Pre fabrication

METHOD STATEMENT FOR OFF- SITE PRE- FABRICATION OF METALLIC PIPING

Equipment description: PIPING

Tag/Item number(s):N/A

A

18-09-08

AR

MKM

O

19-08-08

AR

MKM

OA

02-08-08

AR

Rev.

Date

By

SKS

IFL

Issued For Implementation

SKS

ICC

Issued For Company Comments

MKM

SKS

IIR

Issued for Internal review

Chkd

Appr.

Status

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Revision reason for issue description Unit: 0-0000

Sheet: 1 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

TABLE OF CONTENTS 1.0

SCOPE .......................................................................................................................................... 4

2.0

PURPOSE ..................................................................................................................................... 4

3.0

REFERENCES .............................................................................................................................. 4

4.0

DEFINITIONS ................................................................................................................................ 5

5.0

ORGANIZATION CHART.............................................................................................................. 6

6.0

RESPONSIBILITES....................................................................................................................... 7

6.1

Engineering Dept. .......................................................................................................................... 7

6.2

Workshop Manager........................................................................................................................ 7

6.3

Piping Engineer.............................................................................................................................. 7

6.4

Piping Supervisor/ Forman ............................................................................................................ 7

6.5

Welding supervisor/Forman ........................................................................................................... 7

6.6

QC Engineer ................................................................................................................................. 7

6.7

QC Inspector.................................................................................................................................. 7

6.8

Material Controller/ Storekeeper .................................................................................................... 8

6.9

Consumable Controller .................................................................................................................. 8

7.0

SHOP FABRICATION ................................................................................................................... 8

7.1

General .......................................................................................................................................... 8

7.2

Preparation ................................................................................................................................... 9 7.2.1

Marking and Transfer of Heat No........................................................................................... 9

7.2.2

Cutting and Bevelling ............................................................................................................. 9

7.3

Fit-Up and Assembly of Piping Components ................................................................................. 9

7.4

Tolerances ................................................................................................................................... 10 7.4.1

7.5

Length .................................................................................................................................. 10

Joint Identification ..................................................................................................................... 10 7.5.1

Shop Weld Joints ................................................................................................................. 10

7.5.2

Field Weld Joints.................................................................................................................. 11

7.6

Hard Stamping of spool Identification .......................................................................................... 11

7.7

Inspection of Fit up....................................................................................................................... 11

8.0

WELDING .................................................................................................................................... 12

8.1

General ........................................................................................................................................ 12

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 2 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

8.2

Production Welding...................................................................................................................... 12

9.0

PRE-HEAT REQUIREMENTS AND APPLICATION METHODS ............................................... 13

10.0

VISUAL INSPECTION OF JOINTS............................................................................................. 13

11.0

NDT AND PWHT ......................................................................................................................... 14

11.1

Post weld Heat Treatment ........................................................................................................... 14

11.2

Non Destructive Testing (NDT).................................................................................................... 14

11.3

Inspection Class for Piping....................................................................................................... 14

12.0

STORAGE AND HANDLING OF PRE FABRICATED SPOOLS................................................ 16

13.0

RELEASE OF SPOOLS TO SITE FROM DOHA SHOP............................................................. 16

14.0

FLAWLESS START UP INITIATIVE........................................................................................... 16

15.0

ATTACHMENTS.......................................................................................................................... 17

Attachment 1: JOB SAFETY ANALYSIS ................................................................................................. 18 Attachment 2: SPOOL RELEASE REPORT............................................................................................ 23

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 3 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

1.0

SCOPE This document defines the methods to be adopted for issue of material, pre-fabrication , welding, NDT, painting ,Inspection ,documentation and delivery of spool to site when fabrication done at Doha workshop.

2.0

PURPOSE Purpose of this document is to give methods and guidelines for proper execution of material control, Pre fabrication, welding and delivery when piping spool are fabricated at an off site facility away from site Fabrication shop This document gives the method of documentation to be followed for the activities undertaken at shop and appending the same to the mainstream documentation of the project.

And further purpose of this Method Statement is the following: Intends to define the responsibilities of the project personnel involved at different levels for execution of the activity.

Shows correct procedure of identification and selection of material and right method for material traceability maintenance through out the fabrication stages.

Gives proper method for performance of every activity Precautions and controls to be adopted to complete an activity according to the requirements.

