METHOD OF STATEMENT FOR

PIPING FABRICATION AND

ERECTION

METHOD OF STATEMENT
FOR PIPING FABRICATION
AND ERECTION

Page 1

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

Incorporate
comments
ISSUE FOR
APPROVAL
DATE

Status

Written by

Checked
By

TABLE OF CONTENTS
Page 2

Approved
By

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

1.0

PURPOSE

2.0

SCOPE

3.0

REFERENCES

4.0

DEFINITION

5.0

PROCEDURE

5.1

GENERAL

6.0

MATERIAL INSPECTION

7.0 FABRICATION
7.1

FIT UP

7.2

WELDING

7.3

NDT

7.4

PAITINNG OF PIPE SPOOL

7.5

PIPE SUPPORT

8.0 ERECTION
8.1

SPOOL HANDLING

8.2

CHECKING OF LOCATIO AD LIFTING PERMIT

8.3

ERECTION PROCEDURE

8.4

IDETIFICATION OF JOINTS AND LINE NUMBERING

8.5

THREADED PIPE, FITTINGS AND SOCKET WELD

9.

PRESSURE TEST

9.1

PREPERATION FOR HYDROTEST

9.2

REINSTATEMENT

9.3

PRESSURE TEST PIPIG PUNCHLIST

9.4

HYDROSTATIC TEST

1.0

PURPOSE
This procedure serves as a guideline in carrying-out Piping Fabrication to ensure
Systematic approach of work and the requirements are followed.
Page 3

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

2.0

SCOPE
This procedure covers the processes associated for the Piping Fabrication, Such as
marking, cutting, fit-up, Weld-up, Testing, Painting etc.

International Standards
B31.1
B31.3
B31.8
B1.20.1
B16.11
B16.25

4.0

Power Piping
Process Piping
Gas Transmission and Distribution Piping Systems
Pipe Thread, General Purpose (Inch)
Forged Steel Fittings, Socket-Welding and Threaded
Butt welding Ends

DEFINITION
WPS SMAW NDT DPI MPI RT UT PWHT NPS API TFE TPI-

5.0
5.1

Welding Procedure Specification

Shielded Metal Arc Welding.
Non-Destructive Testing
Dye-Penetrate Inspection
Magnetic Particle Inspection
Radiographic Test.
Ultrasonic Test.
Post Weld Heat Treatment
Nominal Pipe Size
American Petroleum Institute,
Poly-tetra- fluoro ethylene
Third Party Inspector

PROCEDURE
General

5.1.1 It is the responsibility of the Production Superintendent to ensure that key personnel
Involved in piping Fabrication Understand fully the requirement mentioned in this
Page 4

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

procedure.
5.1.2 All storage, traceability, identification, tolerances, welding, Inspection and testing shall
be Carried out as stipulated within the specifications procedures and codes.
5.1.3 All materials shall have end caps inserts or plug fitted on Pipes, valves, fitting etc.
during of After blasting and painting Activities.
5.1.4 Only qualified welders that have been approved by TPI Shall be used for any piping
welding.
5.1.5 The electrodes or wire to be utilized for piping welding will be as stipulated in each
W.P.S as approved by Client.
5.1.6

All welding information for each specific operation shall be displayed at the working
area. Welding consumable control, shall be as stipulated in QCP-06

5.1.7

The Quality Control Section shall develop and maintain a record of each welders
performance. This record shall Show the defect rate of each welder, based on linear weld
length.

5.1.8

Prior to any fit-up or welding, all material i.e. pipe, fitting, Valve etc. shall be recorded
and documented as stipulated In material control procedure.

6 .0

MATERIAL RECEIVING INSPECTION

All piping, Fittings, welding consumable materials received at site shall checked as per
approved drawing/ Specifications shall approved by contractor/Client.

7.0
7.1

FABRICATION
FIT-UP
Pipe spool fit-up shall be carried out in a sequence adhering to Isometric drawings and tolerances.
Cutting equipment shall be separate for each kind of materials i.e., stainless steel separate from
Carbon steel pipes to prevent contamination. For stainless steel, use only suitable grinding disc.

