METHOD STATEMENT OF HEAVY SCHEDULE PIPING FABRICATION

 METHOD STATEMENT OF FABRICATION OF HEAVY SCH. PIPING

INDEX

1.0           OBJECTIVE.

2.0           EXECUTION OF WORK.

3.0           WPS AND PRQ.

4.0           RELEVANT STANDARD.

5.0           MATERIALS.

6.0           FILLER WIRE.

7.0           CONSUMABLE.

8.0           TOOLS AND TACKLES.

9.0           EDGE PREPARATION.

10.0        FIT UP, ALINGMENT AND WELDING.

11.0        HEAT TREATMENT.

12.0        NON DESTRUCTIVE TESTING.

13.0        BLASTING AND PAINTING.

14.0        FINAL INSPECTION AND DISPATCH.

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1.0      OBJECTIVE

     TO EXECUTE THE WORK AND PROVIDE SAFE, COMPETENT, PROFESSIONAL AND QUALITY SERVICE WITHIN THE TIME SCHEDULE.

CLIENT’S REQUIREMENT

      TO CARRY FABRICATION, STRESS RELIVING, RADIOGRAPHY AND BLASTING & PAINTING OF HEAVEY SCHEDULE PRESSURE PIPING.

-          SAFETY OF PERSONNEL & SAFE WORK PRACTICE.

-          GOOD ENGINEERING PRACTICE

-          ENSURE QUALITY OF WORK

-          ADHERE TO TIME SCHEDULE

-          MOBILIZATION OF RESOURCES ON TIME

         

2.0      EXECUTION OF WORK:-

2.1      WORK SHOP

THE SITE SHALL BE MOBILIZED WITHIN STIPULATED PERIOD THE AWARD OF LOI / WORK ORDER.

3.0      WPS & PQR

3.1       THE WELDING PROCEDURE SPECIFICATION (WPS) FOR PIPING SHALL BE SUBMITTED TO CLIENT FOR REVIEW AND APPROVAL.

3.2       ON APPROVAL OF WPS, THE WELDING PROCEDURE QUALIFICATION (PQR) AND SUBSEQUENTLY WELDER’S QUALIFICATION SHALL BE CARRIED OUT AT WORK SHOP.

4.0      RELEVANT STANDRAD

ASME 31.3

5.0      MATERIALS

5.1       CONTRACTOR SHALL ARRANGE TO RECEIVED AND STORE ALL FREE ISSUE MATERIALS.

5.2       PIPES AND FITTINGS USED IN THIS PARTICULAR PIPING SHALL BE AS SPECIFIED IN PIPING SPECIFICATION.

5.3       CONTRACTOR SHALL VISUALLY INSPECT MATERIALS BEING COLLECTED AND IMMEDIATELY BRING IN TO THE NOTICE CLIENT ANY DISCREPANCY OR SHORT FALL NOTICED

5.4       CONTRACTOR WILL DEPLOY ONE MOBILE CRANE WITH SUFFICIENT MAN POWER AND LIFTING TOOLS FOR SAFE HANDLING OF MATERIALS AS ILLUSTRATED IN SKETCH.

 

6.0      FILLER WIRE

1. CONTRACTOR SHALL ARRANGE TO SUPPLY FILLER WIRE REQUIRED FOR THE JOB.
2. CONTRACTOR SHALL ENSURE THAT APPROVED BRAND OF FILLER WIRE IS USED.

3. CONTRACTOR SHALL PRODUCE THE BATCH CERTIFICATE FOR EVERY BATCH OF FILLER WIRE.

7.0      CONSUMABLES:-

1. CONTRACTOR SHALL ARRANGE AND SUPPLY ALL CONSUMABLE

2. CONTRACTOR SHALL ENSURE THAT ALL REGULATOR, HOSES ETC. USED ARE REPUTED BRAND.

 

3. PURITY OF ARGON SHALL BE 99.995% WHEN USED FOR SHIELDING AND PURGING.

4. FLOW RATE OF PURGING GAS SHOULD BE ESTABLISH DURING PROCEDURE QUALIFICATION RECORD TEST.

8.0      TOOLS AND TACKLES.

1. CONTRACTOR SHALL PROVIDE ALL NECESSARY TOOLS AND TACKLES REQUIRED FOR THE JOB. LIST OF TOOLS AND TACKLES ARE MAILED TO CLIENT.

