Method Statement

Pipe Works, Equipment Installation

& Steel Fabrication

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 Table of Contents

PAGE

1. SCOPE 3
2. CODE OF STANDARD 3
3. IDENTIFICATION 3
4. STORAGE AND HANDLING 3
5. GENERAL REQUIREMENTS 3
5.1 Document
5.2 Fabrication
5.3 Fit-up of Girth Welds
5.4 Backing Strips or Rings
5.5 Ends for Field Welding

6. TOLERANCES 4
7. WELDING 5
7.1 Minimum Distance
7.2 Materials
7.3 Welding

8. REPAIRS 6
9. VISUAL INSPECTION & DIMENSIONAL CHECK 6
9.1 Visual Inspection
9.2 Dimensions Check

10. PNUEMATIC & TIGHTNESS TEST &

QUALITY INSPECTION OF WELDS 6

11. EQUIPMENT INSTALLATION 7

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PIPING WORKS QUALITY SPECIFICATIONS

1. SCOPE

This specification cover the basic, minimum and general quality requirements for the fabrication,
installation, inspection and testing of the plant piping.

2. CODE AND STANDARDS

All materials, Fabrication and welding shall be in accordance with the following standards:

2.1 Philippine National Standards

2.2 JIS Standards
2.3 ANSI and ASTM Standards

3. IDENTIFICATION OF MATERIALS

All pipes and fittings which will be supplied by Employer have the material specification and grade
stamped, stenciled, or otherwise marked on it.

4. STORAGE AND HANDLING

4.1 Pipes shall not be used stored directly on the ground. Pipes shall be placed on mounds or
sleepers.
4.2 Pipes shall not be stacked so high that pipes or coatings may be damaged.
4.3 Fittings and valves shall be stored in shipping crates or on racks.
4.4 All materials shall be handled with care during fabrication and installation to prevent damage.
4.5 Stainless steel, lined and coated pipes and fittings shall be lifted with wide fabric or rubber-
covered slings and padding. Shall be used to prevent damage to lining or coating.

5. GENERAL REQUIREMENTS FOR FABRICATION

5.1 Document

5.1.1 The contractor shall prepare, if necessary, the detailed shop fabrication
drawings prepared by the Employer. The shop drawings need not be submitted to
Employer for approval prior to fabrication unless special details are proposed or
when so requested by Employer.

5.1.2 Standard piping symbols used on Piping Detail Sheets and isometric drawing are
identified on standard drawing.

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 5.1.3 Approval of the Contractor’s drawing, in any case, by Employer does not relieve the
contractor of the responsibility for compliance with the code this specification and
the contractual requirement.

5.2 Fabrication

5.2.1 All branch attachment welds including the attachment welds of couplings and weld
shall be full penetration groove welds.

5.2.2 If fabrication aids such as temporary fixtures and backing rings are removed after
welding, the attachment locations on the main pressure part shall be properly ground
to eliminate surface stress risers.

5.3 Fit-up of Girth Welds

Parts to be joined by circumference but welds shall be shaped and matched so that any
misalignment at the bore of the spool shall not exceed 1.6 mm (1/16 in) at any point at the
circumference of the point. Fit up works shall be limited to pressing, hammering, local
heating or grinding as required to reduce any misalignment due to diameter tolerances out of
roundness, and unequal wall thickness to 1.6 mm or less.

5.4 Backing Strips or Rings

When used, metal backing rings or strip shall be removed, after welding and the internal joint
ground smooth. Permanent backup strips are not permitted.

5.5 Ends for Field Welding

5.5.1 The ends of pipes which are to be joined by girth welds field installation, shall
be prepared and matched per paragraph 6.3 to facilitate fit-up in the field, except
where the drawing indicate extra length to be cut back in the field for
adjustment in length, corresponding welding ends shall be clearly marked.

5.5.2 All welding ends shall be beveled with an angle 35 degrees, plus or minus 5
degrees and a root face of 1.6 mm (1.16 in). The bevels shall be either machine
cut bevels or smooth, clean, slag free flame cut. The end plane shall be normal
to the pipe axis as defined on the piping drawing, within 0.25 degrees.

