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: GCC/C-3461/M-007/SC-1/EMEC
ZADCO Project #
: 8374
: P20054
: C.3461
COMPANY
CONTRACTOR
SUB-CONTRACTOR
Code A
Code B
Code C
Code D
Code E
Date Received :
Signed :
Date
DOCUMENT CLASS 2
X1
08-11-15
TM/ PM
NP / CM
REV
DATE
DESCRIPTION
PREPARED BY EMEC
REVIEWED
BY EMEC
APPROVED
BY GCC
APPROVED
BY ABB SpA
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TABLE OF CONTENTS
1.
PURPOSE ..................................................................................................................................................... 3
2.
SCOPE OF WORK...................................................................................................................................... 3
3.
DEFINITIONS ............................................................................................................................................. 3
4.
REFERENCE ............................................................................................................................................... 3
5.
LOCATION .................................................................................................................................................. 4
6.
RESPONSIBILITY ..................................................................................................................................... 4
7.
8.
PROCEDURE .............................................................................................................................................. 5
9.
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1.
2.
3.
PURPOSE
The purpose of this document is to provide a detailed outline for preparation, cutting
and welding of in-service lines for branch take-off related to piping tie-ins TP-60.
Branch at TP-60 will provide connection for new flare line 10-FL-9123-A31BN with
existing flare line 12-FL-5321-1D.
Hot tapping technique shall be used to facilitate the Branch take-off on an
operational line without plant shutdown.
SCOPE OF WORK
1) Mobilize manpower
2) Mobilize equipments
3) Scaffold works
4) Arrangement of Pipe fitting
5) Pipe preparation
6) Welding of Split Tee (Hot tie-ins)
7) Complete Qty 1 off 10 class 150 vertical hot tap on to 12 existing piping TP60
by other party
8) Documentation ,QC and safety Coverage for welding activities
9) Dismantle scaffolds
10) Demobilize manpower, scaffolding materials and Equipments
DEFINITION
1)
Company
- Zakum Development Company (ZADCO)
2)
Main Contractor
- ABB SpA
3)
Sub-Contractor(Hot Tap) - Unique Wellube (UW)
4)
Sub-Contractor
- Granite Construction Company
5)
4.
Euro
Mechanical
Contracting(EMEC)
&
Electrical
REFERENCE
ASME B31.3
API 2201
Process piping
ASME B16.5
ASME B16.9
ASME B16.25
ASME Sec IX
A3-400-P-0136
A0-440-50-0053_2
A1-400-P-0624
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5.
Location
The location of proposed scope of work is in Zirku Island at Plant 430/423
6.
Responsibilities
1) Project Manager
a) He will be responsible for overall site management
b) He will be in-charge for organizing the construction team
c) He shall be responsible for all construction activities
d) It is his responsibility to ensure that job is carried out as per the project
specification, monitor the job quality, priorities and achieving the milestones
of project schedule.
e) Project Manager will be responsible to ensure that the requirements of this
method statement are implemented.
f) He will ensure that the work is executed in a safe manner
2) Project Engineer
a) He will be responsible for supervision at site and ensuring implementation
and adherence to project specifications, procedures and HSE policies.
b) He shall provide technical support to the construction team
c) He will ensure the latest IFC drawings and specifications are followed at
work locations.
d) He shall control all resources and ensure productivity.
e) He shall report the progress of work and coordinate with project manager.
3) Foreman
a) He shall be directly coordinating with project engineer
b) He shall ensure that all site activities are performed in safe and responsible
manner in accordance with HSE safety procedures and permit to work etc.,
c) He shall provide all technical support to the team and will be engaged in
direct supervision at site
d) He will ensure that the work is progressing in compliance with the
established project schedule, project specification and standards.
e) He shall report daily to project engineer regarding the daily progress and
manpower utilization.
ABB Doc Ref.
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5)
QC Engineer
a) He shall be responsible verifying ,monitoring and recording , the compliance
of all activities as per project specifications
HSE Officer
b) He shall be responsible for implementing HSE procedures and coordinating
with the safety team.
c) He shall ensure that all work activities are performed in safe manner
d) He will be responsible for making site safety reports, tool box talks and
trainings.
e) It is his responsibility to check all the work location for any unsafe conditions
and liaise with project engineer to resolve the issues.
f) He shall coordinate with project manager and project engineer.
