1. PURPOSE
This method statement is to establish the work plan and inspection instruction for the assembly, fabrication, inspection and documentation to be performed in order to complete the construction of pipe hangers and supports which shall be in compliance with applicable drawings and specifications.
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2. SCOPE
This method statement covers all pipe hangers, spring, cold shoe, clamped, supports and embedded plate to be assembled, fabricated, installed and inspected Project.
3. REFERENCE
- Basis for Piping Engineering
- Piping Material Specification
- Piping Standard Drawing
- Piping Support Standard Drawing
- Specification for Piping Work
- Specification for Piping Fabrication by Each Service Class
- Specification for Painting
- Welder Qualification Procedure
- Material Control Procedure
- NDE Control Procedure
- Method Statement for Painting
- Method Statement for PWHT
- ASME B31.1 Power Piping
- ASME B31.3 Process Piping
- ASME Sec, IX Qualification Standard for Welding and Brazing
- ASME Sec. V Nondestructive Examination
- ASME Sec. II Welding Rods, Electrodes and Filler Metals
4. ORGANIZATION AND RESPONSIBILITIES
The Construction Manager has the responsibility to:
- Plan the fabrication program and report it’s progress
- Manage all fabrication drawings.
- Preparation, revision and control of this document.
- Managing of raw materials.
- Managing of welding consumables.
- Inspect the fabrication and installation of support and changes of it’s design.
- Ensuring that design changes are incorporated into the work.
- Requesting NDE or PWHT, if any
- Requesting inspection to the QA/QC Team.
- Preparation of material requisition of material for support fabrication work.
- Control of welder and support welding data
- Requesting and preparation for welder and welding operator qualification.
The QA/QC Manager has the responsibility to :
- Review of all request including Daily Welding Inspection Report.
- Managing welder qualification.
- Managing welding control system.
- Managing of quality control.
- Managing inspection and test with regard to support fabrication and installation.
The Material Control Manager has the responsibility to:
- Receiving and maintaining of material
- Control of material stock status before release to construction team.
- Issuance of material to Support shop and other sections.
- Request the material receiving inspection to QA/QC team
5. GENERAL
Material to be installed will be withdrawn from the receiving area in accordance with material control procedure, the prefabricated sub assembly storage area, or the lay down area. Transferring the material from the storage area to work site will be performed in a manner which will not be deleterious to the material.
When storage requirements are not defined, the type of storage and protection shall be determined through arrangements with project owner.
5.1. General Work Sequence
- Make production plan considering material availability and area priority.
- Issuance of Isometric drawing or support style list to support fabrication shop.
- Request support material to material warehouse
- Receiving support material from warehouse and perform receiving inspection.
- Issue work order
- Cutting and end preparation
- Fit-up and tack welding
- Welding
- Inspection
- Blasting and primer painting work at paint shop
- QC documentation
- Release support and store on stock yard (13) Support issuance to Field support team.
5.2. Storage and handling material
- Material shall be stored separately by its type and specification and it shall be marked according to its designated color.
- Certificates verifying that materials or items used in the fabrication comply with Purchaser’s requirement. Certificates for each category of material shall be submitted.
- Materials shall be maintained to comply with any warranty conditions imposed by the manufacturer.
- Nylon slings shall be used for handling stainless steel material and straps.
5.3. Drawing and materials
- Pipe support shall be fabricated and installed in accordance with the approved drawing, pipes support style list.
- For pipes requiring post weld heat treatment, attachments required for supporting purposes shall be indicated on the piping isometric drawings.
- Pipe stanchions, pipe dummies and trunnions shall be made with same type of material as the connecting pipe. All other support material to be welded directly to the pipe shall be same type of material as the pipe itself.
5.4. Inspection and test
The inspection and test shall be notified to QA/QC team 24hours in advance prior to inspection and testing, and it shall be performed in accordance with the inspection and test plan.
6. WORK PROCEDURE
6.1. Control of pipe supports fabrication
All material of pressure retaining parts shall be identified.
Part number, material specification and heat number shall be marked on the piece to be cut, and it shall be recorded on the material identification record, and it shall be inspected by QC inspector before cutting.
Support materials may be cut to shape and size by flame or thermal cutting.
Stainless steel materials shall be cut by mechanical means or plasma arc cutting, but flame cutting shall not be allowed. Surface to be welded shall be free from slag and excessive notch foreign matter.
Pipe support assemblies may be acceptable if items having greater strength are substituted for those indicated on the drawings.
- Materials requiring post weld heat treatment (PWHT)
- Non-ferrous materials
6.2. Control of Pipe supports installation
- Isometric drawing
- Piping arrangement drawing
- Pipe support standard drawing
- Special pipe support drawing
- Pipe support index
Installation of concrete expansion anchor bolt shall be performed in accordance with vendor information.
The support height shall be adjusted by construction team to the actual field condition. All threaded connections, except high strength bolts, shall be secured by locking devices to prevent loosening during service.
Wherever possible bolts/stud shall be locked in place with double nut. (Jam nut) A nut tack welded to the bolt/stud shaft may also serve as a locking device and may be used except where welding is prohibited on the bolt material.
Grouting is required between concrete surface and structural pipe support attachment plates.
All grout work shall be performed in accordance with relevant work procedure.
Non shrink grout shall be mixed and placed in according with the manufacturer’s written instruction.
6.3. Welding and welding attachment
- All welding shall be in accordance with approved welding procedure specification.
- The material of the attachment which is directly welded to the pipe shall be as shown on the pipe support detailed drawings.
- Welding must be carried out by qualified welder in accordance with approved welding procedure specification.
- Material traceability report shall be recorded the heat-number of attachment and verified by QA/QC inspector and Contractor’s inspector for stainless steel and alloy steel. (Attachment 2)
- Daily welding inspection report shall be signed off by QC inspector after visual inspection.
- All weld attachment on pipe shall be identified by marking the weld and welder number.
- All welds will be identified on the isometric drawing and shall be inspected by welding inspector and recorded in daily welding inspection report. (Attachment 3)
- Performance of PWHT shall be in accordance with post weld heat treatment procedure.
- The QA/QC shall review PWHT record and submit to owner for review.
- The management and request of NDE shall be in accordance with NDE control procedure.
- The QA/QC shall review NDE record and submit to owner for review.
6.6. Paint and Touch up painting
- At completion of fabrication and installation, painting subcontractor shall paint or touch up paint the pipe support according to painting specification and procedure.
- Pipe construction manager is responsible for keeping and maintaining all related documents.
6.7. Progress check
- Progress of fabrication and installation in pipe support shall be measured together with piping progress using progress measuring program.
- Every support item shall be tracked by this system.
7. HEALTH SAFETY ENVIRONMENT AND SECURITY
All workers shall wear PPE required as below.
- Safety helmet
- Safety glasses
- Safety shoes
- Gloves
- Mask, if required to prevent inhalation of dust and welding gas
- Ear plug, if required by conditions.
Safety shall be requested and carried out in accordance with safety procedure.
8. ATTACHMENTS
- Attachment 1: Daily Fabrication Inspection Report (DFIR)
- Attachment 2: Material Traceability Record (MTR)
- Attachment 3: Daily Welding Inspection Report (DWIR)
- Attachment 4: Inspection Report for Embedded Plate Fabrication (IREPF)
- Attachment 5: Release Note for Field Installation (RNF)
- Attachment 6: Release Note for Painting (RNP)
- Attachment 7: Job Safety Analysis (JSA)
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