7.1.1

All pipe prior to fit-up, shall be internally and externally Cleaned to a minimum of
Page 5

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

25mm from the edge preparation and shall be free of rust and surface contamination
7.1.2 Small bore pipe can be fit-up with the use of angle bar. Large bore pipe shall be fit-up
With the use of interior or exterior line up clamps HI-LO shall be kept within tolerances
as Stipulated in ASME B31.3 i.e. 1.5 mm.
7.1.3 Snaking and distortion in pipe spools shall be limited to 1.5 mm per meter length.
7.1.4 After marking the pipes as per the isometric drawing. The Pipe shall be checked by QC
inspector.
7.1.5

The piping shown on the isometric shall be divided into spools for handling transport and
erection convenience.

7.1.6

After mark-up has been checked by the QC Inspector the pipe should be cut as
per mark-up.

7.1.7

Fit-up tack welds are allowable and if in the root shall be as Per WPS electrode
Requirement and bridge tacks are also Allowable using GTAW. All tacks using GTAW
Electrodes shall be removed during the welding of the joint.

7.1.8

The fit-up spool at this stage shall be submitted to QC Inspector for their approval and
Fit-Up to be signed that fit-up is OK prior to any welding on the spool.

7.1.9

FLANGE ALIGNMENT TOLERANCES

all flanges connection between the piping and rotating equipment
shall be aligned to within the following tolerances.
NORMAL SERVICE

Out of parallel
alignment

3/32 in. per ft. (1:125) of

nominal pipe diameter max.
Out of parallel alignment of
flanges measured at any
point on the flange
circumference.

Special Service Design

Temp.454C or Flange, Rating
ANSI CL900

1mm maximum, measured

across any diameter

Out of axial Alignment

3mm Page
maximum
6

3mm maximum

Flange face Separation

Space required for

Gasket1.5

Space required Gasket

1.5mm

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

7.2

WELDING

7.2.1

The spool fit-up can now be welded as per the relevant WPS and preheating
Requirements As specified in the WPS.

7.2.2

The completely welded pipe spool shall be visual and the Dimension inspected by the
QC Inspector prior to NDT.

7.2.3

Welding Supervisor shall ensure that there is adequate ventilation at the work place
Prior to any purging of pipe Works. AWS D1.1 provides a summary of unacceptable
environmental conditions for welding in section 5.12.2: Welding shall not be done
(1) When the ambient temperature (temperature in immediate vicinity of weld) is
below 0 F (-18 C), or
(2)

When surfaces are wet or exposed to rain, snow.

(3)

High wind velocities up to 35 mph (56kph).

(4)

When welding personnel are exposed to inclement conditions.

7.3

NDT

7.3.1

All non-destructive Testing (RT, MPI, DPI, and UT) shall be Carried out after the spool
has been visually accepted by the QC Inspector and documented. NDT requirement
Page 7

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

will be performed as per isometric drawing and NDT Procedure. All NDT results shall
be documented.
7.3.2

Weld repairs shall be carried out as per the relevant WPS and in accordance to Client
specification and welding repairs Procedure.

7.4

PAINTING OF PIPE SPOOL

7.4.1

Following satisfactory NDT and PWHT results, pipe spools can be released for painting
as per project Standard.

7.4.2

According to project standard surface to be coated shall be free

from grease, oil dirt, salts or any other contaminants, which could affect the integrity of
the applied coating ,the cleaning shall be by detergent or solvent cleaning according to
methods as outlined in the NACE equivalent. All pipe spools intended
for insulation and heat tracing shall be blasted and primed only.

7.4.3

Where abrasive blast cleaning is not possible hand tool cleaning or power tool cleaning
Shall be per NACE equivalent. Approval by
Client is required before power tool cleaning can be substituted for abrasive blasting.

7.4.4

Where possible all pipe spools will have its final coat before erection.

7.4.5

Weld joints to be marked before painting.

7.5

PIPE SUPPORTS

7.5.1

Ensure that pipe guide, anchor, sliding shoes, stoppers are installed correctly where
Specified according to the IFC drawings

7.5.2

Field engineer inspect the spring hanger/ supports to ensure that the type (suspension,
Compression variable load of fixed load types) and capacity are correct and that the
Actual loading is within designed capacity.

7.5.3

For insulated piping, ensure that the load is transmitted directly from the piping to the
Page 8

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

Supporting structure through the pipe support, and not through the insulation.
7.5.4

Ensure that correct type of flexible connections is installed where specified in the IFC
Drawing or by the machinery vendor.

7.5.5

Weep hole required in some cases of welding such as in reinforced and supports. It
Works as a ventilator.

