piping installation works on pipe racks

Sadara Project مشروع صدارة Polyethylene Envelope

Transmittal

Page: 1 of 1 Form Version: 23-Apr-2012

Sadara Unit(s) 455 460 470

Sadara Transmittal Sadara-L&T-T-1233

Issue Date 29 June 2013 Date Reply Needed N/A

From Majid Al Majid To Mr. P. Sankaranarayanan

Company L&T ATCO

Subject SADARA Response to L&T-SADARA-T-882-13, Method Statement of Piping Installation Works on Pipe Racks (Rev.1)

In respect of the above referenced transmittal;

Accepted with comments. SADARA request L&T to resubmit the Method Statement after incorporating the comments in the attached file for our records.

Subject File Name Date Rev Method Statement of Piping Installation Works

on Pipe Racks (Rev.1) SA-RTIP-PEAAA-LTAT-50-5001-

commented N/A N/A

SADARA Polyethylene LSPB-1 Project

METHOD STATEMENT FOR PIPING INSTALLATION WORKS ON PIPE RACKS

Date Doc. No Rev. No Page

28-May-13 SA-RTIP-PEAAA-LTAT-50-5001 1 Page 1 of 12

PROJECT: SADARA POLYETHYELENE LSPB -1

CONTRACT NO: 10001 / 6600028371

CLIENT: SADARA

CONTRACTOR: LARSEN & TOUBRO ATCO SAUDI


(SA-RTIP-PEAAA-LTAT-50-5001)

1 28-May-13 Issued for Review and Approval KRK DKU CTK/PSN

0 21-Apr-13 Issued for Review & Comments KRK DKU CTK/PSN

Rev Date Description Prepared Reviewed Approved Approved

L&T L&T L&T SADARA





REVISION RECORD SHEET

Rev. No. Date Reason for

the revision Revision details/ Locations

0 21-Apr-13 Issued for

Review and Approval

Superseded

1 28-May-13 Issued for

Review and Approval All Sections has been modified





CONTENTS

1. PURPOSE……………………………………………………………………............................... 4

2. SCOPE……………………………………………………………………………………………… 4

3. REFERENCES………………………………………………………………............................... 4

4. RESPONSIBILITIES………………………………………………………………………………. 4

5. DEFINITIONS………………………………………………………………................................. 6

6. HSE REQUIREMENT……………………………………………………………………………....6

7. EQUIPMENT AND TOOLS……………………………………………………………………….. 7

8. MANPOWER……………………………………………………………………………………...... 7

9. GENERAL PREPARATORY WORKS…………………………………………………………… 8

10. WORK EXECUTION PROCEDURE………………………………………............................... 8

11. ATTACHMENTS…………………………………………………………………………………...12





1. PURPOSE

This method statement will serve as a guide line to carry out and complete the pipe installation works at pipe racks for Polyethylene SADARA Project.

2. SCOPE

This procedure will cover random pipes and pipe spools installation at pipe rack 640,565,500,440,305,350,400,235,200,220,150,700,750,775,825,850,905 for SADARA POLYETHYLENE LSPB PROJECT and to ensure that the entire recommendations are read and understood well prior to Start of erection works at site.

3. REFERENCES

� SADARA HSE Standard – A554-K-PRG-QM-GEN-PLN-004 � L&T ATCO HSE Standard – SA-RTIP-PEAAA-LTAT-50-9001 � Construction work detail procedure (Extra Length Management)- SA-RTIP-PEAAA-

LTAT-50-3047 � Construction work detail procedure (Welding Brazing) - SA-RTIP-PEAAA-LTAT-50-

3004 � Construction work detail procedure (spools cleaning) - SA-RTIP-PEAAA-LTAT-50-

0057 � Fabrication and Erection of On shore � ITP for AG Piping - SA-RTIP-PEAAA-LTAT-31-5001 � ASME B31.3 - Process piping � Shop Drawings & Erection Drawings � General welding requirements – RT85-6500-01

4. RESPONSIBILITIES

4.1 CONSTRUCTION MANAGER

� Schedule the project in logical steps and time required to meet deadlines. � Determine labor requirements and dispatch workers to construction sites � Inspect and review projects to monitor compliance with building and safety norms

and other regulations � Interpret and explain plans to staff and clients representing the L&T and SADARA





� Co-ordinate with all internal department and obtain necessary permit and licenses for smooth installation of structural activities

4.2 ENGINEERING DEPARTMENT

� Provide Technical Support to construction site execution section by providing drawings, procedures, material specifications, standard and technical specifications.

