Al-Karrar Engineering Company

Janubia PWD Phase 2- Fire Water and Dammam Line ReroutingMethod Statement for
Construction of Piping Works at South Rumaila

Method Of Statement

Janubia PWD Phase 2- Fire Water and Dammam

Line Rerouting

Revision Status:

First Issue Hassan K. Zaidon Imad Murtadha M.

REV DATE STATUS PREP.BY CHKD. BY APPD.BY
Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

TABLE OF CONTENTS

1. PURPOSE

2. SCOPE

3. REFERENCES

4. DEFINITIONS

5. RESPONSIBILITIES

6. SEQUNCE OF WORKS

7. QA/QC

8. RESOURCE

9. HSE REQUIMENTS

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

1.0 Purpose:
The purpose of this methodology is to provide a systematic control and direction for the activity
to Demolish Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
& backfilling after Fabrication work farther to wrapping underground section of Jinubia fire water
& Dammam line . This method statement provides the expectation to execute work in safe, eco-
friendly manner and in compliance to the ROO HSE and Quality requirements.

2.0 Scope:
As part of E-100 WASH WATER scope at DS-4 AL-KARRAR is to carry out Tie-Ins work &
EXTEND underground section as per drawing. Of:
PI-ISO-0006-001.
PI-ISO-0007-001.
. This installation will be comprised of welding of field joints and the assembly of completed pipe
spools which were prefabricated in advance.
As it stands the mentioned lines will require replaced by new piping.

3.0 References

ROO- Shop and Field Fabrication of Piping

ROO Technical specification for piping system
ASME B 31.3- Process piping
ROO-ALL-HS-PRO-0025 REV 10 Ground Disturbance and Excavation Procedure
ROO Specification for welding and inspection of shop and field fabricated
carbon steel process and utility.
DOC No P12169 REV1- Project Quality Plan

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

4.0 Definitions

Client - Rumaila Operating Organization ( ROO)

QHSE - Quality, Health, Safety & Environment
QCI - Quality Control Inspector
ITP - Inspection and Test Plan
WPS - Welding Procedure Specification
NDT - Non Destructive Testing

5.0 Responsibilities
AL-KARRAR shall arrange all the resources deemed necessary for carrying out the works
related to the piping installations. In addition to the above AL-KARRAR will also ensure that
adequate safety precautions are put in place in order to carry out the job in a safe manner.

Construction Manager:
The Construction Manager is responsible in executing the works as per ROO procedure and
approved method statement.

Supervisor/ Foreman:
Ensure that welding equipment, baking oven, quiver are in good condition.
Ensure welding is done as per the approved WPS and approved for construction
drawings and in line with ROO HSE requirements.
Ensure that weld maps / spool drawings are available.
Coordinate with QC personnel to study the cause of any reported weld defects and
arrange to take corrective and preventive action.
Adhere to the ROO HSE requirements.
Comply with ROO requirements.

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

QC Inspector:
Carry out the inspection as per the Inspection and test plan.
Approving/ rejecting the item based on inspection.
Submitting the quality records to the client and getting their approval.
Responsible to keep records of all inspection related activities & Material traceability.
Adhere to the HSE requirements.

HSE Officer:
Advise the construction crew on HSE aspects and ensure their safety.
Arrange through Job performer for tool box talk covering risk assessment in language
understandable by workers.
Cross checking certified material devices and equipments are used.
Do weekly, monthly HSE audit.
Ensure appropriate safety measures are taken as per the risk assessment and controlled
documents.
Ensure that all staff adhere to the HSE plan and HSE requirements.

6.0 Sequence of Works

6.1 PTW Issuance
A Cold cutting Work permit will be issued to carry out the works, along with the
permit will be the attached crane certificate, approved method statement, risk
assessment, and approved drawings shall also be attached.
Identify each Tie-In(s) (TP-3/TP-4/TP-5& TP-6) schematic location on P&ID.
Create a Tie-In Index (or List) with key information about each Tie-In .
Go to the Field to locate physical point of Tie-In.
Meet with plant personnel and review Tie-In requirements.

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

Define if the lines can be shut down, when, how long, draining, depressurize.
Visually inspect the existing pipe. Are more extensive tests needed to determine
condition and suitability for the Tie-In.
Mark or tag the selected Tie-In point.
Determine locations of all existing block valves, vents and drains.
Finalize (check, correct and approve) all Tie-In isometric drawings.
AK will carry out all De-watering activities during cold cutting by vacuum Tanker.

