
2/18

Q -CHEM I

I

Qatar Chemical Company II, LTD .

TEC fIIfitOflT

E thylene D erivatives Comp lex

e

D A E W O O E &

C

O

4

Project Number : QC2-000 9

° *U-riso?*

?k7

9

1

QATAR CHEMICAL COM PANY tTU

.

O W N E R ID . C O D E

QC2 00 CSTR MSP 00002

8

METHOD STATEMENT FO

R

PIPING INSTALLATION

C O N T

Jo

b E

C-

IN S

CO D E

3412-XH-PM-201 6

IN QCHEM I

Plants :

QCheml

Client : Q-Chem

. I I

Location

: Mesaiee d

City, Qatar

Q

Pab c 2 of 18

Issue

0

CONTENT S

Para Description

Pag e

.0 PURPOSE

.0

SCOPE

3

.0 REFERENC E DOC UMENTS

4

.0 DEFINITION O F TERMS

5

.0 RESP ONSIBIL IT IES

6 .0 GENERAL

7 .0 PROCEDURE

8 .0

A T T A C H M E N T S

0


3/18

Q-CHEM I I

Qatar Chemical Company II , LTD .

;

TECf11fI1Df1

T

E thylene D erivatives Comp lex

V

D A E W O O E &

C

4 Project Number

: QC2-000

a*'

O u M a r

Q A T A R C N E M I C A L G O M P A t 1 Y l T G

O W N E R ID . COD

E

QC2 -00 -CSTR-MSP-00002

8

METHOD STATEMENT FO

R

PIPING INSTALLATION

CONTR

°

CO D

E

ob-ECT

I

N

3412-XH-PM-201 6

IN QCHEM I

Plants

:

QCheml

Client: Q-Chem

. II

Location

: Mesaiee

d

City, Qatar

Pag

e 3 of 18 Issue 0

1 .0

PURPOS

E

The purp ose of this procedure is to establish the minimum requiremen t to be carried out l ik e

work plan, handling of material, testing and examination requirements, storage an

d

documen tation, etc

. with regards to piping installation for Q-CHE M II Ethylene D erivative

s

Project at Q-Chem I Plant

2 .0

SCOPE

This procedure covers the work plan, material handling, examination and test requirements

and docum entation etc . with regards to Piping Instal lat ion at QC HE M I P lant for Q-CH E M I

I

Project

3 .0 REFERENCE DOCUMENTS

3

.

1

3 2

3 3

3

4

3

5

3 6

3 . 7

3

. 8

3 9

3

. 1

0

3

. 1

1

3 . 1 2

3

. 1

3

3 . 1 4

3

. 1

5

3 . 1 6

M6

5

M7 9

M7 .9 . 1

M7

.9

2

M1 0

0

M1 2 0

M3

7

QC2-00-GENE-D SS-00001

2

QC2-00-QAQC-CPP-00000 7

QC2-00-QAQC-CPP-00000 8

QC2-00-CSTR-PMP-00006 2

QC2-00-QAQC-MSP-00000 1

QC2-00-GENE-PMP-00010

1

QC2-00-QAQC-EPQ-00000 1

QC2-00-QAQC-MSP-00000 2

QC2-00-CSTR-MSP-000008

Materials of C onstructio

n

Pipin

g

Piping Material Class Inde x

Metallic Piping Material Class (Piping Specs

)

General C onstruction Requirement

s

Quality M anagemen t

Health Safety E nvironmen t

Piping W elding G eneral Specification s

W elder Qualif icat ion P rocedure

W elding M aterial Control Procedur e

Site Material Managem ent Procedure

Method Statement for W elding Contro l

Field D esign Change Control Procedur

e

Receiving Inspection P rocedur e

Method Statement for ND E Contro l

Method Statement for PW H T

4 .0 DEFINITION OF TERMS

4 . 1

MTR - Material traceability recor

d

4

.2 DWR - Daily Welding Report

4 .3 CS - Carbon Stee

l

4

.4

ITCS - Impact Tested Carbon Stee

l

4 .5 SS - Stainless Stee

l

4 .6 PWHT - Post Weld Heat Treatmen t

4

.7

ND E - Non-D estructive E xaminatio

n

4 .8 CTQ - C onstruction/Comm issioning Technical Querie s

4

.9 DDCC - Drawing and Document Control Cente

r


4/18

Q-CHEM

I

1

Qatar Chem ical Company II , LTD

.

