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| METHOD STATEMENT FOR DUCTWORK INSTALLATION-PIPEWORK INSTALLATION |
The Method Statement for Ductwork and Pipework Installation by RaMsProZone outlines the systematic approach for safe and efficient installation. It includes planning, material handling, assembly, and securing of ducts and pipes, ensuring compliance with design specifications and safety standards. Procedures for quality checks, testing, and commissioning are detailed to guarantee optimal performance. The document emphasizes adherence to health, safety, and environmental regulations throughout the project lifecycle.
Table of Contents
1.0. Purpose
2.0. Document/ Standard Reference
3.0. Drawing
4.0. Pre-Preparation Work
5.0. Welding and Erection
6.0. Pre-commissioning
7.0. Testing / Records
8.0. Forms
1.0. Purpose
This procedure aims to define and manage the processes involved in the installation and inspection of piping systems.
The piping installation refers to the construction, and erection of all major piping work carried out throughout the project.
2.0. Document/ Standard Reference
2.1. Piping Welding Procedure and Qualification Record
2.2. Hydrostatic Pressure Test Procedure
2.3. Air Leak Test Procedure
2.4. Piping NDT Procedure
2.5. Material Handling and Control Procedure
2.6. Piping Insulation Procedure
2.7. API 1104 - “Standard Welding Pipelines And Related Facilities”
2.8. ASME IX - “Qualification Standard For Welding and Brazing Procedure, Welders, Brazers, and Welding and Brazing Operators”
3.0. Drawing
The drawing applicable for piping installation and work shall be as follows:
3.1. Working Drawings including Piping Installation typical detail Drawings
3.2. Piping Schematic Diagram (P&ID)
3.3. Piping Spool Drawings
3.4. Equipment Layout and Detail
3.5. Pipe Support Layout
4.0. Pre-Preparation Work
4.1. Before the commencement of any piping activity, [Sub-Contractor] shall provide and ensure that the [CLIENT] representative approves respective working drawings, Welding Procedure Specification (WPS), and procedures.
4.2. Pre-insulation, cutting, and preparation of pipe sections shall be carried out as per:
- Method statement for pipe insulation.
- Approved working drawing for dimension and material detail.
- Approved Welding Procedure Specification (WPS) for bevel preparation.
4.3. Cutting of pipe shall be carried out by torch/machine. The cutting end/bevel shall be ground smooth before alignment and tacking of the pipes.
4.4. Temporary support and attachment if necessary shall be established before tacking. The temporary attachment, support, and bracket, which are to be welded to the pipe, shall be the same as pipe material.
4.5. Tacking shall be carried out by an approved Gas Tungsten Arc Welding (GTAW) Welder (other may specify by respective WPS) Minimum tacking length shall be 2 x of pipe thickness or 25mm, whichever is lesser. A minimum of 4 nos. of tack weld shall be carried out around circumferences of pipes.
5.0. Welding and Erection
5.1. Welding shall be carried out by a qualified welder, with the approved WPS, SC Welder Qualification test procedure guidelines.
5.2. Identification such as spool no, joint no., welder no and inspection status shall be marked (by permanent marker pen) according to the sketch drawing for the joint to be welded. (See attached).
5.3. Welding shall not be carried out before fit-up/material verification inspection.
5.4. No welding shall be done if there is impingement on the weld area of rain, sleets, and excessive wind or if the weld area is frosted/wet and not properly cleaned. Any paint, oil
5.5. To welding. Welding shall be done in a continuous process.
5.6. Erection shall be carried out safely and comply with safety requirements.
5.7. Installation of pipe supports shall be accompanied and in line with piping erection to prevent unsafe working conditions.
5.8. As far as practicable, all permanent specified items such as valves, gaskets, strainers, etc. shall be installed during erection. Temporary parts (gaskets, bolts, etc.) may be installed if testing such as pressure test; leak test, or flushing will affect the item. Temporary items shall be identified and to be replaced after completion of respective testing.
6.0. Pre-commissioning
The pre-commissioning activity shall include the following activities:
6.1. Hydrostatic test
6.2. Air Leak test
6.3. Pre-commissioning shall be carried out to fulfill the requirement of system design and ITP.
6.4. The activity to be carried out shall adhere to the Hydrostatic /Air leak test procedure.
7.0. Testing / Records
The following inspection and testing shall be carried out to fulfill the Inspection and Test Plan:
7.1. Material Receiving Inspection.
- Applicable for major items such as reticulation pipe and fittings.
- Acceptance standards shall follow the specification, P.O., and/or Mill certificate.
- Applicable Inspection Form: Goods Inwards Inspection.
7.2. Fit-up and Material Inspection
- The root gap and root face shall follow the approved WPS.
- Material shall be checked and shall comply with approved technical submittal.
- Dimension measurement and slope shall be confirmed with the approved working drawing.
- Check sufficient gap/final spacing for insulation (if applicable
- Applicable Form: Material Fit-up Inspection Record For Piping
7.3. In-process Welding Monitoring
- In-process welding monitoring is a preventive activity aimed at ensuring that welding complies with the inspection Test Plan (ITP) and Welding Procedure Specification (WPS) requirement.
- Inspection/monitoring will consider certain criteria such as welder qualification, consumables, etc. as detailed in the Welder Qualification Test Procedure.
- Any non-conformances of works that arise shall be stopped and rectified immediately. NCR may be issued by QA/QC rep. for unresolved site non -conformance/deficiency.
7.4. Weld Visual Inspection
- Upon completion of welding, the welding and adjacent area shall be properly cleaned for Visual Inspection.
- Visual inspection shall be carried out before the commencement of any NDT work.
- Inspection Form: Weld Visual Inspection Record for Piping
7.5. Line Verification / Inspection
- Line verification walk down/inspection shall be carried out upon completion of the line (s).
- This is to ensure complete installation and punch list item identification.
- Respective working drawings and equipment detail drawings shall be used as an inspection guideline.
- Outstanding items and major punch lists identified shall be recorded and copied to be handed over to the respective subcontractor for further action.
7.6. Hydrostatic/Air leak Test
- The above activities shall be carried out per the Hydrostatic/Air leak test procedure.
- The result shall be recorded in the Hydrostatic/Air leak test record.
8.0. Forms
8.1. Checklist for Piping Installation Inspection
8.2. Goods inwards inspection
8.3. Material fit-up inspection record for piping
8.4. Weld visual inspection record for piping
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