6.2 Safety Setup

Arrange the required safety signs, barricades and other related safety precautions
highlighted in the risk assessment and permit prior to commencing the works.
The works shall only commence after the job performer has checked and ensured that
all safety precautions and safety requirements are in place.
Ensure employees understand the hazards and control measures related to the critical
activities, i.e. lifting, welding & heat stress.
Ensure personnel stay away from heating zone.
Qualified First Aider must be on site and identified by a sticker on his helmet.
Display Emergency Contact number on site.

6.3 Site Works

6.3.1 Preparatory Work
Ensure that the document received bear the stamp Issued for Construction and are
of latest revision.
The documents submitted/referred with this method statement shall be considered as
an integral part of this method statement and shall be read in conjunction with the same.

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

Lifting Supervisor & crane operator will check & plan the travel routes prior to
mobilization. Ensure travel routes & access to the jobsite is in good condition and free
from obstruction.
Check and confirm crane set-up positioning.
Positioned the trailer near the designated area and proper and adequate clearance
should be maintained between the fence and the trailer
Trailer must be secured with hand breake.
Working area shall be barricaded with proper devices & warning signs to display.
Unauthorized person are not allowed in the area barricaded off
Workers shall wear appropriate PPE for the task.
Safety Coordinator & supervisor shall be present at all time during work activity.

6.3.3 Existing pipe Removal.

All lifting tools, equipments and ropes used for lifting shall be inspected and
certified. Activities shall be done according to approved lifting plan
Submit method statement and RA for review and approval by ROO before
commencing the mentioned work.
Apply the lifting permit before work commence. Lifting supervisor will conduct tool
box and brief the safe lifting operation before work start.
Lifting check list shall be filled up and attached with load chart and LM certificate
shall be submitted during application for permit.
Prior to Lifting Works, it must have an approved Lifting permit and lifting check list .
Which indicate the type of cranes & lifting gears accessories indicated. The check list
must be attached with the lifting permit.
Before starting the lifting work, the assigned people must wear proper PPE and
adequate safety procedure must be implemented.

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

All employee and worker involved in the work should first undergo training or safety
induction with
WEC shall employ an experienced, competent and responsible Lifting supervisor to
plan and execute lifting operations.
Barricade the marked location scheduled for lifting operation with safety signage.
To Provide safe work during lifting of pipes, there are consideration which take
according to weight of the pipe.
The site supervisor should prepare the site area to be clean and clear from obstruction.
Positioned the Lorry Crane / Mobile Crane near the designated area and steel plate
should be place over the landed of the crane out-rigger.
Positioned the trailer near the designated area and proper and adequate clearance
should be maintained between the fence and the trailer
Trailer must be secured with hand break.
Repeat the process until all materials were loaded.
Safety equipment must always present and ready for immediate use.
Care must be taken such that the boom cannot hit the live pipe.
Prefabricated pipe spools shall be carefully loaded and transported to site. The
transported spools will be tied down with ample support to prevent any damage. Spools
will be tied down using nylon straps/belts. Under no circumstances will the pipes be
tied down using chains or cables to prevent any scratches or damage.
Upon receiving the pipes at site, they shall be offloaded and placed either in position
on the pipe supports or placed on the ground on top of wooden supports. All flanged
ends or open ends will remain sealed to prevent any sand or debris from entering.
Lifting of the pipe spools shall be done by using either a HIAB or Crane. Third Party
certified slings and riggers shall be used during the lifting operations. All lifting tools
and tackles shall be color coded based on the current color code.
Once the spools are lifted into position, the fabricator/pipe fitter shall ensure that proper
alignment is achieved, lengths of spools are correct as per the piping layout and
isometric sheet prior to either bolting the spools together or welding any field joints.

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

Welding and grinding of field joints shall be carried out inside a closed habitat made
of fire retardant material. Any live facilities will be covered with the fire retardant
blanket as an additional precaution.
Welding shall be done as per the approved procedure, specification and approved for
construction drawings.
Approved welders for the specific WPS shall be used for welding.
Welded surfaces shall be clean and free from grease, oil, paint or other foreign material
which are detrimental to welding.
When the weather does not permit satisfactory workmanship welding shall not be done,
on site in windy condition the pipe ends shall be closed to prevent through draughts
during welding. Suitable covering using tarpaulin (fire retardant) shall be provided.
Welding shall not be done when the weld surface is wet or when the area is exposed to
rain and strong windy conditions. Preheating to be done properly during cold weather.