TEC fII ilOf1

T


0

D A E W O O E &

C

4 Project Number : QC2-000 9

z l y

k

:+

r

Q A T A R C R E M I C a L C O M P A t ir M I

OW NER ID . COD E

QC2 00 CSTR MSP 00002 8

METHOD STATEMENT FO

R

PIPING INSTALLATION

CONT

I

° COD

E

o b E C-

N

3412-XH-PM-201

IN QCHEM I

Plants

:

QCheml

Client

: Q-Chem

. II

L o c a t io n ' M e s a i e e

d

city, Qatar

o

a e 4 of 18

Issue 0

4.10 DW - DAEWO

O

4 .11 ITP - Inspection and test pla

n

4

.12 RT - Radiographic Tes

t

4

.13 MT/PT - Magnetic Particle Test / Dye Penetrate Tes t

4

.14 WPS - Welding Procedure Specificatio

n

4 .15 GTAW - Gas Tungsten Arc Weldin g

4

.16 QC Assistant

A

personnel who is in charge of QC Inspection assistance activities fo r

example, DWR, NDE

4.17 Piping material controller-A personnel who is in charge of controlling pipin

g

material at fiel

d

5 .0

RESPONSIBILITIES

5

.1 Construction Manager is responsible for

;

Management & implementation of this work procedure

5

.2 Field Engineering Manager have the following responsibilities

:

1 ) Coordination with engineering team (DW & TCM) for any engineering problems a t

site .

2)

Preparation and issue of piping isometric and as-built drawings for construction

.

3)

Revision of piping isometric drawings to apply design changes

.

5 .3 Piping Construction Manager is responsible for ;

1 ) Implementation of work activity including preparation of work schedule, issue of pipin g

material, welding, storage, etc .

2) Control of welder and spool welding data

.

3)

Prepare daily welding report (DWR) and submission to Company .

4)

Implementation of work activity incorporated in the latest revision drawing and desig n

change .

5 )

Requisition of NDE and maintenance of NDE report .

6)

The implementation of PWHT and maintenance of report concerned

.

7) Preparation of Material Requisition for field materials

.

8)

Control of storage, handling, and preservation of piping materials received from th

e

Material Control Team for the process of installation .

9)

Clearance of Pre-Test & Post-Test Punch Item(s) .

5 .4 QA/QC Team Manager is responsible for

;

1 ) Site inspection and test, operation of welding training center and NDE yard, NCR

backlog for repair work, etc .

2) Review of all request forms, reports of inspection and record of piping & welding an

d

submission to Company for review .

3)

Control of welder performance and tracer status and to inform the Construction Team o

f

qualification status

.

4 ) Control and maintenance of inspection record for piping and welding .

5 )

Control of welding consumable .

6) Review Test Pack and submission to Company for review

.

5 .5 QC Welding Inspector is responsible for

;

1 ) Visual inspection of fit-up joint

.

2) 100% visual inspection of all completed welds

.

3)

Marking up defect area on weld joints for repair, and ensure that NDE shall be carried ou t


5/18

Qatar

Q-C H EM I

I

Chemical Company II, LTD

.

Derivatives Comple

x

Number : QC2-0009

Ethylen

e

Project

TECnIrnonT

[r j D A E W O O E & C

Q A T A R C H E M I C A L. C O M P P H Y L T D

METHOD STATEMENT FOR

O W N E R ID . COD E


8

C O N T

Jo

b EC

INo

CO D

E

PIPING INSTALLATIO

N

IN QCHEM I

3412-XH-PM-201 6

Plants :

QCheml

Client

: Q-Chem . I I

Location

: Mesaiee d

City , Qatar

p

a n

e 5 of 1

8

o

Issue 0

after the repairs

.

4)

Verify whether correct WPS and welding consumables are being used by welder

.

5)

Review and sign off on DWR, SIR, PWHT report

s

5

.6 Material Control Team Manager is responsible for

;

1 )

Receipt of materials

.

2)

Control of material stock status and protection of material

.

3)

Issuance of material to site for installation

.

M

GENERAL

6

.1 This method statement shall be read in conjunction with reference procedures

.

6 .2

Health, Safety and Environmen t

6 .2

.1 All workers shall wear required PPE as listed below as a minimum requirement in QCHEM

1

Fire Retardant Clothing (Cover All

)

Safety Helme

t

-

Safety Glasses (Mono Goggles

)

- Leather Glove

s

-

Safety Shoe s

-

Dust Mask (as required to prevent inhalation of dust and welding gas

)

Ear Plug as required inside process uni

t

6

.2

.2 When scaffold is needed for

access,

the scaffold shall be inspected by Certified Scaffoldin g

Inspector and appropriate Safety Tag shall be attached in accordance with applicable HSE

S

procedures .

6 .3

Control and handling of materia l

6 .3 . 1

The Piping Construction Manager shall implement requisition and material handling

i n

accordance with Site Materials Management Procedure

.

6

.3

.2 Color coding shall be applied in accordance with PFIES-22 if required

.

6 .3

.3 Handling of SS material in contact with zinc, halogens or zinc containing part shall b

e

prevented

. Both materials shall be kept separately to prevent corrosion and rust

.

6

.4

Control of welding material and welde r

6.4

.1 Welding consumables shall be controlled in accordance with Welding Material Contro

l

Procedure

.

6 .4

.2 The Welder shall be qualified in accordance with Welder Qualification Procedure

.

6 .5

Control of Pipe Spool(s)

6

.5

.1 Pipe spool(s) shall be released from the pipe fabrication shop after all activities includin

g

primer painting (if required) are completed .