Quality control requirements in an activity Safety and risk assessment of the activity and mitigations actions Identifies Key performance areas to mitigate flaws, if any

3.0

REFERENCES F15032-AJE-0-0000-CMT-PLA-0001_O (T-4.120.342)

Construction Execution Plan

F15032-SSA-0-0000-PMT-PLA-0001_O (T-4.116.980)

Project Quality Plan

F15032-SSA-0-0000-HSE-PLA-0001 (T-4.116.982)

Project HSSE Plan

F15032-SSA-0-0000-PMT-PLA-0005 (T-4.132.019)

Flawless Start-Up Plan

F15032-AJE-0-0000-CMT-MST-1889

Hydrostatic / Pneumatic/ Leakage

(T-4.143.074)

Testing of Piping

F15032-AJE-0-0000-CMT-MST-1902 (T-4.143.087)

Positive Alloy Material Identification

ASME B31.3

Process Piping

F15032-AJE-0-0000-QCS-SPC-3475

Welding Book Piping

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 4 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

(T-4.255-798)

4.0

F15032-AJE-0-0000-CMT-MST- 1897 (T-4.143.082)

Method Statement For Fabrication and Erection Of Piping

DEP31.38.01.31

Shop and Field Fabrication of Piping

F15032-AJE-0-0000-CMT-MST-1883 (T-4.132.095)

NDT and PWHT Control

T-13.377.441 DEP 30.10.60.18

Quality Control Requirements For Welding Welding of Metals

DEP 31.38.01.29

Pipe supports

T-13.377.453

Specification For Flange Joint Integrity and Tightness

DEFINITIONS PROJECT

Effluent Treatment Plant - Pearl GTL C8

COMPANY

Qatar Shell GTL Ltd.

CONTRACTOR

VSA Consortium

DOC

Doha Operating Centre

ETP

Effluent Treatment Plant

IC

Implementation Contractor

PMC

Project Management Contractor (JGC/KBR)

VSA Consortium

Consortium, Consortium consisting of O2 Pearl (The OTV S.A., SAIPEM S.A .JV) AND Al Jaber Transport and General Contracting LLC

QC SMAW GTAW HSSE RFC DWR ITP

Quality Control Shielded metal Arc welding Gas Tungsten Arc Welding Health, Safety, Security and Environment Released For Construction Daily Welding Report Inspection and Test Plan

OFF-SITE SHOP

Deutsche Babcock Al Jaber Workshop at Doha

Sanayya New Industrial Area.

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 5 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

5.0

ORGANIZATION CHART

QC MANAGER

WORKSHOP MANAGER

ENGG.MANAGER

HSSE QC ENGINEER PIPING ENGINEER

QC INSPECTOR

DATA ENTRY OPERATOR

STOREKEEPER

CONSUMABALE CONTROLLER

WELDING SUPERVISOR

PIPING SUPERVISOR

WELDER HELPER

PIPING FOREMAN

FABRICATOR / FITTER / HELPER

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 6 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

6.0

RESPONSIBILITES

6.1

Engineering Dept.

It shall be the responsibility of the Engineering Dept to prepare and issue (Through Document Control dept) detailed fabrication drawings. Spool drawings and isometrics shall be issued complete with Weld joint/Flange joint numbering and with RFC status stamp. Engineering shall issue a Request For Fabrication for the Spools which are to be fabricated at offsite shop with the Material Take Off .

6.2

Workshop Manager Work shop manager is responsible for the implementation of this procedure for Prefabrication of spools at Work shop

6.3

Piping Engineer Shall be responsible for the over all control of fabrication, welding, surface preparation and painting of the spools fabricated at shop

6.4

Piping Supervisor/ Forman Shall be responsible for direct supervision of the piping work, ensuring that the piping work is done according to project specifications and quality requirements. Supervisor is further responsible for the maintenance of a clean and safe working (House Keeping) environment at his site.

6.5

Welding supervisor/Forman Supervision of welding activities like, issue of correct consumables, storage and handling of consumables, maintenance of, baking, holding, issuing, records of consumables, execution of welding according to correct WPS, preparation of DWR, shall be the responsibilities of the welding Supervisor. Safety and House keeping of the work area are also supervisor’s responsibility. Welding Supervisor reports to Piping Engineer, but shall work in close coordination with QC dept. in matters of Consumable control and Welder/Procedure Qualifications activities.

