PROJECT

...

METHOD STATEMENT

For Mechanical Scope of Work

Pipe Welding Procedure

METHOD STATEMENT i
 Contents
PROJECT ............................................................................................................ i

Contents ...............................................................................................................ii

1 PURPOSE..................................................................................................... 1

2 SCOPE ......................................................................................................... 1

3 DEFINATION ................................................................................................ 1

4 RESPONSIBILITY......................................................................................... 1

5 EQUIPMENTS: ............................................................................................. 2

6 INSTALLATION............................................................................................. 3

6.1 CONSTRUCTION DRAWINGS .............................................................. 4

6.2 END PREPARATION, FIT UP AND CLEANING .................................... 4

6.3 WELDER ................................................................................................ 7

6.4 TACK WELDING AND WELDING .......................................................... 7

6.5 PIPE SUPPORTS AND PERMANENT ATTACHMENTS ..................... 10

7 TESTS AND INSPECTION ......................................................................... 10

7.1 FIT UP INSPECTION ........................................................................... 10

7.2 WELD VISUAL INSPECTION............................................................... 11

7.3 Liquid Penetrant Examination Procedure ............................................. 12

7.3.1 Schope ................................................

7.3.2 APPLICABLE CODES & SPECIFICATIONS .................................... 12

7.3.3 SURFACE PREPARATION .............................................................. 13

7.3.4 BRAND OF PENETRANT CONSUMABLES..................................... 13

7.3.5 CLEANING ........................................................................................ 13

7.3.6 TEMPERATURE OF THE TEST SURFACE ..................................... 14

7.3.7 APPLICATION OF PENETRATION .................................................. 14

7.3.8 EXCESS PENETRANT REMOVAL................................................... 14

7.3.9 DRYING AFTER REMOVAL OF EXCESS PENETRANT ................. 14

METHOD STATEMENT ii
 7.3.10 DEVELOPER APPLICATION ........................................................ 15

7.3.11 EXAMINATION .............................................................................. 15

7.3.12 EVALUATION OF INDICATIONS .................................................. 15

7.3.13 ACCEPTANCE STANDARDS ....................................................... 16

7.3.14 REPAIR REQUIREMENTS ............................................................ 16

7.3.15 POST EXAMINATION CLEANING ................................................ 17

7.3.16 INSPECTION REPORT ................................................................. 17

8 APPENDIX .................................................................................................. 17

APPENDIX 1 Welding Procedure Specification (WPS) .................................. 18

APPENDIX 2 Permit to Work (PTW) .............................................................. 20

APPENDIX 3 Job Safety Analysis (JSA) ........................................................ 21

METHOD STATEMENT iii

1 PURPOSE
The purpose of this statement is to document the correct procedure and
installation of Welding Pipe for ... project. at site, identify the reference
documents or applicable codes and standards, the construction of the ... under ...

2 SCOPE
Mechanical for Welding Pipe of the ... under ... shall be the scope of this
Field Inspection and Test Plan.

3 DEFINATION

TERMS DEFINATION
Project
Owner
Consultant (RE)
Main Construction
MOS Method of Statement
MSA Material Submission Approval
Table 1 Definition

4 RESPONSIBILITY
NO DESIGNATION QTY RESPONSIBILITY
Responsibility for Overall Commercial,
Project Manager
contractual & technical performances
1 1
associated with specific project. Reporting to
the Project Director.
M&E Engineer
2 3 Planning and supervising installation activities

QA/QC Engineer
Inspect, verify, and prepare work statement for
3 1
a quality installation works.
Safety Officers To provide toolbox and guidance to work and
4 1 to ensure that work is carries out in a safe
manner

METHOD STATEMENT 1
NO DESIGNATION QTY RESPONSIBILITY
Obtain permit to work, control the sequence
according to MOS, approved shops drawings,
and MSA, ensure mechanical aspect of the
work are according to the specification, ensure
safe practices are followed and ensure quality
of workmanships during execution.
5 Supervisor 3-5
Ensure material temporary storage and

practice / standard requirement

Ensure all the tools being used for the
installation are calibrated and meeting the
rement
To carry out all the mechanical aspect of the
Pipe Welding installation
6 General Worker 10-15