6 .5

.2 Pipe spool(s) shall be stocked in a Contractor designated lay-down area inside QCHEM

after painting .

6

.5

.3 Before the pipe spool(s) are transported to field from QCHEM I lay-down area, th

e

dimensions and orientation shall be checked against the isometric drawing(s) by the pipin

g

spool controller

.

6

.5

.4 Before pipes are erected, the pipe fitter shall ensure that pipe spool(s) orientation an

d

material specification conform to relevant Isometric Drawings

. And that the pipe spool(s) ar

e

clearly identified with their respective isometric identification reference number

. If th

e

identification marking is unclear then it shall be re-marked

.

6 .6

Weld and Welder Identificatio

n

6.6

.1 Weld number and welders unique identification number shall be marked on each joint

.


6/18

Q-CHE M I

I

Qatar Chemical Company II, LTD

TECnIrilOfl T

(*

E thylene D erivatives Comple

x

Project Number :

QC2-0009

* *** D A E W O O E &

C

I

OURCHEMICAL C OMPAttr

L

T D


O W N E R ID . CO D

E

Q C 2 -0 0 -C S T R -M S P -0 0 0 0 2 8

C O N T J o b

EC-

I N o

CO D E

PIPING INSTALLATIO

N

IN QCHEM I

3412-XH-PM-201 6

Plants

:

QCheml

Client

: Q-Chem

. I I

Location

: Mesaiee d

City

,

Qatar

P a na

g

e 6 of 18 Issue 0

6

. 7

Sche dule for Piping installation on sit

e

6 . 7

.1 Piping installation shall be scheduled on a per Test Pack basis

6

. 7

.2 Pipe spool(s) shall be delivered as per piping installation schedule

6 . 8

Rework / Re-we lding of Shop weld join

t

The cutting and re-welding of fabrication shop weld joint(s) shall be restricted

6 .8

.1

If re-work of shop weld joint is required because of field condition, re-welding shall b

e

carried out and the iso drawing revised

6 .9

W elding of pipe attachmen ts (reinforcem ent pads, trunnion(s), encirclement pads, etc

)

All welding of pipe attachments shall be carried out in the Pipe Fabrication Shop . W h ere

weld joints are labeled as with Field Joint, the requirement(s) stated on Method Statemen

t

for Piping F abricat ion ap pl ies

.

6 .1 0 Temporary Suppor

t

6 .1 0

.1 In cases where pe rmane nt supports are not yet avai lable, temp orary supports may be use d

during installation so that no bowing, over-hang or unbalanced deficiencies exist

6

.10

.2 Temporary support(s) shall be of sufficient size and strength to support the weight of pipin

g

until permanent support(s) are in place

6

.11

Non-Conforming item(s) shall be reported and corrective action shall be taken

7

.0 PROCEDUR

E

7 . 1

Receipt and change of Drawin

g

7

.1

.1 The Field Piping Engineer shall receive the latest revision of drawing from DDCC

7

.1

.2 If changes are required in the ISO drawing(s), the Drawing Change Request is submitted t

o

Field E ngineering in accordance with Field D esign Change Co ntrol Procedure

7

. 2

Cutting and edge preparatio n

7 . 2

.1

All cutting shall be done by skil led personnel

. Detail procedure of cutting and en d

preparation shal l be fol lowed in accordance with Method Statement for W elding C ontrol an

d

Piping W elding G eneral Specificat ions

7 . 2 .2

Prior to cutting, heat number shall be transferred to each piece by metal marker or punch

7 .2

.3 Before end preparation, the CONTRACTOR Piping Inspector shall sign on the MTR form

(A ttachment 1 ) of Method Statement for Piping Fabricat ion, for SS and LT CS m aterial whic h

is prepared by Construction Team and reviewed by the QA /QC Team

. This procedure wil l

be followed strictly in the case of small-bore fitt ings because the heat number may b

e

removed during grinding work

7

.3

Fit-up and tack weldin g

7 .3

.1

The root gap and internal alignment shal l be in accordance with the appl icable W eldin

g

Procedure Specif ication (W PS) /ASM E B31

.3 and P iping W elding G eneral Specificat ions

7

. 3

.2 Fit-up shall be done by an experienced pipe fitter

. Tack weld shall be done by a qualifie d

welder or welding operator

7 .3

.3 WPS shall be qualified before welding and fit-up commences and same filler metal used fo

r

root pass shall be used for tack welding

7 .3

.4 In case the pipes have longitudinal weld seam, the longitudinal weld seam shall be at leas

t

50 mm or 45 degree a part from the adjacent seam

7

.3

.5 Temp orary Tack w elds shal l not touch the root gap or the root face

7 .3

.6 Detail procedure of fit-up tack weld shall be followed in accordance with Metho

d


7/18

Qatar

Q-CHEM I

I

Chemical Company II, LTD

.

D erivatives C omple x

Number

: QC2-000

9

Ethylen e

Project

TECfIIriIDfI

T

6 D A E W O O E &

C

4

a

9 o

I

-+1 91oi*

1*

âY

n

QATAR CHEMICAL COMPANY

LTD

.


