It is
confidential and cannot be disclosed to any third party for any purpose without prior written
FOR CONSTRUCTION
Method Statement
for
Underground Piping
consent.
DISTRI.
20 Pages including Cover Sheet
CLIENT 4
MHI 1
REVISION
PROJECT
2 03.12.09 REVISED AS MARKED I.S.K. C.G.J C.K.S J.D.J.
QA/QC
1 17.10.09 FOR CONSTRUCTION I.S.K. C.G.J C.K.S J.D.J.
SAFETY
APPD APPD
NO. DATE DESCRIPTION REFERENCE SECTION PROJECT TEAM PROCURE
ORDER NO. OWNER
CIVIL
PROJECT TEAM AOFP BILDING
APPROVED J. D. Joh El-Djazairia El-Omania Lil Asmida Spa MECHANIC
PIPING
ELECTRIC
QA / QC C. K. Seo PROJECT
INSTRU
SECTION Piping Team
APPROVED C. G. Joung Algeria Oman Fertilizer Project (AOFP) PAINTING
SUBCON
DWG. NO
DRAWN D. J. Lee .
6423DP420-00-00200 00 REV. 3
DRAWN DATE 27. Aug, 2009 TOTAL
MHI-DEC Consortium
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCE
4.0 DEFINITIONS
6.0 GENERAL
7.0 PROCEDURE
8.0 TESTING
9.0 SAFETY
10.0 ATTACHMENT
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1.0 PURPOSE
This document is to define the methods and processes to be adopted in order to ensure that all
underground piping system are installed in accordance with Algeria Oman Project (AOFP) specifications,
applicable code and standard.
2.0 SCOPE
This method statement covers the excavation, installation, jointing and backfilling of underground coated
carbon steel piping.
Pressure testing of all piping systems will be conducted in accordance with Hydrostatic Test Procedure
(6423DP420-00-0130000).
3.0 REFERENCE
3.1 Codes & Standards
DPEM Circular No.2 Technical Control Regulation for Installation for the Treatment and
Storage of Hydrocarbons and Electric Power Generating Stations
Decree 90-245 Statutory Regulations of Gas Pressure Equipment.
Decree 90-246 Statutory Regulations for steam / Vapor Pressure Equipment.
ASME B 31.3 Chapter V Fabrication, Assembly and Erection
ASME B 31.3 Chapter VI Examination, Inspection and Testing
ASME BPVC Sec. II Part C Welding Rods, Electrodes and Filler Metals
ASME BPVC Sec. V Nondestructive Examination
ASME BPVC Sec. IX Welding and Blazing Qualifications
ANSI/AWWA C209 Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections
and Fittings for Steel Water Pipelines
Steel Structures Painting 1.Steel Structures Painting Manual
Council (SSPC) 2. SP-3 Power Tool Cleaning
3.SP-10 Near White Blast Cleaning
NACE RP-02-74 Recommended Practice, High Voltage Electrical Inspection of Pipeline
Coatings Prior to Installations
3.2 Technical Specifications / Documents
The following technical specification / documents shall be used in conjunction with this document
6423MS231-00-00100 00 Specification for Piping Fabrication by Each Service Class
6423MS230-00-00200 00 Specification for Inspection of Piping Work
6423MS285-00-00100 00 Specification for Flushing & Cleaning of Piping
6423MS286-00-00100 00 Specification for Hydrostatic & Pneumatic Pressure Test
6423MP201-00-01200 00 Specification for Field Joint Rubber Lining
6423MP201-00-01100 00 General Specification for Rubber Lining (Seawater Piping)
6423MP201-00-01101 00 Rubber Lining Materials For Site Lining Work
6423MP342-00-91100 00 Wrapping Procedure For Underground Piping
6423MP202-00-00100 00 Piping Material Specification
6423DA060-00-00500 00 Qualification of Welding Procedure Specification
6423DA060-00-00700 00 Welder Qualification Procedure
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6423DA060-00-00900 00 Welding Control Procedure
6423DA060-00-01200 00 Welding Material Control Procedure
6423DP420-00-00420 00 Method Statement of Painting
6423DS202-00-01300 00 Confined Space Procedure
6423DS202-00-01600 00 Excavation Work Safety Procedure
6423DC420-00-00700 00 Procedure for Earth Work
6423DP420-00-01300 00 Hydrostatic Test Procedure
Note : If there are any conflicting requirements between this specification and individual specification or
drawings, the requirement shall be governed in accordance with the following order.
(1) Drawing and individual specifications
(2) This specification
(3) Codes and standards
4.0 DEFINITIONS
For the purposes of the document the following definitions shall hold.
4.1 Owner
This shall mean EL-Djazaria El-Omania Lil Asmida Spa (A joint venture of SBGH & Sonatrach) who
initiated the project and ultimately specifies the technical requirements.
The Owner may also include an agent or consultant authorized to act for on be-half of Owner.