7.5.5

Ensure the pipe supports foundations are adequately Reinforced.

7.5.6

Shim plate shall use for unbalance supports to make balance.

7.5.7

Teflon shall use in threaded joints for good tightening in high temperature services.

8.0

ERECTION
SPOOL HANDLING

8.1

Pipe spools shall be lifted using flat nylon sling pipes. Care should be taken with the
same manner as in fabrication, especially stainless steel and other alloy steel that
needs extra care and protection.

8.2

CHECKING OF LOCATION AND LIFTING PERMIT

Prior to any lifting, the piping supervisor shall check the spool locations. Upon identification
of locations, he shall seek a lifting permit to authorized personnel and start to lift the correct
spools for the identified locations and lines. Care shall be taken during lifting

8.3
ERECTION PROCEDURE
8.3.1
The Above ground piping will be erected as per the piping plan drawing/P &I D/ Isometric
Drawings issued during the course of construction.
8.3.2

8.3.3

Necessary scaffolding platforms and access shall be made available in advance to suit the
Planned erection sequence working stage shall be provided wherever required to facilitate
Rigging/fit-up/welding activities.
All Pipes and Pipe spools are to be checked for inside cleaning before erection.
Page 9

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

8.3.4

The ends of the spools shall be checked for the bevel as required by the Project Specification
And any bevel damages. The spools shall be fitted up within the tolerance limits (1.5
to3.2mm) as mentioned in WPS.The coordinates, elevation, alignment, orientation etc., of
Piping components shall be checked to confirm the tolerance limits specified in the Project
Specification during & after completion of the fit-up.

8.3.5

The erected piping shall be checked for correct elevation, coordinates and alignment before
Welding.

8.3.6

The Fit-up Inspection shall be carried out as specification & release for welding.

8.3.7

After Welding and inspection are completed the accepted joints/spools will be cleared for
NDE.

8.3.8

After NDE acceptance spool or pipe release for Pressure Test. Pressure testing shall be
Carried out as per approved specification/Drawings.

8.3.9

After completion of Pressure testing, the line shall be touch-up as per approved drawing/
Specification.

8.4

IDENTIFICATION OF JOINTS AND LINE NUMBERING

8.4.1

Joint Numbering and Line Numbering shall be sequential as per approved Isometric
Drawings

8.5

THREADED PIPE, FITTINGS AND SOCKET WELDS

8.5.1

All treaded pipe and pipe fitting, shall be installed with the use an anaerobic pipe
Threads Sealant with T.F.E. on the following which do not required seal welding.
a)
b)
c)
d)

8.5.2

Thermo well
Union ring threads and union bonnets of valves.
Instrument tubing fittings.
Union nut rings.

For service employing hydrocarbon, acid and toxic materials, Threaded

Page 10

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

++Connection shall be seal welded. The threads are to be made up using no sealant
And two threads maximum Exposed followed by back welding.
8.5.3

Seal welding shall be done with electrode not to exceed 3.2mm in diameter using
Amperage in low range.

8.5.4

Prior to assembly, all cutting oil shall be removed.

9.0
9.1

PRESSURE TEST
PREPARATIO FOR HYDROTEST
PRE-CLEANING OF STEEL PIPE PRIOR TO SURFACE PREPARATION

9.1.1 All weld spatters and slag must be removed.

9.1.2

Remove loose coating and or heavy layers of rust.

9.1.3

The substrate must be free from moisture.

9.1.4

We shall use the cleaning procedure as, water flushing, card board basting etc.

9.1.5

CLEANING
All pipe work to be pressure tested shall be cleaned prior to testing in accordance with
The applicable specification

9.2

PRESSURE TEST PIPING PUNCH LIST

On completion of reinstatement, the Contractor shall fill-in the cleared column of the
Pressure Test Piping Punch list. The test shall not be considered complete
Until the system has been checked and the Pressure test piping Punch List.

9.3

HYDROSTATIC TEST
Hydrostatic Test shall be carried out as per SIPCHEM standard 00-PI-00-SS-018
Through the section 5.6.After Hydro test pipe shall be air flushed to dry.
Page 11

METHOD OF STATEMENT FOR

PIPING FABRICATION AND
ERECTION

9.4

REINSTATEMENT
Pipe spool and valves that has been removed for hydro testing shall be reinstated.
Reinstatement check of flange connection shall be reinstating.

Page 12