OW NER ID . COD E


8

PIPING INSTALLATION

CONTRACTO R

ob

E C T

I N

o

CO D E

IN QCHEM I

3412-XH-PM-201

Plants

:

QCheml

Client : C 1 - C h e m

. I I

L o c a t i o n

: M e s a i e e

d

C i ty , Q a t a r

p

ane 7 of 1 8 Issue

Statement for Welding Control I Piping Welding General Specifications and ASME B31 . 3

para 328 .4 .2 .

7 .4

W eld in

g

7 .4

.1 The approved WPS and qualified welder shall be applied to the welding work

.

7 .4

.2 The QA/QC Team Manager shall qualify welders in accordance with Welder Qualificatio

n

Procedure

.

7

.4

.3 For stainless steel piping without back welding of the internal side, the root pass shall b

e

carried out by the GTAW process with an inert gas purge which shall be maintained until th

e

completion of the second pass

.

7 .4

.4 Welder shall receive welding electrode(s) everyday in the morning from Welding Materia

l

Control Center with Welding Material Issue Slip prepared by welding foreman and shal

l

return the unused welding material upon completion of the day's activities to the Weldin

g

Material Control Center

.

7 .4

.5 After the welder receives electrode(s), he shall use calibrated and fully functioning quiver s

for coated electrode and only one type electrode shall be kept in the quiver at any give

n

time

. On no account shall there be SS and CS electrodes in one quiver

.

7.4

.6 Fillet welds (including socket welds) may vary from convex to concave

. The size of a fillet

weld is determined as shown in ASME B31

.3, Para 328 .5 .2, Fig

. 328 .5 .2A, B and C

.

7

.4

.7 Austenitic SS welding in accordance with ASME B31

.3 and WPS .

7

.4

.8 The dissimilar joint shall be welded in accordance with ASME IX and WPS

.

7 .4

.9 Weld repair shall be implemented in accordance with the Method Statement for Weldin

g

Control and ASME B31 .3 para 328

.6 and shall be approved by Welding Inspector befor

e

commencing .

7 .4

.10 Welding Inspector shall check NDE criteria for branch or trunnion joint before weldin

g

reinforcing pads .

7 .4

.11 Detail procedure for back purging shall be followed in accordance with Method Statemen

t

for Welding Control .

7 .4

.12 QC Assistant shall prepare the request for inspection (AFI) to Piping and Welding Inspector

NDE request, Material Traceability Record (MTR), and Daily Welding Report (DWR)

.

7

.5

Post Weld Heat Treatment (PWHT

)

7.5

.1 PWHT shall be implemented as per line specification

.

7 .5

.2 Detail requirements of PWHT shall be in accordance with Method Statement for Post Wel

d

Heat Treatment .

7

.5

.3 Hardness test shall be in accordance with ASME B31

.3 para 331 .1 .7 .

7 .6 Non-Destructive Examination (NDE

)

7

.6

.1 NDE shall be carried out in accordance with the NDE Procedure for RT, MT, PT & UT

.

7 .6

.2 For NDE request, use a form (attachment 1) from Method Statement for NDE Control

.

Welding Inspector and NDE Controller shall review the request and send it to NDE Sub

-

contractor

.

7 .6.3

Random examination selection will be as per Piping Welding General Specification an

d

A S M E B 31 .3

7

.6.4

For supports welded directly on pipe in accordance with typical support drawing, RT is no

t

required, but 100% PT shall be performed for welds

. Welded joints used for fabrication o

f

piping supports shall be examined by liquid penetrant test (PT) on 5% of joints unless note

d

on support drawings and specifications

.

7

.6

.5

RT & PT shall be applied on 100% of dissimilar welds

.

7

.6

.6

When welding joints require PWHT, all NDE shall be performed after PWHT as per Pipin

g


8/18

Q-CHEM I

I


.

TECf111T1Df1

T

E thylene D erivatives Complex

Project Number

:

QC2-0009

A E W O O E & C

O W N E R ID . CO D

E

QATAR CHEMICAL COMFatIYLTO

QC2 -00 -CSTR-MSP-00002

8


PIPING INSTALLATION

C O N T R A C T O R I D

. C O D E

3412-XH-PM-201 6

IN QCHEM I

Plants :

QChem1

Client

: Q Chem . II

L o c a t i o n

: M e s a i e e

d

C i t y , Q a t a r

Page 8 of 18 Issue 0

W elding G eneral Specif ication para 14 .6

7 . 6 .7

QC A ssistant shal l arrange preparations required for ND E

7

. 6

.8 Welds requiring NDE shall be tied with colored ribbon in accordance with Metho d

Statement for NDE Contro l

7 .6

.9 Original NDE report shall be kept by the NDE subcontractor and a copy shall be submitte

d

to the piping construct ion team and the QA /QC Team

7 . 9 Temporary W elded A ttachments and Their Remova

l

7 . 9

.1 Temporary welded attachment shall be of the same material as Pipe

.

