PROJECT- INDIAN INSTITUTE OF ART

& DESIGN

PMC- COLLIERS INTERNATIONAL

METHOD STATEMENT

INSTALLATION AND WELDING OF MS PIPE

CONTRACTOR

NITIGYA BUILDCON PVT LTD

CLIENT

TEAMWORK EDUCATION

Title Signature Date

Issued By: PROJECT MANAGER,

CONTRACTOR

Reviewed by Project Manager, PMC

Approved By: PROJECT MANAGER , CLINT

TABLEOFCONTENTS

1. Purpose:..............................................................................................................................................3

2. Scope:..................................................................................................................................................3

3. Responsibilities:.................................................................................................................................3

4. Materials &Tools...............................................................................................................................4

5. Material Storage................................................................................................................................4

6. Work Execution Procedure:.............................................................................................................5

7. Health and Safety Management Control Measures........................................................................8

8. Reference Documents.........................................................................................................................8
1. PURPOSE
The purpose of this Method Statement is to establish a uniform procedure for the installation and
welding of stainless steel pipes and MS pipes. It aims to ensure that the work force involved to perform the
operations have a complete understanding of the operating standards and safety practices associated with
the use of machinery/equipment /tools.

2. SCOPE

This Method Statement shall describe the procedure and sequence of the install action and welding of
stainless steel pipes and MS pipes.
The installation and welding of stainless steel pipes and MS pipes will be performed by PGCC team
who specialized/qualified in this type of work, and who have suitable equipment/tools as well as
experience in this type of work.
PGCC shall ensure the safety of all personnel and equipment in the work area where the work is being
performed. In this respect, PGCC shall supply all the safety and protective equipments required to
complete the works.

3. RESPONSIBILITIES

Project Engineer: The Project Engineer’s responsibility is to assist the Project Manager in
controlling overall works and coordination between site and management.

Site Engineer: The Site Engineer is responsible for executing the work and controlling the
manpower according to customer work standard, requirements and all health & safety
procedures.

QC Engineer: The QC Engineer is responsible for ensuring the job is completed according to
Customer’s required Standard.

Safety Officer: The Safety Officer is responsible for maintaining the site in a safe condition
and to monitor the ongoing works according to the Customer Safety Standards.

Supervisor/Foreman: The Site supervisor/foreman is responsible for executing the works

according to the Method Statement.

Installers: Responsible for the installation and all required preparation works according to the
Method Statement.

Lifting Supervisor: Responsible for all lifting activities the work requires.

Welder: Welder will be responsible for all welding activities as per approved drawing.
4. MATERIALS & TOOLS

 Materials

o Stainless Steel Pipes, fittings &accessories

o MS Pipes ,fittings & accessories

 Tools &Machineries

o Magnetic drill machine, Drill machine, wrench, hammer, pliers etc.

o Level baror Level hose
o Mobile Crane or Boom Truck
o Chain blocks, Slings, shackles, belts, chains etc.
o Welding machine, Electrodes and welding units
o Measuring tape, pipe fitter wrap-around, marker pen, Cleaning rags
o Cutting/Grinding machine with carborendum cutting &sanding/grinding disc
o Pie tape, Curve-o-mark, Angle Grinder, Emery disc
o Electrical extension wires
o Level bar or Level hose

5. MATERIAL STORAGE

 All paper work &permits to be completed by Technochem for the transferring of pipe and fittings
to designated location.
 Handling and transportation of the materials (pipe & fittings) shall be done with utmost care to
avoid any damage.
 Separate area shall be assigned for the storage of piping support and Stainless Steel piping
materials. Pipes shall be stored in open area resting on wooden sleepers and small pipe fittings,
bolts, nuts, and gaskets shall be stored in shelved containers.

6. WORK EXECUTION PROCEDURE

SITEPLANNINGANDPREPARATION

 All relevant documents shall be approved for execution.

 All the person involved in the job should attend the safety training.
 Ensure all workers are equipped with PPE (i.e. hard with chin strap ,goggles ,safety shoes, gloves,
safety harness, etc.) relevant to the nature of work to be carried out.
 Determine manpower and delegation of task.
 Fully barricade the work are and restrict entry to authorized person only.
 Deliver to the site the required materials to be installed.
 All required machineries, tools and equipments shall be placed into the designated area.
 Prior to installation of the steel frames and bracket plates, the location should be cleaned and must
be free from any obstructions.
 Prior to transferring of the Evaporator from yard to outside of building, the road must be checked
and free from obstructions for the truck and mobile crane to have easy access.
 Prior to shifting of the evaporate or from outside to inside of the building, ensure that the steel bed
frame and railing are properly fixed, aligned and leveled.
 All qualified and authorized personnel shall be notified when commencing works.
 For night work, ensure that lightings are adequate.
 A proper line of communication throughout the job must be detailed.
 Anticipated problems shall be discussed and resolved immediately.

INSTALLATION AND WELDING OF STAINLESS STEEL PIPE& MS PIPE

GENERAL PRINCIPLE

 Installation drawings shall be placed on site at all times.