6 TOLERANCES

6.1 The tolerances for axial dimensions face to face center to face and location of attachment
shall be +/-3mm (+/-1/8 in) maximum.

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 6.2 Flattering of bends, measured as the difference between the largest and smallest outside
diameter at any cross section shall not exceed 5 percent of the nominal diameter of the pipe.

6.3 Lateral transition of branches and connections from centerline of run shall not exceed +/1.6
mm (+/-1/6 in).

6.4 Flange bolt holes shall straddle the established centerline. Rotation of flanges, measured as
the offset between elevation of bolt holes on opposite sides of a flange centerline, shall not
exceed +/- 1.6 mm (+/-1/6 in).

6.5 The tilt of flange measured at the periphery across and diameter shall not exceed 1 mm (1/32
in) from the square position.

7 WELDING

7.1 Minimum Distance

All minimum distance stated below shall be measured between the adjacent edges of the cap passes.

7.1.1 Adjacent butt welds shall be separated by a minimum of 19 mm or three times the wall
thickness (3t), whichever greater.

7.1.2 A butt-weld which is intersected by or separated by less than 19 mm from the pressure
containing weld of a welded branch connection (disregarding reinforcing pads, saddles
or sleeves) shall be 100 percent radiograph.

7.2 Materials

Electrodes, filler wires, fluxes and other consumables may be used only with the specific
approval of employer.

7.3 Welding

7.3.1 No welding shall commence without the welding procedure having been qualified.
Each and every organization entrusted with the execution of piping works shall quality
its own welding procedures and is not permitted to use any welding procedure
qualified by another organization.

7.3.2 TIG and GTAW are only welding processes to be considered by the contractor for site
welding work.

7.3.3 Welding materials like electrodes, fillers and flukes shall be properly store and shall
be properly heated/dried before use.

7.3.4 Unacceptable discontinuities shall be completely removed by chipping, gauging,

grinding, or other methods (suitable for the type of materials being repaired) to clean

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 sound metal, and the excavated area shall be examined by dye penetrant methods to
assure complete removal of defects.

7.3.5 Repair to correct weld shall be made by the same welding procedure specification
used for the original weld or any other previously approved welding procedure
specifications.

7.3.6 All site-welding activities shall be done under protection against weather conditions to
the satisfaction of Employer.

7.3.7 For the pipelines connected to the entry side of machines including the reciprocating
types, the root pass shall invariably be executed by GTAW.

8 REPAIRS

8.1 Cracks shall be repaired only if approved by Employer in writing. The contractor shall
submit details of the repair procedure and nondestructive examination of repair areas for
employer’s approval for any cracks repairs.

8.2 Unsuccessful weld repair after the second attempt shall be cut as cylinder and shall be
replaced with a new section of pipe.

9 VISUAL INSPECTION & DIMENSIONAL CHECK

9.1 Visual Inspection

Visual Inspection on welding joints and the roundness of spool pipe should be done
properly to insure good quality appearance.

9.2 Dimensional check

Pipe spools and shall be checked and corrected when Employer requests after Visual
Inspection to assure proper alignment of flanges and correct centerline dimensions.

10 PNEUMATIC AND TIGHTNESS TEST AND QUALITY INSPECTION OF WELDS

10.1 Pneumatic and Hydrostatic Testing shall be performed using clean potable water with
chloride content of maximum 50 ppm (if applicable).

10.2 If hydrostatic or pneumatic testing are not applicable, good quality weld appearance, thru
visual inspection, will be the basis of the weld qualification. OTV France Philippines has
the prerogative to demand for testing using dye penetrant method on those welds which are
suspected to have unacceptable discontinuities after thorough visual inspection.

10.3 Final inspection on the tightness of the welding joints will be done during Air Pattern Test.
All weld joints and flange connections be properly inspected by applying soap suds while

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 the blower is running during Air Pattern Test. Any signs of leak and loose joints will be
connected by bolt tightening if leak occurs on flange joints and weld repair on welding
joints. Item 7.3.4 and 7.3.5 will be followed on welding repair if there’s any.