7 . 9

.2 Tem porary we lded attachm ents (such as al ignmen t lugs, straps, t ie straps, etc) on pipe shal

l

be removed without any reduction of pipe thickness and shall be ground smoothly

. MT or PT

shall be performed as pe r Method Statement for W elding Co ntrol para 5

.2 . 4 .

7

.9

.3 Removal of the temporary welded attachments by chipping is not permitted

7 .1 0 Inspection & Testing

7 .1 0

.1 A l l inspect ion must be performed by QA /QC Team in accordance with AS ME B 31

3

Chapter VI

7 .1 0 .2 QC Assistant shall notify QA/QC Team for inspection

. QC shall then notify Company o f

Hold or W itness point inspection

7

.1 0

.3 Acceptance criteria of welds are in accordance with ASME B 31

.3 Para . 341 .3 .2 and Tabl e

A 3 4 1 .3.2

7 .1 0

.4 Prior to root pass weld, fit-up inspection shall be performed by QC Inspector . At that time ,

inspector shall check orientation, and dimension of piping line

. In any case of inspection

all welding joints shal l be inspected by CO NTRA CTO R welding inspector

.

7

.10

.5 Dissimilar welds shall be inspected on fit-up, root pass and final weld by Contracto

r

welding inspector .

7 .1 0

.6 The followings shall be checked for in-process inspection of piping installation

-

Joint preparation and cleanlines s

- Fit-up, joint clearance and internal alignmen

t

- W PS, electrode and welde r

-

Temporary attachment and surface condition of weld join t

-

Applied drawin

g

7

.10

.7 Leak test for reinforcing pads shall be performed in accordance wih Method Statement fo

r

Pneum atic Leak Test for Reinforcement Pad

7

.10

.8 QC inspector shall check the line slopes, plumbness, straightness and alignment based o

n

IFC drawings

. All deficiencies found shall be rectified before carrying out pressure testing

7 .1 0

.9 O rifice flanged joints internal welds shall be groun d flush to sound metal

. Penetrant test (PT

)

shall be done to check an y cracks & pin holes

7 .1 0

.10 Before bolting up, flange faces shall be aligned to the design plane within 1mm in 200m

m

measured across any diameter

; f lange bolt holes shall be aligned within 3 mm maximu

m

offset

7

.10 .11

Flange B oltin

g

-

Flange faces shall be thoroughly cleaned removing all rust and burrs

. Particula

r

attention shall be paid to the sealing surfaces

. Use like material tools if sealin

g

surfaces are stainless

-

Sealing surfaces on flange faces shal l be thoroughly inspected

. Any damage shall b

e

repaired by refacing

. The QC Inspector shall accept or reject all flange surfaces prio r

bolting


9/18

Q -CH E M I

I


TECnIfi10r1T


0

D A E W O O E & C

4

Project Number : QC2-0009

OWNER ID. COD E

QATAR CNEMICALCOMPAtlYLTD*


Q C 2 -0 0 -C S T R -M S P -0 0 0 0 2 8

CONTRACTOR ID . COD E

PIPING INSTALLATION

Job-EC-T-N

IN QCHEM I

3412 XH PM 201

Plants :

Location : Mesaiee

d

QCheml

Client

: Q-Chem

. II

City, Qatar

Pa

o

e 9 of 18 Issue 0

- Bolts shall be checked for proper size, length, conformance to specifications

cleanliness and absence of burrs

-

The surface of flanges where contact is made with the nuts or washers shall be wire o

r

power brushed to remove any material that will affect the torque value

-

Gaskets shall be as per the applicable piping material class

Spiral wound, metal gaskets, or sheet gaskets shall not be re-used

Proper thread lubrication shall be applied to every friction surface of the bolt assembly

This includes threads, and all bearing surfaces of the nut, washer and bolt head

Lubrication on the bolt threads shall be applied prior to putting on the nuts

Thread lubricants shall be suitable for the operating temperature of the system

Thread lubricants shall not contain lead

. Thread lubricants for austenitic stainles

s

steel shall not contain chlorides

Insert the g asket with care being taken t i insure proper centering of the g asket

. A ligh t

coating gasket adhesive may be used to help keep gasket in place

. Gaskets shall no t

be held in place with tape

All flanged joints shall be snugged up squarely so that the entire flange face bear

s

uniformly on the gasket

Measurements of the gap between flange faces shall be taken around th e

circumference of the flange to ensure that the flanges are being drawn up evenly .

- Stud bolts and nuts shall be checked to ensure they are hand tight . The stud end

s

shall extend one thread 3mm (1/8-inch) beyond the nut, except for use of tensionin

g

device .