6.6

QC Engineer QC Engineer or, QC inspector designated by him, shall be responsible the Quality of the work at shop. Assure proper implementation of the project procedures on Quality Control and FSI is the responsibility of QC Engineer. QC Engineer/Inspector, in close coordination with store, shall ensure that the consumable control procedure is followed in receipt, inspection, issue , control and processing of consumable.

6.7

QC Inspector QC inspector shall be responsible to verify the correct implementation of the project specifications in the execution of Fabrication and welding .Witnessing of tests, preparation of records according to ITP, shall also be the responsibility of the QC Inspector. QC Inspector shall check the correct implementation of consumable control procedure. QC shall ensure that

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 7 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

the fabrication and welding data are entered and updated in the system at Fab. shop and appended to the SOC system regularly by the data entry operator.

6.8

Material Controller/ Storekeeper Receipt of material according to the MTO attached to the RFF for spool fabrication and reissue of the same to shop will be the responsibility of the material controller. A dedicated material controller shall be assigned to carry out the receipt of GTL material, issue, preservation and handling of spools and delivery back to site.

Issue of material according to the material issue request, storage of materials according to procedure, and book keeping shall be the responsibilities of the Material Controller/Storekeeper in the context of this procedure.

6.9

Consumable Controller Consumable issued from GTL shall be received and stored at the consumable store separately by the consumable controller. All GTL consumable shall be labelled with a GTL sticker .

Consumable controller in co ordination with the QC inspector and Welding supervisor shall implement the consumable receipt, treatment and issue according to the method statement for Welding consumable control.

7.0

SHOP FABRICATION

7.1

General Piping shall be fabricated based on the latest revision RFC (Released for Construction) drawing. The RFC drawing shall be complete with, weld numbered isometric /spool drawing, weld map, Bill of materials, support location, support detail and any additional information necessary.

In addition to weld joint numbering, the flange joints also shall be numbered.

While numbering flange joints, disturbed and undisturbed flange joints (as differentiated in Spec: T-13.377.453) shall be identified with distinct notation. (Key Performance Area Q11) A controlled copy of the concerned drawing shall be available with the Supervisor/Forman/Fabricator while fabrication of piping. (Key Performance Area Q11) Fabrication of different material like Stainless Steel, Carbon steel and Low alloy steel shall be done at separate areas . Separate tools shall be used for stainless steel fabrication. Wire Brush, grinding wheels Earth clamps used shall be of SS material when working on SS piping.

All fabrication tables and pipe stands shall have sufficient isolation between SS pipe and CS table with suitable non contaminating material, like wood.

Galvanised materials shall not be used to support pipe so as to avoid zinc contact with pipe material.

Shops shall be kept clean to maintain a healthy and safe working environment.

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 8 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

7.2

Preparation

7.2.1

Marking and Transfer of Heat No. On issue and receipt of pipe material according to the BOM, fabricator shall ensure that the pipe received are colour coded correctly to the colour of the required material in the BOM, size/thickness are as required. After confirmation, he may proceed with marking of the items on the pipe.

After marking each item and before cutting, original heat number punched/stencilled on the pipe shall be transferred by hard stamping the same on all marked items and on the balance pipe.

Hard stamping requirements are given elsewhere in this document while describing spool ID marking. On completion of fit up, the fabricator shall enter the heat number of each component to the working drawing for further reference to prepare DWR. This is a Key Performance area for the traceability documentation of material incorporated in fabrication. QC Shall confirm the Heat numbers in the DWR.

7.2.2

Cutting and Bevelling Cutting and bevelling of pipes may be done by mechanical means, flame cutting, plasma cutting or water jet cutting. The following shall apply: • For carbon steel, flame (or arc) cuts shall be reasonably smooth and all oxides shall be removed from the surface by grinding to bright metal.

•

For low-alloy steel, after flame cutting a minimum of 2 mm of material shall be removed from the cut surface by grinding.

•

For stainless steel, flame cutting shall not be used but plasma or water cutting may be used. The surface shall be ground to bright metal after plasma cutting.

Weld bevels for butt welds of pipes and fittings shall be in accordance with ASME B16.25.

Shop-bevelling of field welds is not required if a make-up length (extra length for field cutting to size) is provided. In these cases, bevels shall be prepared after cutting the relevant pipe spool to the required length. Cutting oil shall be removed.

Pipes for socket weld joints shall be cut square and burrs removed.