2. ALL GAUGES USED ARE TO BE TESTED SHALL BE CALIBRATED AND TEST CERTIFICATES MADE AVAILABLE FOR VERIFICATION.

9.0      EDGE PREPARATION

1. EDGE SHALL BE PREPARED BY BEVELING MACHINE.

2. EDGE SHALL BE CLEANED TO REMOVE ANY DUST, DIRT OR RUST WHICH MAY BE PRESENT PRIOR TO FIT UP.

10.0   FIT UP,ALINGMENT AND WELDING

1.     ALIGNMENT AND FIT UP OF INDIVIDUAL PIPING COMPONENT IS ESSENTIAL TO OBTAIN A GOOD JOINT THERE FOR LOT OF CARE MUST BE TAKEN DURING FIT UP.

2.     CONTRACTOR SHALL BE RESPONSIBLE FOR ACCURACY OF FABRICATION. CONTRACTOR SHALL REVIEW THE DRAWING AND IN CASE ANY ARROW OR OMISSION IS IDENTIFIED THE SAME SHALL BE BROUGHT INTO THE NOTICE OF CLIENT

3.     COMPONENTS TO BE ALIGNED SHALL BE SPACED AS PER APPLICABLE CODE.

4.     WIRE SPACERS SHALL BE USED TO OBTAIN PROPER ROOT GAP, HOWEVER AFTER TACK WELDING THERE SHALL BE REMOVED.

5.     ALL TACK WELDER DEPLOYED SHALL BE TESTED AND QUALIFIED. ALL TACK WELD SHALL BE DONE UTMOST CARE SINCE THIS WORLD FORM A PART IF FINAL WELDING.

6.     TACKS SHALL BE EQUALLY SPACED. THE MINIMUM NUMBER OF TRACKS FOR VARIOUS SIZE OF PIPES SHALL BE AS FOLLOWS

    6.1              PIPE SIZE                                                     No. OF TACKS

a) 3’’ DIAMETER AND BELOW                                                2

b) BETWEEN 3 AND 12’’ DIAMETER                                         4

c) ABOVE 12’’ DIAMETER                                                        6

7.     ALL DEFECTIVE FIT UP OF TACK WELDS WHICH ARE REJECTED BY THE CLIENT SHALL BE REDONE.

8.     PRIOR TO WELDING FIT UP SHALL BE JOINTLY INSPECTED BY CONTRACTOR, CLIENT AND CONSULTANT AND RELEASE FOR WELDING

9.     WELDER QUALIFICATION AS PER THE SPECIFICATION SHALL BE CARRIED OUT PRIOR TO COMMENCEMENT OF WELDING.

10.  ONLY QUALIFIED TACK WELDERS OR WELDERS ARE ALLOWED TO WORK ON THE JOB

11.  CONTRACTOR SHALL MAINTAIN THE FOLLOWING DOCUMENTS FOR THE WELDERS.

a)    WELDING PROCEDURE SPECIFICATION.

b)    PROCEDURE QUALIFICATION RECORD.

c)     WELDER IDENTIFICATION CARD.

12.  ALL DOCUMENTS SUCH AS DAILY FIT UP AND WELDING REPORT SHALL BE MAINTAINED BY THE CONTRACTOR. CLIENT OF CONSULTANT SHALL BE FREE TO INSPECT AND RECORD HIS OBSERVATION ON THESE DOCUMENTS

13.  ABOVE ACTIVITIES IS FURTHER ILLUSTRATED IN THE SKETCH.

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11.0    HEAT TREATMENT (STRESS RELIVING)

11.1    HEAT TREATMENT OF CARBON STEEL IS NOT REQUIRED, UNLESS SPECIFICALLY STATED IN THE DRAWINGS

11.2    CARBON STEEL MATERIALS HAVING CARBON CONTENT 0.35% MAXIMUM AND WALL THICKNESS LESS THEN 19 MM DO NOT REQUIRE TO BE HEAT TREATED.

11.3    CARBON STEEL MATERIALS HAVING CARBON CONTENT 0.35% MAXIMUM AND WALL THICKNESS 19 MM OR ABOVE NEED TO BE STRESS RELIVED.

11.4    CARBON STEEL MATERIALS HAVING CARBON CONTENT ABOVE 0.35% MAXIMUM IRRESPECTIVE OF WALL THICKNESS REQUIRED TO BE HEAT TREATED.

11.5    THE JOINT SHALL BE WRAPPED IN ASBESTOS OR MINERAL WOOL TO A DISTANCE OF 150 MM ON BOTH SIDE OF WELD JOINT DURING HEATING OR COOLING.

11.6    STRESS RELIVING CAN BE DONE BY DEPLOYING A FURNACE OR BY USING ELECTRIC RESISTANCE OR INDUCTION HEATING EQUIPMENT.