If a tensioning device is to be used, the stud shall protrude 1 bolt diameter beyond th e

nut to allow attachment of the tensioning device . The other end of the stud shal

l

extend three threads 9 mm (3/8-inch) past the nut

- All stud bolt protrusions for the tensioning device shall be from the same side of th

e

flanged joint . Protrusions may be alternated from one side to the other only i

f

interference occurs with the tensioning device

-

Stud bolt tensioning shall be performed on all bolting 2 inch and larger

7

.10

.12 Flange connections shall be bolted to the required torque

7

.10 .13 All vents and drains shall be installed as per IFC drawings and situated at high and lo w

points during hydrotest

7 .1 0

.14 A l l valves shall be checked for i ts f low direct ion . W hen required by-pass shall be als

o

installed

7 .1 0 .15 Bolt Tightening P rocedur e

-

The bolt should be torqued to provide compressive strains in the flange face thicknes

s

establishing a residual compressive stress

-

Use new bolts and nuts . The thread should be clean and lubricated . There are

numerous conditions that can affect bolt torquing (i

.e

. bolt thread condition, dirt

y

threads, re-used bolts, lubricant and weather)

-

Install the bolts and nuts finger tight . Inspect to insure that the sealing faces contac

t

each other and are parallel to each other all around the circumference

-

Using a torque wrench with 20 of the final torque, tighten the bolts in criss-cros

s

sequence . Take care at all times to ensure that the sealing faces are in contact an

d

parallel all around the circumference . Repeat this step each time increasing th e

torque by 20% of the final value

-

After reaching the final torque value, use rotational tightening until all the bolts ar e


10/18

Q-CHEM I

I


.

TECf11fT10f1

T


e

v DAEWOO E C

®

4

Project Number

: QC2-0009

O W N E R ID . CO D E

Q T R C H

E

M I C A L C O M P A N Y L T O

.

METHOD STATEMENT FO

R

PIPING INSTALLATION


C O N T R A C TO R I

N S

CO D

E

IN QCHEM I

3412-XH-PM-201

6

Plants

:

Location

: Mesaiee d

QChem1

Client

: Q-Chem

. I I

City, Qatar

s

10

o

1 8

Issue 0

stable at the final torque value

.

-

If flange leaks occurs and the bolts on the leaking side have been properly torqued ,

further tightening shall be avoided so as not to damage the sealing faces . The bolts

on the opposite side should be loosened by a quarter turn at a time and then the bolt s

on the leakage side should be tightened by the same amount . If the leak persists, th e

bolts should be removed and the sealing faces examined for scratches or dents acros

s

the entire face that could provide a leak path

.

-

If leakage occurs after the system has been cycled to an elevated temperature an d

back to ambient temperature, the bolts should be removed after the cool down period

.

No further tightening is necessary

.

Torque value

s

Nominal pipe size

Torque

t-l

b

2

35

3-4

4 0

6 5 5

8 8 5

10

9 5

12

1 1

0

18 16

0

24

220

7 .1 1 Documentation of inspection and tes

t

7

.1 1

.1 The QA/QC Team submits a copy of DWR to Company then inputs the data in the pipin

g

data system after review

7

.1 1

.2 Documents to be completed prior to testing are as follows

.

-

A s-built Drawing s

MTR

: for LTCS and S

S

-

NDE Report / PMl report : If require d

PWHT Report

: If require

d

inforcing Pad leak test report

: If require d

7 .1 1

.3 Above documents will form a part of the Test Pack which will be submitted to QA/QC Tea

m

for review

. Control of Test Pack shall be in accordance with Method Statement fo

r

Pressure Test of Piping .

8

.0

A TTA CHMENT

S

1 .

Material Traceability Record (Field

)

2. Check sheet for flange fac e

3.

Piping Inspection Shee

t

4 . Bolt Torque Sequenc

e

5 . Job Safety Analysis


11/18

Q-CHEM I I


* Tecnimonr


Q ja

DAEWOO E&

C

410 4


9

aaeaa*

*ty

k

Q A T A R C H E M I C A L C O M P A N Y L T D

O W N E R ID . CO D

E

QC2-00-CSTR-MSP-00002 6

?* T

FOR

ETHOD

STATEMENT FOR

C O N T R A C T O R I D . C O D E

PIPING INSTALLATION

J o b -EC- T - N°

3412-XH-PM-201

6

P

:a^t

s

NAO/PFJOFFSITES

Client : Q-Chem

. II

Location

: Mesaiee

d

City, Qatar

Page] 1 of 18

Issue 0

Attachment 1

M A T E R I A L TR A C E A B IL IT Y R E C O R D ( F IE L D )

(QCHEM II )

D A E W O O

E& C

r

sometric No . Shee t No

. Draw ing No . LSpool No . Re v . No

Remark s

Mar

k

No

.

Componen t

Description

Hea

t

Number

Size

Sc h

.

Material

Cu

t

Length

D A E W O

O

QC Sign

Q-CHEMI I

Sig n

F I E L

D

The Field components have been verified against the erected piping and are complete and accurate

.