7.3

Fit-Up and Assembly of Piping Components Piping components shall be fitted up according to the dimensions given in the drawing and to the joint details specified in the concerned WPS, and of course, with in the tolerances. An approved WPS shall be applied for tacking the weld joints.

All surfaces to be welded shall be thoroughly cleaned from oxide, scale, oil or other foreign matter and be dry. The cleaned surface shall extend at least 25 mm beyond the substrate surface touched by the arc.

Tack welding shall be carried out by qualified welders in accordance with the same requirements and parameters as for the root pass of the base material Tack welds may be performed directly on the joint if welding to commence immediately after tacking. Otherwise “Bridge Tacks” are preferred. Bullets used as bridge pieces shall be, of the same material as that of the tacked pipe/component, shaped to suit the profile of the bevel.

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 9 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

Care shall be taken to avoid damage to the root face of the joint during tacking the joint and again while removing the bridges during welding.

Also the below mentioned norms shall be followed; Non welded fit-up clamps shall be used for alignment of all pipes.

The minimum distance between the edges of two pressure-containing welds shall be twice the wall thickness of the thicker pressure part. The same requirement applies to the distance between non-pressure attachment welds and a pressure-containing weld in order to allow nondestructive inspection of the pressure-containing weld. Longitudinal welds in two adjacent pipes should be 180° apart, but in any case shall be separated by at least twice the wall thickness of the thicker pipe. (In the case of an additional pup piece, minimum length shall be the pipe diameter but not less than twelve inches unless otherwise specified in the drawing) If the pipe contains a longitudinal weld, this weld shall not be located at the bottom of the pipe after installation; it should be located at least 45° from the bottom of the pipe.

In order to avoid excessive shrinkage stresses during weld solidification, a gap shall be left between the end of the pipe and the stop of the socket-welding component in accordance with ASME B16.11. Failure to include this gap can lead to premature piping failures.

Pipes that are required to be free of scale shall be suitably cleaned before the welding shop accepts them for further handling.

Refer to DEP 31.38.01.11-Gen. for flange misalignment acceptance criteria and also requirements for cold and hot bending. (in case fabrication of bends called for) 7.4

Tolerances The following dimensional tolerances shall apply:

7.4.1

Length For Length distance of any two parallel or crossing centre lines Centre to flange face Flange face to flange face

7.5

< 1.5 m

≥ 1.5 m

± 1.5 mm

± 3 mm

Joint Identification After completion of fit up, the joint number shall be hard stamped at two locations about 180 degrees apart and with in 50 mm from the joint .The fitter/fabricator doing the fit up shall sign off the joint with paint marker.

The following nomenclature is used for identification of weld joints.

7.5.1

Shop Weld Joints SBW SFW

-Shop Butt Weld -Shop fillet Weld

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 10 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

SOW SSW SCW SPW SLW

7.5.2

-Shop Olet Weld -Shop Socket Weld -Shop Branch Weld -Shop Pipe Support Weld -Shop Sleeve Weld

Field Weld Joints FBW -Field Butt Weld FFW -Field fillet Weld FOW -Field Olet Weld FSW -Field Socket Weld FCW -Field Branch Weld FPW -Field Pipe Support Weld FLW -Field Sleeve Weld Any re-weld due to, design modification shall be represented with letter ’D’ and due to repair or by mistake of fabrication with a letter ‘C’ as given below SBW 3 Re-welded --- Design Modification becomes SBD 3 RW1 SBW 3 Re-welded – repair/wrong fabrication /distorted becomes SBC 3RW1 The same follows for other shop and field welds. “TR”-suffix added to any weld number denotes a tracer weld for that welder. “N” suffix added to any weld number shall represent a Re-weld after second repair failure.

7.6

Hard Stamping of spool Identification Fit-up completed spools shall be hard stamped with a minimum of the following details at two locations .These locations shall be within 500 mm from both ends of spool and at diametrically opposite sides of pipe. Low stress stamps shall be used for stamping in pipe. Pipes with thickness less than 5mm, vibrato-etching method shall be employed.

• ISO NO and Spool No • Line No • Line Class/Inspection class • Painting Code • Project ID

7.7

Inspection of Fit up QC inspector shall make surveillance inspections to see that the fabrication is going on according to the project requirements in, but not limited to; • pre-heat, • Qualification of personnel, • consumable control • and weather conditions QC Inspector shall confirm that the fit up and visual check of the reported joints completed and accepted , while reviewing Daily Welding Report(DWR).