6.4 Scaffolding
Scaffolding if required shall be erected by qualified personnel in a safe and suitable
manner.
Scaffolding above 0.5 m in height shall be inspected by a ROO scaffolding inspector
and a scaff-tag shall be signed and provided on the scaffolding near the ladder. No one
shall use the scaffolding without the scaff-tag being approved.
Scaffolding material to be used shall be in good conditions, brass hammer shall be used
to assemble and tighten the scaffolding locks.

7.0 QA/QC
7.1 Weld Identification
Each weld shall be uniquely identified with the joint number and welder number.

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

After completing the weld the welder shall mark the joint no: & welder no: near the
weld using paint or indelible crayon.
After welding each spool the line no, spool no & etc shall be marked / tagged on the
spool and stocked over wooden sleepers or other suitable material above ground.

7.2 Non Destructive Testing

Nondestructive testing shall be done as per the approved procedure.
Third Party should submit UT inspection report as required to ROO for approval
processing.
7.3 Alignment Circumferential Welds
Butt weld alignment shall satisfy the requirement of ANSI B 31.3 and conditions
Stated below.
Internal misalignment of pipe work shall not exceed 1 mm in order to facilitate welding
of the root pass. When a GTAW process is to be used maximum misalignment shall not
exceed 0.8 mm. If there is excess misalignment tapering of the internal diameter of the
thicker member to a taper of 1:4 shall be done. Ensure minimum wall thickness is
maintained.
If misalignment up to 3.2 mm exists, internal grinding or machining may be conducted
to improve root alignment, provided the taper does not exceed 1 in 4 maximum and the
minimum required wall thickness is maintained.
External or internal clamps shall be used not only for misalignment correction but also
for alignment in general. Misalignment correction using heavy hammering or heating of
the pipe shall not be done.

7.4 Weld Separation

Circumferential welds (Girth welds):
Distance between weld shall be measured between the adjacent edges of the cap passes.
Circumferential butt welds (Girth welds) shall be separated by maximum possible distance.

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

However between fittings, short pipe lengths may be required. In this case, butt welds shall
not be within 75 mm of adjacent girth weld for nominal pipe sizes of 75 mm and above.
For pipe sizes less than 75mm nominal, girth weld shall not be within the greater of 4 times
the wall thickness or one pipe diameter of adjacent girth welds. Girth welds closer than the
above limit shall require approval of the client and may require PWHT solely at the
discretion of the company.

Branch / Nozzle / attachment welds.

Branch / nozzle and other pressure attachment welds shall have minimum 3 distance to
adjacent pressure welds. Non pressure containing attachment welds shall be separated by
2 from adjacent pressure containing welds.
Longitudinal seams of adjacent pipes shall be separated by at least 4.

7.5 Repair Welding

Any defects which require repair shall be entirely removed to sound metal. Metal shall
be removed 1 on both side of the defect without substantial removal of the Base metal.
By grinding, the metal shall be removed and the groove shall be smooth without any
undercut. Visual examination and magnetic/dye penetrant test shall be done on the
grove.
If repairs are done after hydro test / PWHT, the same will be repeated after repair.
Welding repair shall be done only twice. After second repair if the weld is not
acceptable the weld shall be removed, re beveled and re welded.
Same NDT technique & acceptance criteria for the original weld shall be done after
repair welding.
Proper cutting disc shall be used. Grinding disc shall not be used for cutting purposes.
8.0 Resources
Welding machine
Grinding machine

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Al-Karrar Engineering Company
Janubia PWD Phase 2- Fire Water and Dammam Line Rerouting
Method Statement for Construction of Piping Works at south Rumaila

Preheating torches with propane gas cylinders

Holding ovens/baking ovens
Hiab, Crane, trailer
Cutting tools
Generator
Vacuum Tankers

9.0 HSE Requirements

9.1 Risk Rating
Risk Rating is Medium: Job will have to be closely supervised by Job Performer, Safety
officer and Supervisor.
9.2 HSE Requirements
Basic PPE, such as coverall, helmet, safety shoes, gloves, goggles and face mask (during
windy days).
Appropriate approved PTW and certificate shall be obtained prior to commencing the
job.
Standby vehicle will be present for emergency purposes.
Daily TBT
Approved and valid fire extinguishers (dry powder) shall be available.
Third party certificates of all riggers and cranes
Proper color coding of all lifting tools, tackles

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