Prepared By

:

Name :

Signature

:

Date :

Inspected By

:

Name :

Signature : Date :

Form No

. : 3412-X1I-PM-2004-

0 3 (I )


12/18

Q-CHE M I

I


T E C f 1 1 f 1 1 0 1 1

T

aA E W O O E & C

thylene Derivatives Comple

x


a



O W N E R ID . C O D E

Q C 2 - 0 0 - C S T R - M S P - 0 0 0 0 2 6

C O N T R A C T O R ID . C O D

E

J o b -EC- T - N°

3412-XH-PM-201

6

IPING INSTALLATIO

N

Rant

s

NAOIPFIOFFSIIES

Client

:

Q-Chem

. II

Location : Mesaiee d

City, Qatar

o

Pa*e12 of 18

Issue 0

Attachment 2 Check Sheet for Flange F ac

e

(

Q - C H E M I I

D A E W O O E C

Drawing No Description of Flange Remark s

D e s c r ip t i o n o f D a m a g e

D a m a g e C h e c k P o i n t s

R e m a r k

s

F

EB

C

Min . Requirement(30 %, mm )

Size of damage(Radically, mm )

D amaged due to

(Handling

or Corrosion )

Result of

checkin

g

D a m a ge d b y( D A E W O O )

Re-facing or no

t

Result of re-facin g

( Se e F l an g e

Inspection S heet

)

b y D

Form No . :

3412-X11-PM-2004-04(1)

V e r i f i e d b y


13/18

Q -C H E M I I

ECf11fi1Df1

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.

r


D A E W O O E &

C


b

J

OWNER ID . CODE

a*4 . o 7 I

y 91 o

:-

J*

.* Fy

Q A T A R C H E M I C A L C O M P A N Y L T D QC2-00-CSTR-M SP-000026


CONTRACTOR ID . COD E

PIPING INSTALLATION

Job-EC-T-N

3412 XH PM 201

Plants

.

NAO/PE/oEFSHES

Client : Q-Chem. II

Location

: Mesaiee

d

City, Qatar

o

Pa*el3 of 18 Issue 0

Piping I nspection Shee t

A r e a

D wg N o . Sht . No

Re v. N

o

Pipe Cls Ins . Cls . Materia l

No

Inspectio

n

Item

Description

Verified By

D ate Remar

k

---

D A E W O O

C O M P A N

Y

1 Piping

Installation of inline items a

s

per drawing

2

Piping .

Installed valv

e

-

Valve type

:

-

Valve tag no

. :

- Valve serial no . :

-

Flow direction

:

3 Piping

Location & orientation o

f

piping lin e

4 Piping

Elevation & levelness o

f

line

__

p

g

5

P iping P lum bness of piping lin e

6

Piping

Flange alignment fo

r

connection equipmen t

7

Piping

Support location & typ

e

8 Flange

Verify flange specification a s

drawin g

9

Flange

Grease, tape, paint & rust ha s

been removed from flang e

fac

e

1

0

1

1

1 2

1 3

14

Flang e

Flang

e

Flang

e

Flang e

Flange

Flange face are undamage d

and free scratc h

O rifice flange internal weld s

flush grindin g

Use the correct gaske t

Use the correct bolt with th e

correct type lubrican t

Ensure stress-free flang

e

alignment and clearance

Form No .

: 3412-XH-PM-2004-05(1)


14/18

Q-C H EM I

I


TECntmon

T


r l D A E W O O E & C


9

a e

t

t,

i

r

O W N E R ID . CO D

E


QC2 NC00002

METHOD STATEMENT

FOR

C O N T R A C T O R

ID

. CO D

E

PIPING INSTALLATION

Job-EC-T-N °

3412-XH-PM-201

6

P

:acts :

NAOIPE/OFFSfTES

Client : Q-Chem . II

Location

: Mesaiee

d

City, Qatar

v

Pa s

e14 of 18

Issue 0

4 HOLE FLANGE

TIGHTENING SEQUENCE

8 HOLE FLANGE

BOLTS No

.

O P P B O L T S N o

.

2

3 4

BOLTS No .

O P P B O L T S N o .

1 2

4

5

7

I


15/18

Q-CHEM

II

TECnimon T

Qatar Chem ical Company II , LTD .


DAEWOO E& C

4

Project Number

:

QC2-000 9

a

a5

r - * 9 DS1


O W N E R ID . CO D

E

Q C 2-00 -CSTR-MS P-00002

6


C O N T R A C T O R I D

. CO D E

PIPING INSTALLATION

Job- E C - T- N °

3412-XH-PM-201

6

rants

NAOIPE/OFFSIrES

Client

:

Q-Chem

.

II

Location

:

Mesaieed

City, Qatar

p a*e15 of 1

8 Issue

0

12 HOLE FLANGE

20 HOLE FLANGE

TIGHTENING SEQUENCE

B O L T S

o .

OPP

BOLTS NO

.

2

--

5 6

9

1

0

1 1

2

1 3

4

15

1

6

17

1

8

19

2

0

3

7


16/18

Q-CHE M I

I

Qatar Chemical Company II , LTD

.