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 11 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

8.0

WELDING

8.1

General Before starting any welding work, Welding procedure Specification (WPS) shall be prepared, qualified and approved by the company. Latest revisions of the WPS in The Welding Book Piping (T-4.255.798) shall be used for the welding of any piping work connected to C8 ETP ,Shell GTL project Qatar • • •

8.2

All the welders working in the Project shall be qualified on the WPS he is working, thickness and position of the weld joint he is working on.

All the welders shall be given unique welder numbers specific for the GTL project.

The Gas Tungsten Arc Welding (GTAW) process shall be employed for root welds of all pipes, and for welds of pipes, branch fittings and flanges DN80 and below. Above DN80 filling and capping layers may be performed with SMAW or other approved processes. For process limitations Refer DEP30.10.60.18 Art 2.2.6

• •

All GTAW machines shall be equipped with arc starting devices (high frequency, lift arc).

Two-sided welding should be applied whenever possible.

•

Shielding and Purging/backing gas used shall be according to the WPS

Production Welding A copy of the approved WPS shall be available with the welding supervisor/Forman during execution of welding work. Copies of the WPS shall be displayed at suitable area in the work place for the reference of welders and welding operators.

The first ten production welds of all welders shall be radiographed in addition to the percentage requirements according to the line class Welding of carbon steel, ITCS, stainless steels and other corrosion resistant alloy materials shall be carried out in separate workshops to avoid mix-up and/or contamination of materials and welding consumables.

Joint fit up cleared by Welding Supervisor/or QC Inspector only shall be taken up for welding.

Pipes shall be supported in such a way that the joint being welded is not stressed/loaded and so not distorted.

The root pass welding should start immediately after acceptance of the fit-up. No welding shall be carried out when the parts to be welded are wet. No welding shall be performed unless the welder and the work are properly protected from wind.

Arc strikes shall be situated in the fusion path. When interruption in welding takes place, a proper restart procedure shall be used, ensuring full fusion with the previously deposited weld metal.

Irrespective of the base material, root runs shall be made without interruption other than for changing electrodes or to allow the welder to reposition himself. Welds shall not be allowed to cool until at least half the wall thickness has been welded.

Thorough inter-run cleaning and slag removal shall be carried out.

Back-chipping, or gouging and grinding, shall be carried out thoroughly to sound metal before deposition of subsequent layers

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 12 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

After completion of root run in Austenitic stainless steel material, welding supervisor/foreman shall perform Alloy verification with a permanent magnet and result shall be updated in the DWR. This activity shall be a witness point for QC inspector in the ITP The QC inspector shall confirm that the welders are qualified and that the correct welding consumables, as shown on the WPS are used - this applies in particular to stainless steel and high alloy welding.

On completion of all welding activity of the day, Welding Forman/Supervisor shall make a Daily Welding Report (DWR) for all completed spools and submit to the QC Dept. for verification and updating in the system.

9.0

PRE-HEAT REQUIREMENTS AND APPLICATION METHODS Preheating of the parent metal prior to any welding, tack welding and thermal cutting may be necessary to avoid cold cracking of certain ferritic steels in the weld and HAZ. When the base metal temperature is below 5 °C, both sides of the weld preparation shall be preheated to a temperature of approximately 50 °C or the preheat temperature prescribed in the WPS, whichever is higher.

The preheat temperature shall be calculated (in accordance with either BS 5135, or ANSI/ASME B31.3) to suit particular combinations of welding process, heat input, metal composition, welding consumables and plate thickness and shall be given in the applicable WPS. For preheating temperatures below 200 °C, fuel gas/air burner systems, high-velocity gas/oil burners may be employed (either locally or in a furnace), or electric resistance, induction heating or infra-red radiators may be employed.

For piping welds made in the shop, electrical heating should be used, but ring torches may be used if burning sulphur-free fuel.

For piping welds made in the field, the following methods of preheating shall be applied: • Pipe diameter up to 250 mm, heating by appropriate torches is allowed (sulphurfree fuel); • Pipe diameter > 250 mm, electrical heating or heating by means of infra-red or ring burners (sulphur-free fuel) is required.

10.0

VISUAL INSPECTION OF JOINTS All joints shall be inspected visually to make sure that the joints are clean, no visual defect present and not distorted.