4.2 Contractor
This shall mean MHI & DEC who carries out all or parts of the engineering, procurement, supply,
construction and commissioning.
4.3 Media
The technical document may be prepared, submitted and reproduced using any of the following media.
- Hard copy
- Reproducible (transparencies, tracings). Photocopies and electronic copies
- Photographs
- Electronic media including compact diskettes / floppy diskettes.
4.4 Shall
This shall mean mandatory requirement.
4.5 Should
This shall mean desired requirement.
4.6 Document
This shall include output in the form of hard copy, drawing, tracing, reproducible, floppy diskette, compact
diskette and field inspection reports.
6.0 GENERAL
6.1 When welder is welding, he shall wear the appropriate safety equipment and clothing to prevent him from
getting an electric shock or burns.
6.2 A confined space entry permit is required before entry to confined space.
When welding in confined space, an extractor must be installed to remove hazardous / toxic fumes and to
ventilate the area, if necessary a mask shall be worn and an assistant will be posted at the entrance to the
work area in case of emergency.
6.3 When welding, inflammable materials must be removed from work area to avoid causing a fire.
7.0 PROCEDURE
7.1 Sequence of work
(1) Pipe transportation
(2) Excavation
(3) Wrapping (External)
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(4) Pin hole test & Inspection
(5) Fabrication for spool and double joint pipe
(6) Internal cleaning and arrangement
(7) Fit-up and welding
(8) Hydrostatic test (for WF line)
(9) Rubber Lining (Welded Joints)
(10) Line leveling and supporting by sand bag
(11) Wrapping (Welded Joints)
(12) Pin hole test & Inspection
(13) Backfilling
(14) Service test (for WCM, WCR, WCS, WW, WSM, WSR & WSS line)
7.2 Material control
(1) Rubber coated carbon steel pipe shall be provided by the contractor (MHI).
All delivery inspections and certifications are done by contractor (MHI/DEC).
All pipes shall be inspected for conformity by QC inspector.
(2) Welding consumables shall be controlled in accordance with Welding Material Control Procedure
(6423DA060-00-012000 00).
7.3 Handling and Transportation
(1) All coated pipes will be handled by means of wide sling bands or belts to avoid damaging the coating
material.
(2) Coated pipe shall be handled with wide nonabrasive canvas, leather belts and or other.
(3) All equipment designed to prevent damage to the coating.
(4) The use of tongs, bare pinch bars, chain slings, rope slings without canvas or composition belt slings
with protruding rivets, pipe hooks without proper padding or any other handing equipment found to be
damaging to the coating shall not be permitted.
(5) All skid used to support coated pipe shall be padded.
(6) Walking on the pipe shall not be permitted.
7.4 Excavation
(1) Excavation by machine shall be carrying out if the working space is within the safe limit against the
existing facilities.
(2) Manual excavation shall be performed if the working area is to close to the existing underground
facilities.
(3) Shuttering or sheet piling (if required) should be done initially to ensure proper protection and stability
of the existing facilities before commencing the excavation work.
7.5 Wrapping
(1) Surface Preparation
Surface Preparation shall be according to Steel Structure Painting Council Specification SSPC-SP-3
(or equivalent), Power Tool Cleaning. SSPC-SP-2 (or equivalent), Hand Tool Cleaning may be used
for narrow sections. Bare pipe shall be free from mud, mill scale, mill lacquer, wax coal tar, asphalt, oil,
grease, or any other foreign materials. All prepared surface shall be coated on the same day it was
cleaned.
No pipe shall be allowed to flash rust before coating.
(2) Liquid Adhesive (Primer) Application
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Prior to any liquid Adhesive application, the pipe shall be cleaned to remove any wetness or other
contamination. Liquid Adhesive shall be thoroughly agitated in its container before application to the
pipe. Liquid adhesive shall be either brush or spray applied to the cleaned pipe surface in a uniform
thin film at a minimum coverage of approximately 7.4 square meter per liter or Liquid Adhesive. Prime
coat shall be dry to tacky at the time the anti-corrosion tape is applied.
The end of each new roll of tape shall overlap the end of the preceding roll by a minimum of 6 inches.
This end lap splice shall be hand applied for a wrinkle free splice to maintain the continuity of the
anti-corrosion tape. The spiral angle of the new roll should parallel the previous rolls spiral angle.
The outer-layer tape shall be applied over the anti-corrosion tape using the same method used to
apply the anti-corrosion tape. The seam for the outer-layer tape shall overlap the exposed seam of
the anti-corrosion tape by a distance of half the tape width so that they do not coincide. The overlap
width shall be 1. The application tension and the minimum end lap of two rolls shall be the same as
the anti-corrosion tape. The total thickness shall be kept in accordance with Wrapping Procedure
for Underground Piping (6423MP342-00-91100 00).