4.3 THE PIPING ENGINEER

� Piping Engineer is required to ensure that all the pipe installation works are carried out as per project specifications, approved drawings & HSE requirements.

� Conduct daily tool box talks, before the commencement of the scheduled work explain the hazards associated with the work and the mitigation measures.

� Strictly follow the project schedule and release of work front to other disciplines like E & I

� Responsible for taking and closure of required work permits from HSE.

4.4 QA/QC MANAGER

� Assist and coordinate with the construction manager and all personnel assigned to the project in establishing an overall Project Quality Management Plan based on approved standards.

� Responsible for ensuring that Project Quality Management policy, plans and procedures are implemented effectively and are suitable for the purposes and use for which they are intended.

� Coordinate and communicate with Client on Project Quality implementation � Coordination with QC-Inspectors(Piping and Welding)

4.5 THE PIPING QC INSPECTOR

� QC Inspector will ensure that all the line clearance activities that are required to be inspected have been inspected and approved as per the project requirements and QP.

� Accompany the company representative while carrying out inspections and release of hold points.





� Qc Inspector will ensure that all fit-up’s inspection done and are according to Isometric and all supports are installed.

4.6 QC WELDING INSPECTOR

� Ensures Daily weld visual inspections are done, and monitor welder’s performance. � Ensures NDT offer are done as per specification requirements. � Ensures test packages NDT are cleared.

4.7 THE HSE SUPERVISOR

� HSE Supervisor will orient all erection people and provide sticker for competent people for identification & authorize to work at height.

� HSE Supervisor will ensure that the steel structural erection work is covered with valid elevated work permits including cold and hot work permit wherever applicable, and all permit & safety requirements are strictly followed.

� HSE Supervisor will ensure that daily tool box talks are carried out before the commencement of work, at all work locations, as per HSE Plan.

� HSE Supervisor will ensure that work locations are safe to work in & with appropriate safety signs and Barriers.

� Any unsafe act or conditions will be immediately stopped and reported to the HSE Manager and Construction Supervisor

� HSE Supervisor will Review and the implementation of Job Safety Analysis (JSA) and Method Statement.

5. DEFINITIONS

� Project - Sadara Polyethylene LSPB -1 � Company - Sadara Chemical Company � Contractor – L & T ATCO � Construction Supervisor - Contractor’s Supervisor � QC Inspector - Contractor’s Quality Control Inspector (Piping) � HSE - Health, Safety & Environment

6. HSE REQUIREMENT

� Safety goggles � Safety face shields





� Safety shoes � Dust masks � Safety helmet � Full body harness � Hand Gloves (Leather) � Reflecting Jacket � Ear Plugs

Client’s safety instruction & Project Safety regulations shall be strictly followed.

7. EQUIPMENT AND TOOLS

� Mobile/ Crawler cranes � Welding Machines � Pulley � Pulling cable � Chain block 2T,3T, 5T. � Man lift � Lifting Accessories � Trolley assembly � Nylon/ Teflon pipe rollers � Hand tools & fixtures as required

8. MANPOWER

� Piping superintendent � Piping supervisor � Rigger Foreman � Piping foreman � Riggers � Pipe fitters � Permit receiver � Fire watcher � Scaffolders � Crane operators � Welders � Mechanic technicians





� Man lift operators � Safety Supervisors

9. GENERAL PREPARATORY WORKS

� Pipe rack sections (640 ,565 ,500 ,440 ,305 ,350 ,400 ,235 ,200 ,220 ,150 ,700 ,750 ,775 ,825 ,850 ,905) should first be turned-over for pipe installation. Secure work transfer sheet from structural group.

� Scaffolding and access are ready for use. Major pipe rack will be provided with mat type scaffolds at elevations where most work will be done. Others will be provided with scaffold individually at work locations.

� Walkway outside the pipe rack shall be provided along with scaffolds. � Manpower, equipment, tools and other logistics are ready and prepared for

installation. � Lifeline to be provided for full length of working platform. � The delivered spools, random length and other materials for erection shall be

verified and checked as follow � Verify piping spools are as per required ISO drawing and check for any damages. � All spools shall be painted prior to erection. � All spools shall be internally cleaned prior to erection.