QC Inspector shall review and sign off the DWR confirming that the data, and activities entered in the DWR are according to the drawing and also to the requirements of the project specifications. These data shall be entered into the system so as to retrieve as weld control sheet to be attached in the Test Pack documentation.

This data along with the NDT, Painting and Release data entered in the system at Fabshop shall be upended in to the SOC system every alternate day.

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 13 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

11.0

NDT AND PWHT

11.1

Post weld Heat Treatment Heat treatment shall be carried out in accordance with an approved heat treatment procedure.

The requirements shall be according to the piping design code /or given in the applicable WPS. The heat treatment procedure shall be reviewed and approved by Company.

QC Inspector shall request for PWHT according to the requirements after review of the DWR. For NDT &PWHT request form, refer Method Statement for NDT (F15032-AJE-0-0000-CMTMST-1883) Construction dept shall arrange for the logistic support for PWHT work by the sub contactor.

Care shall be taken in supporting spools /pipes during PWHT to avoid distortion. Refer Method Statement for PWHT for more details on applications and methods for PWHT

11.2

Non Destructive Testing (NDT) Any NDT shall be done after completing and accepting PWHT (wherever applicable) It shall be the duty of the QC inspector concerned to request for the NDT of the completed and visually accepted spools. QC shall identify the joints/spools for NDT and construction department shall arrangements of logistic supports like transferring spool to the RT bunker, Scaffolding etc. in order to execute NDT work.

Spools shall not be released for erection before completion and acceptance of NDT and PWHT according to the project requirements.

NDT Requirements for Piping are given below (Line class based NDT /PWHT requirements will be developed in due course).

NDT and PWHT requirements are specified in the Welding Book Piping(T-4.255.798) based on the table below

11.3

Inspection Class for Piping ASME RATING CLASS

7), 8)

MATERIAL

SERVICE

RADIO UT

Carbon & Carbon Manganese Steels, including 0.3 & 0.5 Molybdenum Steels

Process – Hydrogen, Very 5) Toxic Substances , LPG Temp < 0 °C

All Ratings

B

Process – Hydrogen + Sulphur Compounds, LPG Temp > 0 °C, Caustic & Sulphuric Acid

150, 300, 600

10 %

C

Process – All Services & Utilities (other than A or B)

150, 300, 600

Random

100 %

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

/

2), 3), 7)

4)

MAG PART

DP

HARDNESS

PMI

1)

N/A

9), 10), 11)

6)

1)

N/A

9), 10), 11)

6)

1)

N/A

9), 10)

6)

Unit: 0-0000

Sheet: 14 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

MATERIAL

SERVICE

7), 8)

ASME RATING CLASS

RADIO UT

> 600

100 %

100 %

/

MAG PART

DP

HARDNESS

PMI

2), 7)

1)

N/A

9), 10)

6)

2), 7)

100 %

N/A

N/A

1), 3)

N/A

6)

N/A

1), 3)

N/A

6)

D

Process – All Services & Utilities

E

All Services

All Ratings

F

Low Pressure Service, T < 400 °C, (Except Hydrogen & Very Toxic 5) Substances )

150, 300

10 %

G

Hydrogen, Very 5) Toxic Substances , Low Temperature & All Services other than F

All Ratings

100 %

Nickel & Nickel Alloys, including 5 % & 9 % Nickel Steels

H

All Services

All Ratings

100 %

N/A

1), 3)

N/A

6)

Dissimilar Metal Weldments

I

All Services

All Ratings

100 %

100 %

100 %

9), 10), 11)

6)

Low Chromium – Molybdenum Steels (Ferritic Alloys)

Austenitic Stainless Steels

7)

100 %

9), 11)

6)

NOTES: 1)

All branch welds with through weld thicknesses > 25 mm shall be crack detected.

2)

Ultrasonic examination may be applied if the configuration precludes radiography and the pipe Diameter > DN 100 and the nominal wall thickness > 10 mm.

3)

In the case of fillet, socket or reinforcement attached welds; radiography shall be replaced by magnetic particle inspection or dye penetrant inspection.

4)

The indicated minimum percentage of welds to be radiographed over the completed circumference shall cover all welders at least once every week.

5)

Hydrogen service and Very Toxic substances are defined in (1.3.2).of DEP 31.38.01.31

6)

Positive Metal Identification (PMI) shall be carried out on all ferritic alloy steel welds and component parts, including 0.3 and 0.5 Mo steels, if any of Steps 1 through Steps 5 in (3.5 of DEP 31.38.01.31) is not followed completely.