 Pipes pools shall be fabricated as per approved drawings.
 Ensure the dimension not the spools before installation or fabricate as per actual.
 Fabricate the tie-incompletely and coordinate with TCL about the shutdown to plan
accordingly.

WELDING OF STAIN LESS STEEL PIPE &MS PIPE

 All the welding shall be as per the drawing or standard.

 Welding must be carried out by qualified and certified welder as per the below welding
preparation and procedures:

 Cutting and Beveling

o Mark-off the dimension of each pipes and fittings as per the approved drawing.
o Proceed with cutting of Stainless steel pipes and fittings, which shall be done by
using cutting disc.
o Once the pipes and fittings are cut ,commence with the edge preparation.
o The edge cleaning and beveling shall be done using abrasive grinding disc/beveling
machines.
o Line number, Spool Numbers and Joint Numbers are to be clearly identified and
marked on the spool with the welder identification for each joint
 Purging arrangement
o Before fit-up, arrange sponge/foam along with argon, gas, hoses from both sides of
the joint.
o Before start of welding open the purging gas in the joint, so we can get back
purging gas during the welding.
 Fit-Up and Tack Welding
o Once the surface e is beveled and cleaned proceed for tack welding
o Welders should put on proper safety equipment prior for welding.
o Fit-up assembly shall be carried out by using locally prepared couplers. All the
required pipe holdings work benches, assembling brackets’’ bolts etc. Would be
made in house to suit the pipe size.
o For Butt welds uniform root gap of1.5-3 mm shall be maintained.
o Before commence the welding ensure hats pool is aligned properly.
o Once required level and alignment achieved proceed for welding.
o The pipe shall be tack welded in three equidistant positions, Tack welding shall as
per approved drawing and standard by a qualified welder.
 Welding
o Ensure that edges are free from dust, rust, oil, grease, paint etc.
o Welding shall be done as per approved drawing and by complying with the
particular piping standard. Preheating and welding consumable shall be checked
before starting of welding.
o Each welding layer shall be cleaned before starting to weld next layer. The cleaned
area shall be free from slag. Any visual defects like cracks, pores, spatters weld
shall be removed by grinding before the next layer is applied. The ends of weld
layer shall be removed by grinding in tack points of each weld. Any possible welds
excess layer will be removed by grinding.
o For the fabrication & welding of stainless steel pipes and fittings only stainless
steel tools and consumables (Wire brush chipping, Hammer, and Abrasive disc)
shall be used.
o Appearance of finished weld shall be as even as possible and free from spatter,
under cutting, cracks, excess reinforcement etc.

INSTALLATION STAINLESS STEEL PIPE& MS PIPE

 Before proceeding with the installation ,the following must be prepared:

o Cutting/drilling of hole to wall of Common Heating Container for the passage of the
MS Pipe.
 Check first the level of the MS pipe to be installed inside the Heating Container
and draw a square line marking the hole to be cut for the 2 pipes to pass from
inside the Heating Container going outside to the pipe support PS-19.
 Drill small holes Ø6mm along the square line marking with a distance of
approximately 6mm and when finished drill again using bigger drill bit
Ø12mm, and then hammer to remove the part to create the square hole.
o Ensure that all pipe supports are aligned and bolts/anchor bolts are tightened and fixed
properly.
o For SS Pipe DN500, ensure the availability of fabricated stainless steel Rest Support,
Rest & Guide Support and Rest & Axial Stop.
o For MS Pipe DN100, Check if the shoe, rest & guide support are fixed and u-clamps
are available.
o Ensure all scaffoldings are properly installed to carry out fit up and welding of field
joints at elevated positions.
o Check and make sure that the cable tray blocking the SS Pipe under the bridge at PS-
26 are already transferred.
o Fabricate &assemble the Tie-incompletely.
 Prepare and set-up scaffolding to assemble the tie-in in a safe area.
 Assemble the tie-in, install the butterfly valves and tighten the bolts.
 Check the levels/height, alignment and measurements as per the actual
condition; and once verified, full weld the connections in the flanges and
reducer.
 Once completed, disassemble from the connection atthevalvetohave2parts.
 Transfer to as per place near the location to install.
o Assemble scaffolding as up port in the location of the new tie-in.
o Welding joint shave already passed in the RT ,with go signal from TCL.
o Modify and extend at least 3m the scaffolding which will support the pipe joining the
elbow from the tie-in Supply Line (Weld Joint #1) and (Weld Joint #2), with the same
level as the lower support of PS-26.
o Welding joints have already passed in the RT, with go signal from TCL.

