equipments which shall be

clarified from SIEMENS/ETA end for conformance at site.

Space adequacy near the vicinity of erection area for temporary

storage of tools and tackles which shall be clarified from SIEMENS/ETA
end for conformance at site.

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Erection clearance from the preceding contractor for structures & pipe
racks.

Identification no.s of support columns and sleeper ways (to be marked

on the respective columns for easy identification)

Man-access at place of adjacent piping systems for its non-hindrance

(especially near the field weld joints)

Support pedestals at pipe racks confirming to drawing requirements.

Scaffolding requirements.

If any inadequacies exist, the same will be reported to SIEMENS/ETA for

clarification.
7.2.13 All the pre-fabricated pipes will be covered at the ends by suitable means so as
to ensure debris free inside surface. Before covering the pipes, the removal of
foreign particles will be ensured.
7.2.14 The pre-fabricated pipes will be coated as per the technical specifications
following all the stage inspection process for surface preparation, primer coat
DFT and final coat DFT. The details will be recorded (as inspection reports) and
submitted for clients review.
7.2.15 Coating on weld joints will be carried out only after successful completion of
the pressure test.
7.2.16 Before shifting the pre-fabricated pipes to site, it shall be ensured for its
completeness in all respects (NDE, PWHT, paint coating etc.,). All the prefabricated pipes are identified by their ISO drg no., line no., joint no., welder
no. and will be ensured by supporting documents for conformance of the test
results.
7.2.17 During transit of pre-fabricated pipes to site, proper care (by suitable means
like wrapping with plastic cover sheets, using rubber sheets to avoid contact

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with metal slings while lifting etc.,) will be taken not to damage the coating on
pipe surface.
7.2.18 After shifting the pipes to site, the receiving end inspection will be carried out
for any transit damages (like coating damage etc.,). Presence if any will be
tended before proceeding with the erection.
7.2.19 Dimensional check of the pipes will be carried out at site to identify
trimming/shortcoming requirements. For this a detailed study of the ISO drg
with the layout drg will be carried out by the piping engineer to interpret the
feasibility conditions.
7.2.20 Erection of pipes on structures will be carried out in concurrence with the JOB
SAFETY ANALYSIS (refer attachment 1) to ensure safe working practices. Tools,
tackles and the lifting equipments are ensured for its adequacy and suitability
for the job requirements. Proper concurrences are met and approved prior to
execution. Risk assessment study will be carried out by the Safety Engineer and
will be submitted separately to client for review.
7.2.21 For multi-tier pipe racks, the erection sequence of piping will be followed from
the lower tier to the upper tier. To insert pipes in the lower tier, the columns at
the road cross-over section shall not be installed with interconnecting beams.
This would enable free access for sliding the pipes into the pipe rack with an
extended boom length from the lifting equipments. This pre-requisite shall be
ensured by SIEMENS/ETA before the starting of erection activities. Such
locations will be identified by the piping engineer in co-ordination with the ETA
engineer prior to the erection activities (refer attachment 2 for main pipe-rack
piping areas highlighted for crane access requirement).
7.2.22 Wherever applicable, the erection of upper tier columns and tie beams shall be
on-hold till the completion of erection of lower tier pipings to ensure sufficient

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man & material access for performing site erection activities. The same should
be ensured by SIEMENS/ETA prior to starting of the erection activities. Such
locations will be identified by the piping engineer in co-ordination with the ETA
engineer prior to erection activities (refer attachment 3 for pipe-racks in Fuel
Oil Storage Tank - areas highlighted)
7.2.23 The necessary scaffolding platforms to enable rigging activities and the
subsequent joint fitup/welding should be ensured by SIEMENS/ETA prior to the
execution.
7.2.24 Prior to joint fitup, the provision of permanent supports will be confirmed with
the ISO drawing. Wherever required, temporary supports will be provided to
avoid line distortion while welding. The provision of temporary supports will be
concurred from SIEMENS/ETA before further execution.
7.2.25 Welding of field joints will be carried out as per approved WPS. For pipes with
connected fittings, the orientation of nozzles, weldolets, half couplings etc.,
will be checked with the connecting piping orientation. The alignment of the
pipe fittings will be given adequate care (via temporary supports wherever
required) to avoid line distortions during welding.
7.2.26 The orientation of drains and vents shall follow the universal rule of highest
point vents and lower point drains.
7.2.27 Wherever SS connected piping and fitting exist, proper care will be taken to
avoid contact corrosion of SS spools with CS materials. As far as possible, only
belt slings will be used for lifting SS materials. If metal slings be used, then the
contact location will be suitably masked & covered.

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7.2.28 Wherever flange connections exists, they will be covered at their faces to avoid
damages at transit (especially at gasket seating faces) by suitable means like
wooden blinds, plastic caps etc.,
7.2.29 The regularization works after the job completion, like removal of fitup cleats,
weld spatters (if any), temporary supports etc., will be carried out and
ensured.
7.2.30 NDE & PWHT for field weld joints will be carried out wherever applicable as per
project technical specifications. Such stage inspections will be backed by NDE
and PWHT test report and submitted for clients review.

7.3
7.3.1

HYDROTEST
A punch list for jobs to be carried out will be prepared by the QC Engineer and
submitted to the SIEMENS/ETA. SIEMENS/ETA on their discretion will add/delete
on the jobs listed. A walk down inspection of the entire loop will be performed
for confirming the drawing requirements. The activities listed out will be
carried out based on the priority status and the same will be confirmed.

7.3.2

Pipe cleanliness for inside and outside surface will be carried out. For inside
cleaning, card board bursting will be carried out for the entire test loop and
cleanliness will be ensured prior starting of Hydrotest.

7.3.3

A TEST PACK will be compiled by the QC Engineer which will contain the
following,

TEST DRAWING showing test limits

ISO & Drawings list

Piping NDE test reports

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PUNCH list (post/pre)

Line welding History Sheet (with NDE reports)

PRESSURE TEST check list

Calibration certificates of pressure gauges used for testing

Reinstatement check list

HYDROTEST certificate

The test pack will be submitted for clients review and approval before the
starting of HYDROTEST.
7.3.4

Water to be used will be from a portable & agreed location.

7.3.5

Fill water through hoses at the lowest points in the loop. After ensuring priming
in the loop, start pressurizing to the test pressure (1.5 times the design
pressure or as per the project specifications).

7.3.6

Holding time for the test pressure shall be as per ASME B 31.1/project
specifications.

7.3.7

Failure in the test (if any) shall be reverted with draining, repairing and retesting with the above procedure.

7.3.8

On completion of Hydrotest, the water shall be drained, ensuring proper safety

precautions. After complete draining of water, the loop should be air flushed to
ensure removal of moisture entrapment.

7.3.9

Reinstate the test loops Paint coating at weld joints, isolation of pressuring
equipment, moisture removal by air flushing etc.,

7.4

EQUIPMENT TOOLS AND TACKLES:

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7.4.1 All required Equipments, Tools and tackles shall be deployed to meet the work
Schedule and satisfactory installation. This equipment is available at GSES Site
store.
7.4.2 All required measurement tools shall be made available to enable correct
installation and inspection of Structures.
7.5

MANPOWER:
Sufficient manpower as required to meet the safe, satisfactory and timely
completion of the job shall be deployed as per enclosed list and these will
consist of but not limited to the following:

8.

Supervisors

Foreman

Skilled workers

Rigging Group

Site Cleaning Crew

JOB SAFETY ANALYSIS.

The job safety analysis for the above ground pipe line erection & testing work is
prepared and enclosed as reference Attachment I documents.
----------------- XXX --------------------

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