7)

All nozzle/branch connections, including small nipples, shall be radiographed unless waived by the Principal.

8)

Film quality requirements: • fine grain film (Class II) for x-ray; • ultra fine grain film (Class I) for gamma ray; • An Image Quality Indicator (IQI) with sensitivity better than 2 % shall be achieved by means of source side location of the IQI. Where access only allows the use of film side IQI, the technique shall be proved by means of a representative sample with IQI set source side and film side.

9)

See (4.3) of DEP.31.38.01.31 for hardness requirements.

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 15 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

10) Hardness reading may be required depending on the tensile strength of the material involved.

11) Refer to DEP 30.10.60.18-Gen. for welding heat treatment requirements.

12.0

STORAGE AND HANDLING OF PRE FABRICATED SPOOLS Pipes, spools, and components shall be handled with utmost care to avoid damage due to handling.

Flange faces shall be protected with wooden/plastic blanks.

Pipe ends shall be capped /closed with suitable covers to avoid entry of debris and dust after internal cleaning with compressed air.

Spools shall be arranged in an orderly manner (Not to dump big size pipe on small pipe and cause damage to the small pipes) Spools shall always be stored 100 mm above the ground on timber blocks, or pallets to avoid contact with soil and water.

Spools after fabrication shall be stored in such away that the identification marked on the spools are clearly visible.

SS spools shall be stored separately after fabrication.

13.0

RELEASE OF SPOOLS TO SITE FROM DOHA SHOP QC inspector shall release piping spools after completion and acceptance of NDT/PWHT, and also spool which do not have any NDT/PWHT .QC Inspector shall prepare a spool release report in the form no 18971(attachment-2) for releasing spools for Painting.

Pressure testing of spools will be done after erection The spools stored after Acceptance of all NDT shall be rechecked for the proper tagging, internal cleanliness and end protection. The delivery note/ packing list shall accompany with the isometric control sheet signed by the QC Inspector showing the completed documentation of the Fabricated spool.

The ICS shall be checked with the soc records for correctness.

14.0

FLAWLESS START UP INITIATIVE Shop Fabrication of piping is an area in which a number of Key Performance Areas involved.

This document address the task of Key performance with the following actions • Issue of controlled copy RFC drawing assures reference of correct document • Joint numbering of flange joints for traceability in flange tightening • Documented control on welding consumables • Following material traceability documentation throughout fabrication and erection and transferred in to the data base on a day to day basis • Specifying storage and handling methods of fabricated spools • Avoiding contact of CS with SS material during Fabrication • Control measures on tools used at Key Performance areas • Pipe cleaning checking and documentation

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 16 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

15.0

ATTACHMENTS

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 17 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR â&#x20AC;&#x201C; C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

Attachment 1: JOB SAFETY ANALYSIS JSA N°: F15032-AJE-0-0000-CMTMST-

JOB BEING ANALYZED : MS For Off Site Pre-Fabrication Of Piping

REV. N°: OA

WORK LOCATION : RAS LAFFAN

JOB PERFORMERS : VSA

JSA PERFORMED BY : VSA

DEPARTMENT : HSSE

DATE :

JSA APPROVED BY :

DEPARTMENT :

DATE :

CLIENT’S APPROVAL :

CLIENT :

DATE :

WHERE REQUIRED) General job requirements/common PPE Stop work, switch off equipment, Supervisor directs personnel to nearest and safest Muster point considering wind direction.

CHANGING CONDITIONS AND EMERGENCY PROCEDURES

A) HSE Induction, B) Hard Hat, C) Hearing Protection

Supervisor accounts for all workers.

Missing persons are reported to HSSE Department.

When all clear is given, check with HSSE Department before resuming the work.

D) Safety Glasses Dark & Clear, E) Cotton Coveralls, F) Safety Shoes/Boots, G) Hand Gloves Both Cotton and Leather H) Hi-Visibility Vests I ) Pre Start Tool Box Talk / TSTI Performed

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 18 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

J) Hard Barricade and Signage On the Area

No. 1

2

Job Steps Pre-task briefing (TSTI) and inspection

Cutting & bevelling

Hazards

Prob.

Control Measures

Prob.

L.C.