8.0 TESTING
8.1 Preparation for testing
(1) A punch list(will be attached in the Hydrostatic test procedure) shall be prepared by construction
team to verify that the piping system are installed to the extent necessary for testing.
(2) A test punch list shall be made through line check and punch list will be to verify that all piping
components requiring post test actions are documented.
(3) After all punch items are completed satisfactorily, both contractor and owner shall sign all necessary
documents.
(4) Pipe lines (FW line) shall be thoroughly blown out by air compressor.
(5) Lines shall be free from all debris such as trash, welding rods, rags, tools, etc.
8.2 Test pack preparation and control
(1) Preparation and control of test package shall be done in accordance with Hydrostatic Test Procedure
(6423DP420-00-01300 00)
(2) All test package shall be approved by owner prior to the start of pressure testing.
8.3 Main pressure testing
(1) Every part that has to be tested should be vented until free of air.
(2) Be aware that there is always a possibility of the presence of entrapped air in a system.
(3) A hydrostatic pressure has to be built up gradually and, in doing so, no fast closing valves and
booster pumps should be used.
8.4 All final inspection and documentation after pressure testing shall be done in accordance with method
statement for pressure test of piping.
8.5 Service test line (Seawater, CCW and etc) shall be back filled after lapping & testing.
8.6 Records of pressure test and leak test shall include the following items.
(1) Date of test
(2) Identification of piping tested(line number and service)
(3) Test fluid
(4) Test pressure
(5) Certification by examiner
(6) Design pressure
(7) Photograph of pressure gauges and indication board showing the test sequence (time and pressure,
etc.)
8.7 Repairing of defects
(1) When the defective material found during construction, a repairing method and extent shall be
prepared.
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(2) Imperfections in welds exceeding specified limitations shall be considered as defects, removed and
repaired in accordance with the followings.
(a) Defects shall be removed completely under the careful examination.
(b) Repair welding shall be also done in accordance with welding procedure specification(WPS)
(3) Repaired welds shall be examined and inspected in accordance with Specification for Piping
Fabrication by Each Service Class(6423MS231-00-00100 00)
8.8 Inspection and testing
(1) All the work shall be inspected or examined as per approved ITP and inspection records shall be
prepared as per ITP (6423DA424-00-00200 00).
(2) Before starting the job the drawings shall be checked for the latest revision.
(3) All piping material & welding consumables shall be checked for conformity to specifications,
construction drawings and approved WPS.
10.0 ATTACHEMENT
1) Attachment #1 : 6423DP420-002-01 Inspection and Testing Coat of Joint & Repairs (Inner-layer
tape application)
2) Attachment #2 : 6423DP420-002-02 Inspection and Testing Coat of Joint & Repairs (Outer-layer
tape application)
3) Attachment #3 : 6423DP420-002-03 Holiday Detector Test Report (HTR)
4) Attachment #4 : 6423DP420-002-04 Rubber Lining Inspection Records
5) Attachment #5 : 6423DA060-009-01 Daily Welding and Inspection Record (DWIR)
6) Attachment #6 : Job Safety Analysis (JSA)
Attachment #1
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Algeria Oman Fertilizer
Report No. : Date :
Sheet Rev. Pipe Spool Weld
PCWBS Drawing No. Remarks
No. No. No. No. No.
Preparation of substrate
Application of primer
Wrap overlap
Prepared by :
(Construction) Name Signature Date
Inspected by:
(QC Inspector) Name Signature Date
Inspected by:
(Owner) Name Signature Date
6423DP420-002-01(3)
Attachment #2
Preparation of substrate
Application of primer
Wrap overlap
Prepared by :
(Construction) Name Signature Date
Inspected by
(QC Inspector) Name Signature Date
6423DP420-002-02(3)
Attachment #3
Drawing Number :
Line Number :
Type of coating :
Repairs required :
Repairs complete :
The testing of the above coating has been satisfactorily completed in accordance with the drawings and
specifications.
Prepared by :
(Construction) Name Signature Date
Inspected by :
(QC Inspector) Name Signature Date
Inspected by :
(Owner) Name Signature Date
All underground pipe coating shall be checked for pinholes and holidays by contractor.
Testing shall be performed using a contractor approved holiday detector
Piping is to be backfilled immediately after being checked for holidays.
This form shall be retained with the appropriate piping field test report (underground piping).
6423DP420-002-03(3)
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Attachmennt #4
DA
ATE :
a b
b
mm
mm
mm
* 50mm overlap
6423DP42
20-002-04(3))
15 / 19
Attachment #5
Prepared by : Inspected by :
Name : Name :
Date : Date :
(Construction) (QC Inspector)
6423DA060-009-01(0)
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Attachment #6
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18 / 19
Safety Helmet Face Shield Goggle Barricade Harness Hand Gloves Safety Shoes
Ear Plug Coverall Safety Glasses Work Permit Fire Extinguisher Dust Mask Others
19 / 19