11.7    THE TEMPERATURE OF THE JOINT BEING STRESS RELIVE SHALL BE RECORDED BY USING THERMOCOUPLES AND RECORDER. THE MINIMUM NUMBER OF THERMOCOUPLES TO BE PROVIDED PER JOINT SHALL BE AS STATED BELOW.

                        JOINT SIZE                             NO. OF THERMOCOUPLES

                  a) UPTO 6 ‘’                                                                  1

                  b) UPTO 10’’                                                                 2

                  c) FOR 12’’ AND ABOVE                                              3

11.8    AFTER COMPLETION OF STRESS REVELING HARDNESS TEST SHALL BE CONDUCTED ON THE JOINTS

11.9    ALL NECESSARY DOCUMENTATION SHALL BE PREPARED AND MAINTAINED BY THE CONTRACTOR AND THE SAME WILL BE FORWARDED TO CONSULTANT FOR REVIEW AND APPROVAL.

12.0   NON DESTRUCTIVE TESTING

12.1   RELEVANT STANDARD

1.0   ASME SECTION V

12.2   VISUAL EXAMINATION

12.2.1   WELDS JOINTS SHALL BE VISUALLY EXAMINED AND RELEASED FOR RADIOGRAPHY

12.3   HARDNESS TEST EXAMINATION

12.3.1   HARDNESS TEST SHALL BE CARRIED OUT AS SPECIFIED IN THE PIPING SPECIFICATION INDEX / DRAWINGS OR AS PER THE INSTRUCTION OF CONSULTANT ENGINEER.

12.4   RADIOGRAPHIC EXAMINATION

12.4.1   PROCEDURE FOR RADIOGRAPHY EXAMINATION TO BE ADOPTED WILL HAVE TO BE FURNISHED BY THE CONTRACTOR TO THE CONSULTANT AND APPROVAL OBTAINED.

12.4.2   CONTRACTOR SHALL FURNISH THE NAMES AND BIO DATA OF THE RADIO GRAPHIC CONTRACTOR. NO AGENCY OR CONTRACTOR SHALL BE DEPLOYED WITHOUT THE APPROVAL OF CONSULTANT. RADIOGRAPHER SHOULD HAVE MINIMUM LEVEL II QUALIFICATION.

12.4.3   THE RADIOGRAPHIC TECHNIQUE AND PROCEDURE ADOPTED SHALL CONFIRM TO THE REQUIREMENTS OF ASME SECTION V.

12.4.4   THE ACCEPTABLE LIMITS OF DEFECTS AND REMOVAL OF DEFECTS SHALL BE AS THE RELEVANT CODE OF FABRICATION.

12.4.5   ALL STATUTORY, SAFETY REQUIREMENT WHILE HANDLING X-RAY SOURCE SHALL BE FOLLOWED BY THE CONTRACTOR.

12.4.6   PERCENTAGE OF RADIOGRAPHY SHALL BE AS STATED IN THE PIPING SPECIFICATION OR DRAWINGS.

12.4.7   CONTRACTOR SHALL RADIOGRAPHY THE JOINTS SELECTED BY THE CONSULTANT INSPECTOR.

12.4.8   AFTER RADIOGRAPHY THE CONTRACTOR SHALL FURNISH ALL THE RADIOGRAPHY TO THE CONSULTANT ENGINEER AFTER PROCESSING ALONG WITH HIS OBSERVATION.

12.4.9   ALL NECESSARY DOCUMENTATION SHALL BE PREPARED AND MAINTAINED BY THE CONTRACTOR AND THE SAME WILL BE FORWARDED TO CONSULTANT FOR REVIEW AND APPROVAL.

13.0   BLASTING AND PAINTING

13.1    BLASTING YARD SHALL BE BUILT UP WITH MACHINERY SUCH AS AIR COMPRESSOR, SPRAY PAINTING EQUIPMENT, HOPPER, HOSES AND COPPER SLAG FOR BLASTING AND PRIMER APPLICATION.

13.2    BARE PIPES RECEIVED FROM CLIENT WILL BE BLASTED AND PRIMED USING COPPER SLAG OR SAND AND ZINC PHOSPHATE PRIMER (RED OXIDE) TO THE REQUIRED DFT OF 30 MICRON PRIOR TO WELDING OF FLANGES.

13.3    SLIP ON OR WELD NECK FLANGES WILL BE WELDED ON THE PRIMED PIPE.

13.4    FINAL EPOXY PAINT WILL BE APPLIED ON FINISH SPOOLS. 

14.0   FINAL INSPECTION AND DESPATCH OF SPOOLS

14.1    FINISH SPOOLS ARE INSPECTED AND DISPATCH TO ERECTION SITE.