The work force does not understand the pre task briefing therefore does not understand the potential dangers and control measures to be implemented.

M

Ensure that the pre task briefing is given out in a language understood by the work force, have it translated. Ask question regarding the briefing to get feed back from the staff, this ensures full comprehension.

L

Y

L

Y

Some of the workers could be lacking PPE or using defective PPE. Burns due to sparks.

Radiation Fire

Issue any required PPE and replace PPE that has signs of defect. PPE must include both hearing protection as well as dust inhalation protection.

M

Take hot work permit. Keep fire extinguisher ready to use.

Depute fire watch Use fire blankets.

Ensure flame arresters on torch & gas cylinders.

Check condition of hoses & ensure that they do not pass over hot surfaces.

Equip calibrated gauges on gas cylinders.

Remove combustibles & flammables from work area.

Wear required PPEâ&#x20AC;&#x2122;s. (Hand gloves, safety glasses, Face shield, Helmet, safety shoes, masks)

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 19 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR â&#x20AC;&#x201C; C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

Check guard of the grinder is in place & cords are in good condition.

Ensure earthing. Use ear plugs/ muffs in the vicinity of Air Compressor.

No. 3

Job Steps Fit-Up and Assembly of Piping Components

Hazards

Prob.

Fall of material, Tripping hazard

M

Control Measures Ensure proper support to pipes to prevent fall of it.

Prob.

L.C.

L

Y

L

Y

Be attentive while manual handling. Proper coordination between workers is must to prevent tripping hazard.

For working at height: Provide safe access, use full body harness.

4

Pre heating

Fire, Burns, Electric shock, Radiations, fall from height

M

Use other PPE’s like safety shoes, safety glass, helmet, hand gloves.

Take hot work permit. Keep fire extinguisher ready to use.

Remove combustibles & flammables from work area.

Check all cords are in good condition.

Ensure earthing.

Wear required PPE’s. (Hand gloves, safety glasses, Face shield, Helmet, safety shoes, masks)

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 20 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR – C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

For working at height: Provide safe access, use full body harness.

Fuel refilling shall not be done at work site.

5

Welding

Fire, Burns, Electric shock, Radiations, fall from height

M

Take hot work permit. Keep fire extinguisher ready to use.

Depute fire watch Use fire blankets.

Check welding machine is in good condition.

Check welding m/c cables & ensure that they do not pass over hot surfaces.

L

Y

Prob.

L.C.

Remove combustibles & flammables from work area.

No.

Job Steps

Hazards

Prob.

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Control Measures For working at height: Provide safe access, use full body harness.

Wear required PPEâ&#x20AC;&#x2122;s. (Hand gloves, safety glasses, Face shield, Helmet, safety shoes, masks)

Unit: 0-0000

Sheet: 21 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR â&#x20AC;&#x201C; C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

7

NDT & PWHT

Health hazard due to inhalation of chemical spray Radiation, Fall from height Electric shock

H

Refer MSDS of chemicals used for dye penetration test.

Use masks while performing dye penetration test.

Stand down wind.

A radiographer should have valid license.

He should wear a combination of a dosimeter, alarming plate meter and a film badge.

A survey meter with audible and visual alarms must be provided for radiation area monitoring and shall accompany the source each time when on the Project.

All employees working at site shall be informed about the time period of radiography and its location.

Source must be checked for leaks at least every six (6) months.

The area shall be barricaded physically.

Caution boards shall be displayed No body shall be allowed to enter the barricaded area The equipment producing radiation shall be properly stored and locked to prevent unauthorised handling.

Always use hand gloves while handling unsealed radioactive materials.

Wear protective clothing (Lab coat, eye protection, shoe covers) as needed

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 22 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR â&#x20AC;&#x201C; C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A

Attachment 2: SPOOL RELEASE REPORT

Shell Project No.: HP-3000-QAT

Contractor name:

Contractor Project No.: 5887

VSA CONSORTIUM

Contractor Contract No.: PI-099

Unit: 0-0000

Sheet: 23 of 23

PCWBS: NA Contractor Doc No:

Pearl GTL Project QATAR â&#x20AC;&#x201C; C8 ETP

Orig. Org.:

F15032-AJE-0-0000-CMT-MST-7414

VSA Project Doc No:

T-4.301.770 Rev.A - Method Statement for Off site Pre- Fabrication of Metallic piping

T-4.301.770

Rev.:A