11 EQUIPMENT INSTALLATION

11.1 Scope

This document specifies the requirements that are to be followed by the contractor during
the installation work of mechanical equipment for the project.

11.2 Reference

11.2.1 The work shall be performed in accordance with this document equipment
drawing, plot plan and other documents the company.

11.2.2 The installation/erection of the machinery shall be performed in accordance

with the manufacturer manuals and specifications.

11.3 General Requirement

11.3.1 All equipment that will be transferred to the contractor for his
installation/erection work at the company’s warehouse located near the site
and or designated location inside of the construction site.

The contractor shall have responsibilities of transportation and offloading of

equipments to the location where the equipments are to be installed.

11.3.2 During work, great care should be observed in order not to damage the
underground pipes, wire and cables of existing facilities, and building.

Furthermore, any goods foreseen to be damage shall be carefully protected in

advance.

Positioning of lifting equipment such as base conditions under out-rigger,

operation circle, etc. shall be carefully be examined before the work.

11.3.3 Special attention shall be paid when handling fire. Necessary permission to
use fire shall be obtained prior to its usage and the responsible supervisor
shall act as an attendant throughout the work.

11.3.4 Hoist and transport of the equipment shall be carried out by the skilled
workers having qualification for rope-knotting work in compliance with the
safety regulations.

11.3.5 Nozzle shall not be used for the purpose of hoisting the equipment.

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11.3.6 The equipment on the foundation shall be approximately supported to avoid
dangerous position and setting using temporary support, structure, etc. prior
to final alignment.

11.3.7 The reinforcement plate, cloth tape, etc. covering the opening parts of the
equipment shall not be removed before commencement of piping work.

11.3.8 Hoisting work shall not be interrupted under any dangerous situation e.g.
interruption during hanging equipment.

11.3.9 Hoisting operation shall be carried out in accordance with the following
procedure.

11.3.9.1 Before winding up, check all the condition, such as crane
positioning wire arrangement, etc.

11.3.9.2 Wind up a little to check the loading conditions.

11.3.9.3 Check the whole situation carefully

11.3.9.4 If any dangerous or abnormal parts are found, immediately

pull down the equipment.

11.3.9.5 Make necessary reinforcement or suitable arrangement.

11.3.9.6 Proceed with the wind up and transfer operation slowly and
carefully.

11.3.10 Hoisting or pulling down shall be directly single responsible for supervisor.
Whistle and signal shall be used in regular method. Further a line system to
transmit the instructions thoroughly from top to bottom level workers shall
be organized.

11.3.11 Installation of Heavy Equipment shall not be executed on rainy days, in

strong wind time of after sunset without adequate lighting. The contractor
shall submit his installation procedure for heavy equipment when the
Company requested for safe operation.

11.3.12 Any accessories which are unnecessary to be attached immediately after

installation, shall be stored in the warehouse item by item.

11.3.13 The contractor shall confirm all necessary consumable for his work is ready
before starting of the work.

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11.4 Equipment Installation Work

Equipment installation work shall be performed in accordance with the following

procedure:

1. Prior check and confirmation of equipment

2. Foundation check
3. Grain raiding (Chipping)
4. Fixing and alignment of liner plates
5. Curing of Mortar for liner plates
6. Placement of equipment on the foundation
7. Filing anchor bolts hole with mortar in case of box of type
8. Curing of mortar in bolt holes in case of box out type
9. Grouting
10. Finishing of foundations surface
11. Fixing of attachment and setting of internals
12. Cleaning inside equipment whose internals are installed by the contractor
13. Confirmation of no leakage from the part, such as manhole, inspection hole, etc.
14. Cleaning

11.4.1. Prior to Check and confirmation of equipment

11.4.1.1 Check the drawings and specification carefully, paying special attention
to the weight of equipment, installation direction, slide base inserted
between foundation and equipment, accessories, davit and stage.
Further, confirm the material of equipment and remarks against
damage.