;I

;

TECfllMOn

T

IeD A E W O O E & C

4

Ethylene Derivatives Comple

x


a

aeaxe

L l

sY*



O W N E R ID . COD E

Q

C 2-00-CST R-M S P-0 0 002 6

C O N T R A C T O R ID . COD E

Job-EC-1-N

3412-XH-PM-201 6

IPING INSTALLATIO

N

P:ar : s

NnO/PE/OFFSrTES

Client : Q-Chem

. II

Location: Mesaiee

d

City, Qatar

a

Page 16 of 18 Issue 0

28 HOLE FLANGE

TIGI-ITENING SEQUENCE

2 7

BOLTS No

.

OPP BOLTS

NO .

1

2

3

4

5 6

9 1 0

1 1

1

2

13

1

4

15

1

6

17

1

8

19

2 0

21

22

23

2

4

25

2 6

27 28

7

3

26

2

28


17/18

Q-CHEM I I

TECIIImon

T

Q D A E W O O E &

C


Ethylene Derivatives Comple x

0

Project Number :

QC2-000 9

aed

r


O W N E R ID

. COD E

QC2-00-CSTR-MS P-00002 6


C O N T R A C T O R I D . CO D

E

PIPING INSTALLATION

Job-EC-T-N °

3412-XH-PM-201 6

I' :a^is

NAOIPEIOFFSITES

Client

: Q Chem

. II

Location

: Mesaiee d

City, Qatar

Q

P a

g el? of 18

Issue 0

JSA FOR PIPING INSTALLATIO

N

SIN

ACTIVITY

H A Z A R D S

P R E V E N T IV E A C T IO N

S

1

• Scaffolding • Danger of

Access and

workers fallin g

Usage f rom height .

•

D anger of fall in g

objects ont

o

personne l

working /

walking at th e

lower level .

Tripping / fallin

g

hazard .

Personne

l

injury

.

• STA RRT required prior to start of task .

•

W earing of PPE shall be mandatory i n

all aspects and areas of p ipin g

installation

.

• Safety harness must be worn a s

required when working on hangin g

scaffolding

.

A ll tools must be properly secured .

Tools equipment or m aterial should no

t

be thrown up or down from one workin g

level to another

. They must b

e

transferred by the use of a hand line o

r

other safe method

.

•

A ll unsafe condition of the scaffoldin

g

must be reported immediately to th

e

Scaffolding Inspector or Supervisor fo

r

proper action .

• O nly qualified personnel shall b e

allowed to m odify / construc t

scaffolding .

•

Pipe and other piping materials shall no

t

be stored for a long time in the hangin g

scaffolding .

• O nly light materials shall be allowed t o

be placed on the scaffolding platform

.

• Smoking is not allowed on the projec t

site except in designated areas .

• Proper housekeeping must b e

maintained at all t imes in order to avoi d

tripping / falling .


18/18

Q-CHEM II

TECf11R10 f1

T


.


av D A E W O O E &

C

10

4

Project Number

:

QC2-000

9

I

44

1 ,1 1

OWNER ID

. COD E



6

y

XFTHOI) STATEMENT FOR

CONTRACTOR ID. COD E

Job-EC-1--N °

PIPING INSTALLATION

3412-XH-PM-201 6

P:a^

:

s

NAO/PFJOFFSITES

Client : Q-Chem . II

Location: Mesaiee

d

City, Qatar

Page 18 of 1

Issue 0

• Hot work permit shall be secured prio r

to start of any welding, and cuttin

g

works

.

•

Always check areas around and below

prior to commencing welding or cuttin

g

operations

. All combustible material

s

under or near the area must be move

d

to a safe distance away or covered wit

h

a fire retardant material

.

•

Fire blanket shall be place

d

accordingly on the scaffolding

platform prior to start of hotwork

This shall be sufficient enough t

o

contain all sparks / slags produce

d

from

welding and cutting

.

•

Dry powder

fire extinguishers shal l

be available near hot work area at al

l

times . Personnel involve on the jo b

shall be trained on the proper use o

f

fire extinguishers

•

Welding leads and gas hoses shall no t

be placed where they will presen

t

tripping hazards .

• Good housekeeping shall always b e

maintained at all times inside and belo w

the platform . Accumulation oft too muc h

trash, or rubbish inside the platform is

a

F IR E H A Z A R D .

•

Oxygen and acetylene cylinders shal

l

be provided with flash back arresters

.

•

Cutting torch and hoses shall b

e

checked on daily basis for any leakag e

or damage .

•

Oxygen and acetylene cylinders shal

l

always be left in vertical position an d

secured properly .

Empty/full gas cylinders shall be kep

t

separately .

•

A dedicated fire watch shall be availabl

e

at all time to monitor closely the ho t

work so as to avoid fire incident, weld

drops and molten metal falling down .

• Welding and

•

Fire, explosion

Cutting Works damage to lives

and properties

.

•

Falling weldin g

sparks an d

slags from th

e

hangin

g

scaffolding .

•

Burning injuries

.

•

Tripping and

falling .

MS for Piping Installation in QChem 1 Site Rev0

Documents