7.
8.
Procedure
A. General Preparations
1) Obtain a proper permit to work with all necessary approved documentations
2) Split Tee shall be in accordance to the design standards of ASME B31.3 and
issued as free issue item.
3) Material upon receipt site shall be inspected through RFI
4) Materials and equipments required to execute the job shall be moved to
location
5) Location on the existing pipe where the split tee has to be welded shall be
identified, verified and approved by ABB/GCC
6) Erect proper scaffold platforms at required elevation to safely execute the job.
7) Arrange charged fire hose at the work location
8) Coating on the external surface of existing piping shall be carefully removed
using power wire brush on the proposed area extending to 150mm all around
ABB Doc Ref.
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9)
10)
11)
12)
13)
14)
15)
16)
the fitting.
The pipe surface shall be visually examined and ensure that no circumferential
weld within 1m of proposed fitting length. Surface shall also be checked for
defects like cracks, pitting, laminations etc.
The proposed location shall not overlap with other welding. Overlapping welds
have greater possibility of forming a crack.
The exposed pipe shall be checked to ensure that the ovality is within the
specified limits
The pipe wall thickness shall be checked by means of UT and the thickness
shall be obtained over complete circumference of the pipe. In case the thickness
measured is less than 5mm at any locations over the pipe circumference
covered by the fitting, such locations shall not be used for welding fittings.
The Proposed location of pipe shall be supported by means of scaffold beam
ladders to accommodate the mounting weight of hot tapping machine.
Prepare the bevel ends of split tee and remove any rust formation from inside
the portion.
Welders shall be qualified for specific WPS
Ensure all assessments are carried out before welding activities.
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Preheat the weld area on the carrier pipe and fitting to minimum 150oC
extending 50 mm along the carrier pipe and 50 mm along the fitting.
2)
Weld shall be completed utilizing two welders working on opposite sides of the
pipe. Stop/start points shall be grinded and overlapped by min. of 1 inch.
3)
Buttering layers shall be deposited onto the carrier pipe. The first run shall be
deposited as close to the edge of the fitting but shall not impinge onto the fitting.
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5)
Required fillet leg length and fitting to carrier pipe gap shall determine the
number of buttering passes required.
6)
On completion of the buttering layers, the joint shall be visually inspected and
accepted prior to being allowed to cool to ambient temperature. The completed
buttering layers shall be examined by Dye Penetrant and Magnetic Particle
Inspection.
7)
Any residue from the magnetic particle shall be removed by power wire buffing.
8)
9)
The first pass in the throat of fillet shall not be extended by the electrode run out
length before being reinforced by the deposition of next run. This technique
shall be used progressively around the joint until the throat of the fillet is sealed.
10) After the root of fillet joint, MPI + DP examination will be carried out.
11) In case of any welding interruption MPI examination will be carried out.
12) The weld can now be completed in blocks or by continuous runs
13) The weld shall be completed in one heat cycle.
14) The completed weld shall be visually inspected and accepted prior being
allowed to cool to ambient temperature.
15) The complete weld shall be examined by magnetic particle inspection.
16) Weld No.4 shall not commence until weld no. 3 has cooled to ambient
temperature
E. Welding Joint no 4
1)
Preheat the weld area on the carrier pipe and fitting to minimum 150oC
extending 50 mm along the carrier pipe and 50 mm along the fitting.
2)
The sequence of welding shall be similar as stated for Weld joint no-3. Welding
shall proceed as per step 11.2 to 11.15
3)
After QC approval the Welded Split tee with flange shall be released for Hot tap
procedure
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11. ATTACHMENTS
1) TIE-IN LIST A3-400-P-0136 (SHT 10)
2) ISO DWG 400-10-FL-9123-A31BN (SHT 1OF 2)
3) PIPING ARRANGEMENT AND SUPPORT A1-400-P-0624
4) PIPING & INSTRUMENT DIAGRAM-A0-440-50-0053_2
5) ULTRASONIC THICKNESS GAUGING REPORT AD-053
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