 Start installation of the Pipes from PS-01 to PS-04 until PS-32 and so on, leaving the area for
PS-26 and tie-in to be installed later on.
 Before the pipeline from PS-01 to PS-32 are finished installing (at least 2 days before)
coordinate with TCL to schedule the shutdown.
 Once everything are prepared and coordinated with TCL, start to dismantle or remove the
existing pipe of the Tie-in.
 Remove the existing tie-in(approximately 2 hours)
o Wrap as ling and hold the tie-in inasteady position by using crane
o Loosen and remove the bolts, then lift and remove using the crane and place in a safe
area.
 Install the new Tie-in(approximately7hours)
o Using crane, lift the tie-in’s first part and position horizontally above the installed PS-
33 and scaffolding and joining the existing DN400 flange, check the alignment and
level, use shim plates if necessary, then support and hold the other end in position by
tyingorclampingtothescaffolding,theninstallthebolt&nutoftheDN400flanges.
o Using crane, lift the tie-in’s second part and position above the existing vertical pipe
withflangeDN300,check the alignment and level, the un support and hold the other end
in position by tying or clamping to the scaffolding, install the bolt & nut of the flange
DN300, and install the valve joining the first part and second part using its bolt& nut.
o After thoroughly checking the assembled Tie-in, tighten the bolt and nuts of the
flanges DN400 & DN300 and the bolts joining the flanges DN500 & the butterfly
valve.
o Install the 2 butterfly valves at the top of the 2 Tees of the installed new Tie-in, and
provide a cover.
 Once the tie-in are completely installed, start the fit-up of the remaining piping parts from tie-in
to PS-26 to PS-01 at Supply Line. (approximately 12 hours)
o First check if the scaffolding which will support the pipe joining the elbow from the
tie-in Supply Line (Weld Joint #1) and (Weld Joint #2) are already installed and
leveled same as the lower support of PS-26.
o Insert the purging foam (with wire rope) inside the elbow at supply weld joint#3.
o Using crane install the assembled elbow (supply-part#1)a the top of the tee in the
Supply Line and put scaffolding support.
o Using crane lift the pipe (supply-part #2) and position in the lower part of PS-26 then
manually push going inside to the previously installed assembled elbow at tie-in
Supply Line, check the alignment and tack weld.
o Using crane lift the assembled elbow(supply-part#3)and position joining the supply
Line at weld joints#2and#3, check the alignment and tack weld.
 Full welding of supply line weld joints#1,#2and#3(approximately14hours)
o Once Supply Line is fitted and tack welded, prepare a hole at the top of the pipe (part
#2) to insert the argon hose (2x argon using Y-adaptor) for purging, and start the full
welding at welding joints #1, #2 and #3. After full welding are finished, weld a nipple
(fillet welded) with valve (or nipple with flange& blind)to cover the hole used for the
purging.
o Remove the butterfly valve at the tie-in to pull out the purging foam with wire inside,
and then return the butterfly valve when it’s done.
 Modify the scaffolding used to support the lower pipe of supply line, by making it same level
with the upper support for the return line, which will support the pipe joining the elbow from
the tie-in Return Line (Weld Joint #1) and (Weld Joint #2). (approximately 4 hours) (Scaffolder
are needed in the site.)
 Once the Supply Line are completely installed, start the fit-up of the remaining piping parts
from tie-in to PS-26 to PS-01 at Return Line. (approximately 12 hours)
o Insert the purging foam (with wire rope) inside the elbow at return weld joint#2.
o Using crane lift the pipe (return-part #1) and position in the upper part of PS-26 then
manually push going inside the direction of tie-in Return Line, check the alignment
and tack weld at return-weld joint #2.
o Using crane install the assembled elbow(return-part#2)at the top of the tee in the
Return Line check the alignment and tack weld.

Full welding of return line weld joints# 1and#2 (approximately14hours)
o Once Return Line is fitted and tack welded, prepare a hole at the top of the pipe (part
#2) to insert the argon hose (2x argon using Y-adaptor) for purging, and start the full
welding at welding joints #1 and #2. After full welding are finished, weld a nipple(fillet
welded)with valve(or nipple with flange & blind)to cover the hole used for the purging.
o Remove the butterfly valve at the tie-in to pull out the purging foam with wire inside,
and then return the butterfly valve when it’s done.
7. HEALTHANDSAFETYMANAGEMENTCONTROLMEASURES

GENERALSAFETYANDREQUIREMENTS

 All Person involved in the job should be trained in work place safety.
 All person involved shall use necessary PPE as required and Site supervisor shall ensure regular
inspection of workers PPE.
 The workers shall be made aware of safety requirements related to this activity through daily tool box
talks.
 The PGCC supervisor will conduct a “Toolbox Meeting” with PGCC personnel to discuss the specific
job task, precautions, and ongoing work in the affected area, review the safe work permit.
 All equipment, plant, machineries and tools shall be utilized in the job shall kept in good working
condition.
 Working are a required to check before start the work. The area must be clear and accessible for
deployment of manpower, tools, and equipments.
 Access and good housekeeping should be maintained in all erection areas.
 Working are shall be barricaded with warning tape.
 Safety shall be present from startup to the completion of the erection work, to provide immediate
response assistance in case of emergency.
 Implementation of the safety rules are to be fully executed by the Safety Officer.
 When welding the all mechanical equipment must be protected with flags, watch man barriers etc.
 Concerned persons area allowed during welding
 All tools and equipment are to be returned to the proper location before the user leaves the area.
 No equipment is to be left running while physically or mentally un attended.

8. REFERENCEDOCUMENTS

 Reference drawings