10. WORK EXECUTION PROCEDURE

10.1 PIPING INSTALLATION USING NYLON ROLLERS ON PIPE RACKS

� Pipe will be loaded using cranes into the extended scaffoldings at designated/ end of pipe rack.(Attached typical lift plan for PipeRack-640)

� Loading of spools on scaffolds is not allowed. � Install extended scaffolding at designated loading area at first level. Once the

erection of pipes at this level was completed, additional extended scaffold will be installed for the next elevation. Additional hanging scaffold with access walkway will be installed for fit-up and full welding of pipe joints and supports not accessible by the hanging mat scaffold.

� Install, align and fix the roller assemblies at rack beams. Nylon rollers will be employed primarily to move random lengths along the racks.

� Install required pulleys to complete with Chain block. The pulley and cable will be used to pull the pipes from loading end, along the rollers and to its final position





� Cranes will pick-up the pipes either directly from trailers or from temporary lay down nearby the pipe rack.

� Pipes will be lifted by cranes using correct nylon slings and will be rigged to position at rollers in working platform.

� Once the pipe is initially positioned at rollers (on two spans), hook the pipe to a Chain block. Pipe should be tied in such a way so as not to damage bevel at pipe end.

� When the pipe is being pulled, a watcher will check the travel of pipe such that it will safely and correctly ride the succeeding rollers. A signaling system for safe execution and control of pulling will be employed.

� Once the length of pipes reaches its destination, it will be removed from rollers using chain blocks.

� Pipe spools such as expansion loops, branch take offs and others will be placed directly in position using cranes or chain blocks where required. Fit up and welding of spooled pieces will be done in place utilizing the mat type scaffold or localized scaffold.

� For pipeline without attachments, a double ended welding execution will be adopted i.e. the first two random length rigged to positioned will be fitted up and full welded together. The succeeding lengths will be installed in the same manner. The double ended lengths are then welded together until the entire run is completed.

� Random Pipes will also be placed from selected intermediate columns also and will be pulled to their places and Aligned.

� During the installation process, if the gap between Grids is less, for erection feasibility chain block pulley will be used for the balancing of the spool in one end and the other end belt will used.

� At interconnecting pipe racks the same roller system will be utilized where new steel works is installed and when there are no obstructions.

� Other areas will utilize cranes or manual rigging method (sticking-out method) to directly install the spools and straight lengths into positions.

� Prior to full welding works, check the fitted up spool/ pipe joint for the following: � The surface is clean and free from paint, oil, dirt, scale, oxides and other foreign

materials. � The bevel angle, weld joint, root opening and alignment as per Isometric drawing

approved WPS. � Flange face is free from damage and scratches. � Weld seam is staggered so that longitudinal joint and also joints shall not touch the

bearing surfaces (structural steel) � Re-in forcing pad is provided with 6mm vent hole as per specification.





� Socket welding gap is in accordance with specification. � Welding consumables should be in accordance with approved WPS. � All fit-ups shall be inspected by contractor or sub-contractor Piping inspector. � Submit request for inspection (RFI) of the fitted spool/ piping. � When fit-up is accepted, proceed full welding. � Welding process shall be as per approved WPS. Only qualified welders can do

welding works. Documents such as welding procedures and specification (WPS) and welders performance qualification record (WPQR) should be made available at site.

� All welding electrodes shall be backed and in site shall be stored in portable oven and shall have continuous power supply.

� During welding process, in-process inspection will be done by welding inspector and will be verifying the following items

� Welding consumables are in accordance with the approved WPS. � Required pre-heat/ inter-pass temperature requirements are done as per approved

WPS. � Purging requirement, as applicable, is being maintained as per approved WPS.

10.2 AFTER WELDING WAS COMPLETED, VISUAL INSPECTION WILL BE DONE CHECKING THE FOLLOWING ITEMS, AS APPLICABLE

� Inside surface of orifice flanges welded joints is ground or machined smooth. � Threaded joints must be checked for fit and roundness as per spec. no. � Weld surface reinforcement in accordance with ASME B31.3 table 341.3.2 � Dimensions of fillet weld in-accordance with ASME B31.3 fig.328.5.2B and

328.5.4D � Root pass in accordance approved WPS. � Arc strikes in areas not covered by the finished weld and grounds. � Temporary materials used are already removed as per spec. � Cleanliness of pipe shall be maintained as per spec. no. The weld spatter, slag,

flux and other foreign materials are removed. � Welders ID, Weld no., and line no & WPS. Shall be marked with permanent marker

on the pipe next to the weld. � Completed weld shall be subjected to require NDE as per line Class. � PMI as required shall be conducted. And marking shall be done as per PMI

procedure PWHT.