11.4.1.2 Check the road condition for transportation of equipment at the jobsite
e.g. Limit of height, width and weight of the road and ground
conditions)

11.4.1.3 Setting place of crane

The grounding conditions and crane rotating space shall be checked in

advance.

11.4.1.4 Receiving checks

Company will check the equipment and their accessories, especially to

confirm the damage and number (shortage) of the parts such as slide
base, anchor bolts and nuts, retainers, stage and stages davits, etc.
when the equipment and their accessories arrive at site. Contractor
shall assists with Company to carry out the receiving checks.

11.4.2 Foundation Checks

Dimensions of foundation shall be checked in compliance with issued IFC

Drawings and equipment loading requirements.

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11.4.3 Grain Raising

Before installation, grain raising shall be performed on upper surface of the

foundation in order to avoid the flaking off of grout material from the foundation
surface.

11.4.4 Setting and alignment of linear plate

11.4.4.1 Cleaning the foundation

Clean the upper surface of the foundation and anchor bolt holes to
remove oil grease dirt and loose particles. Then wet the surface with
water for at least 6 hours prior to mortaring.

11.4.4.2 Setting the linear plates

Place the linear plates on the mortar or horizontal surface on the

foundation, checking their positions and elevations by surveyor’s level
and carpenter’s level.

The upper surface of linear plates to be set shall be in elevation within

tolerance of 3mm (by means of surveyor’s level). Further the
tolerance, horizontally between any linear plates must be 3mm (by
means of carpenter’s level and stretch)

The linear plates under a slide or roller shall be set in the elevation
subtracted the thickness of the slide plate from the equipment.

11.4.4.3 Set position of linear plates

The linear plates shall be set on both sides of anchor bolt with equal
distance and in the nearest position from the anchor bolt.

In case that the distance between each anchor bolt is over 500mm,
additional linear plates shall be set between each linear plate to
reinforce the endurance strength of concrete.

11.4.4.4 Non shrink mortar shall be used as mortar for setting liner plate, half
grouting and grouting except anchor box in case equipment specified
by the company.

11.4.5 Curing time of mortar

More than 5 days are necessary for curing of mortar after placing.

11.4.6 Placement of equipment on the foundation

The placement shall be carried out in accordance with the procedure specified in
section 11.3 of this document. In case of placement to the anchor bolts
previously set the anchor nuts shall be temporarily screwed immediately after
equipment placing. When placement conditions are unsuitable, appropriate
temporary support must be given. Davits, stages etc. shall be attached while the
crane is available.

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 11.4.7 Half-Grouting

In case anchor bolts are set after equipment placing, half grouting shall be
performed in accordance with the following procedure:

11.4.7.1 Wet anchor bolt holes with water

11.4.7.2 Remove water and forming plate with siphon of rags

11.4.7.3 Set anchor bolts

11.4.7.4 Fill the anchor bolt holes with mortar as specified in section 11.4.7

11.4.8 Alignment of static equipment

The following items shall be checked for alignment:

1. Verticality (in case of vertical type)

2. Horizontally (in case of horizontal type)
3. Elevation

Tolerance specified below is standard figure, while the company will request other figures
taking manufacturer’s requirement.

11.4.8.1 Verticality

Verticality shall be checked from two directions. Tolerance of verticality are:

Up to 20 m height: 6mm/10m
Over 20 m height: 12 mm

For the check, a transit shall be used. In case of column, alignment of verticality shall be carried
out by hammering the taper liner plates. After alignment, the protrusive part of the taper liner
plates from base plate shall be cut

Alignment of verticality for the other equipment shall be carried out by inserting shim plates and
a liner plate.

Alignment in strong wind and or under sun beam shall be avoided. Cloudy day or early morning
is suitable for this work.

11.4.8.2 Horizontally

Tolerance of Horizontally is; +/-3mm

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 11.4.8.3 Elevation

4-point of elevation check (at every 90 degrees) which measures distance from the bench mark to the
surface of the bottom face or equipment skirt shall be made and tolerance within 3mm shall be kept. A
surveyor’s level shall be used for this check.

Anchor bolts shall be tightened at the recommended tension after alignment.