� Hardness test as required on some joints shall also be conducted as required by line class. As per approved weld repair procedure.

� Rejected weld will be repaired and will under-go visual inspection as per above mentioned and required NDE as per above

� For threaded line installation, refer specification, method statement of Deluge piping system specification no only gasket installation and inspection.

� Bolt Tightening shall be done by trained persons, in sequence to produce even compression and uniform bolt loads Torque wrench used shall be calibrated valves shall be set daily When using stud tensioner, the manufacturer’s procedure must be followed. The bolt used shall be checked for conformance with the ISO drawing.

� For pipelines with shoes, saddle, others, this attachment will be Tac weld to the pipe after being rigged to position. Shoes and saddle shall be positioned such that it will align and rest properly at beams or supports. Prior to full welding the alignment, support location and orientation must be checked and verified with latest approved drawings. The supports used should be in accordance with the latest approved IFC drawings.

� Pipe Supports to be Over Head welded by only trained welders and cleaning will by means mechanical cleaning.

� For supports directly weld to Alloy pipes, PMI (If Required) shall also be conducted � Pipe stoppers and guides shall be full welded and painted. � Prior to closure of piping section, full compliance with internal cleanliness

inspection and documentation shall be ensured in. � Piping installation at pipe rack areas

640,565,500,700,445,305,440,235,350,400,200,150,905,850,etc., will be done as applicable.

10.3 SAFETY PRECAUTIONS

� Obtain the approval of the work permit from the concerned PERMIT department before starting any work.

� Fire watcher with fire extinguisher shall be at work area whenever there is hot work.

� All electrical tools shall be checked and color-coded. � Continuous monitoring and inspection shall be implemented to detect and correct

unsafe practices while performing the work activities. � Provide warning signs and sufficient barricade on working area and only assigned

personnel will be allowed in the area.





� Welding location shall be enclosed with wind barrier and provided with non-asbestos fire blanket to prevent spread of any welding sparks.

� Safety officer shall monitor the work activities to help and to protect all assigned workers against exposure to safety hazards. He shall ensure that personnel protection equipment (PPE’S) are supplied and used and comply with L & T/SADARA applicable general instruction and standards.

� Safety harness with double lanyards shall be used all the time when working at elevated temporary platforms.

� Man-lift users shall be trained and certified to operate.

11. ATTACHMENTS

� JSA for AG Piping Installation works � Lifting plan of AG Piping

460 470

The Following Drawings Specification Schedule

Data Sheets Calculation Material Requisition

Are Transmitted TBE Vendor Document MOM

Acceptance/Approval Review Information

This is Record Quatation Construction

Original Revision Final

Size No. of Copies

Receipt Not RequiredReceipt Required (Please Acknowlegde the Receipt of the Duplicate and Return)The Above Documents Received By:

Signature: Name:

John HufnagelJulian Archer

Drawings / File Name Description

To Majid Al Majid

Rev. No.

cc Mark Williams

455

L&T-Sadara-T-882/13

29-May-13 Date Reply Needed 30-May-13

Date:

Alshobber Khalid

1 Method Statement of Piping Installation Works on Pipe Racks

Transmittal

Subject

C.T KuriakoseD.K UpadhayM.K Sankar

Sadara Unit (s)

L&T Transmittal

Issue Date

From

cc

Company

Method Statement of Piping Installation Works on Pipe Racks (Revision 1)

P.Sankaranarayanan

Sadara

*** Nothing Follows ***

SA-RTIP-PEAAA-LTAT-50-5001 A4 1

X

X X

X X

X





PROJECT: SADARA POLYETHYELENE LSPB -1

CONTRACT NO: 10001 / 6600028371

CLIENT: SADARA

CONTRACTOR: LARSEN & TOUBRO ATCO SAUDI


(SA-RTIP-PEAAA-LTAT-50-5001)

1 28-May-13 Issued for Review and Approval KRK DKU CTK/PSN

0 21-Apr-13 Issued for Review & Comments KRK DKU CTK/PSN

Rev Date Description Prepared Reviewed Approved Approved

L&T L&T L&T SADARA