11.4.9 Grouting

11.4.9.1 Oil, scale, sand, loose particles, etc. on the foundation shall be removed.
Thereafter, the surface shall be adequately wetted with water to ensure that it
does not dry up immediately after grouting.

11.4.9.2 All grout shall be used Non Shrink Mortar

11.4.9.3 Grout shall be poured form only one side to avoid intermixing of air. Adequate
provision shall be made in advance for removal of intermixing air from the area
between base plate and foundation.

11.4.9.4 At grouting, the following cement mortar shall be used

Item Mixing ration (Weight)

Cement 1.0
Sand 1.0
Water 1.0

11.4.10 Finishing

After grout is moderately hardened, finishing shall be made with mortar using a trowel. The
mortar mixing ratio is as same as specified in the section 11.4.9.4

11.4.11 Fixing of attachments and setting of internals

All attachment such as stage, ladder, etc. shall fixed at the earliest time. Internals shall be set
and filled in accordance with the engineering drawing and the packing charge manual.

11.4.12 Mechanical cleaning using cloths, wire brushes, etc shall be performed after alignment of the
equipment.

11.4.13 No leakage of the parts, such as manholes, inspection holes, etc. to be opened or close for
cleaning, fixing the attachments and or setting the internals shall be confirmed by air leakage
test. The test will be performed at the same time as that for piping.

11.5 Alignment of Rotating Equipment

11.5.1 Alignment of the various equipment shall be in strict accordance with the instructions
provided in the manufacture’s supervisor for erection and by the company.

11.5.2 All coupling shall be left after loose after setting and preliminary alignment. If a piece of
equipment and its driver have been shipped as complete assembled unit, the coupling shall be
loosened before field alignment.

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11.5.3 During the course of assembly and alignment of equipment having components shipped
separately, check affecting performances shall be made in accordance with manufacture’s
instruction, witnessed by the company, if they request.

In particular, all coupling and shaft alignment shall be recorded and turned over for the
permanent record to the Company. These reading shall be taken in accordance with the
manufacture’s and or company’s instructions, with measuring devices of necessary accuracy
by qualified personnel and shall be duly witnessed.

The tolerances for coupling and shaft alignment shall be greater than those indicated in the
installation instructions or as follows, whichever is the more stringent.

After due to allowance for differential thermal expansion of components and for shaft sag, the
face to face distance between disconnected coupling halves at the diametrically opposite
points on their outer edges shall differ by more than fifty (50) micron or the manufacture’s
tolerance, whichever is less. The horizontal and vertical eccentricity of one half of the
coupling relative to the other shall not exceed twenty five micron (25). The actual reading
shall be recorded.

11.5.4 Equipment shall be assembled with proper allowance for end float, seal and wear ring and
thrust collar clearance, relation of magnetic center to rest position for motors, up or down
thrust on vertical shaft equipment, coupling spacing where called for, and all other such
internal clearance as are called for by the manufacture or genetic to the installation. Match
marking of disassembled components shall be closely observed in its final assembly,
including those for proper orientation of factory balanced rotating parts such as coupling.
Motor halves coupling shall be safely secured prior to motor rotation check.

11.5.5 After all piping or ducts have been connected to the equipment, and initial start-up is eminent,
a check shall be made of the alignment, realign if necessary, and written approval obtain from
the company prior to make up of the coupling. Motor halves of coupling shall be safety
secured prior to motor rotation check.

11.5.6 Equipment used for torching of anchor bolts, coupling alignment, etc shall be calibrated and
procedure shall be approved by the company prior to their use.

11.5.7 After final alignment and torching of anchor bolt, locking or jam nuts shall be provided for all
bolts shall be drawn tightly.

All anchor bolts having a projector beyond and locking nut of more than one half the bolt
diameter shall be cut off and debarred when requested.

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11.6 Lubrication

11.6.1 Lubrication shall be maintained in journal and thrust bearings as recommended by the
manufacturer, during storage and layup periods to provide adequate lubrication at rotating
equipment shafts.

11.6.2 All lubrication and oil system shall be free from dust, dirt and other foreign materials prior to
charging of lubricants.

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