Table 2 Responsibility

5 EQUIPMENTS:

Forklift or Crane with suitable capacity

Hydraulic Trolley
Portable Drilling Machine/Grinding Machine & Angle Cutter
Pipe Fitters Tools Boxes
Spirit Level & Level threads
Step Ladder as per site requirement
Scaffolding with platform as per site requirement
Welding machine, Oxy Acetylene Gas cutting set,
Chain Block pulley and Shackles
Pulley and rope
Grooving Machine
Pipe cutter, Grinder, Angle cutting machine and webbing sling

METHOD STATEMENT 2
6 INSTALLATION
Below is the flow chart for the installation, tests and inspection of the piping system:

METHOD STATEMENT 3
6.1 CONSTRUCTION DRAWINGS
Before commencement of the work, reference drawings for construction (such as
isometric drawings, layout drawings) shall be verified for its latest status. Only latest
drawings with Issued for Construction or Issued for Use (IFC/IFU) status shall be
used at site. Any old or obsolete drawings shall be removed from site and shall be
returned to the engineering department/document controller.

6.2 WELDING QUALIFICATION

Qualify procedures and personnel shall be according to the standard stated in
tender specification for different materials and services
. All qualification
must be approved by Kementerian Tenaga Kerja Republik Indonesia by approved
test procedures using methodology and procedures covered in the ASME Boiler and
Pressure Vessel Code, Section IX, "Qualification Standard for Welding and Brazing
Procedures, Welders, Brazers, and Welding and Brazing Operators".
6.3 END PREPARATION, FIT UP AND CLEANING
A. CLEANING
The inside and outside surfaces of pipes, valves and fittings shall be
cleaned of all dirt, sand, loose mill scale and other foreign materials
immediately after removal from storage, and before and after fit up the
inside of pipes shall be air blown before and after fit up using compressor
with dry, clean, and oil free air.
B. END PREPARATION AND FIT UP

In location where platform or ladder is required (working at height),

workers shall not proceed until the platform or ladder is checked and

Before cutting, identification for specification of material shall be

transferred by hard stamping to avoid dissimilar material joining.

Base metal for butt weld joints shall be prepared by machining or

mechanized oxygen cutting. All slag and irregularities shall be removed from
oxygen cut ends by grinding. Bevel pipe ends at a 37.5° angle where

METHOD STATEMENT 4
possible, smooth rough cuts, and clean to remove slag, metal particles, and
dirt.

Use pipe clamps or tack-weld joints with 1" long welds, 4 welds for
pipe sizes to 10", 8 welds for pipe sizes 12" to 20".

Butt-welding end (bevel angle) and root opening (root gap) shall be
prepared according to the approved WPS or as specified in the drawing.

Weld edge preparations shall be cleaned both internally and externally

over a distance of at least 25 mm on either side of the weld edge and shall
be free from paint, oil, rust, scale, or other material that is detrimental to
welding.

The inside diameters of piping components to be butt welded shall be

aligned as accurately as possible. The internal misalignment of the ends to
be joined shall not exceed 2.0 mm. When the internal misalignment exceeds
the allowable, it is preferred that the component with the wall extending
internally be internally trimmed per Fig. 127.3 in Chapter V of ASME Section
B31.1. However, trimming shall result in a piping component thickness not
less than the minimum design thickness, and the change in contour shall not
exceed 30 deg (refer to the figure below).

METHOD STATEMENT 5
 Pipe ends for socket weld connections shall be reamed to full inside
diameter to remove all burrs and obstructions.
In assembly of socket weld joints, before tack welding, the pipe shall
be inserted into the socket to the maximum depth (mark the maximum depth
all around the pipe with pencil or suitable means) and then withdrawn
approximately 1/16 in. (2.0 mm) away from contact between the end of the
pipe and the shoulder of the socket (refer to Figs. 127.4.4 B and C in Chapter
V of ASME Section B31.1 and the figures below). In sleeve-type joints
without internal shoulder, there shall be a distance of approximately 1/16 in.
(2.0 mm) between the butting ends of the pipe or tube.

METHOD STATEMENT 6
 Piping components to be joined shall be confirmed for straightness and
squareness before and after fit up, and after welding.
6.4 WELDER
Qualifications of Welders: Welders performing work under this Contract shall be
certified and qualified in accordance with tests prescribed by Kementerian Tenaga
Kerja Republik Indonesia. All welders shall produce professional welder certificate
with appropriate classes by Kementerian Tenaga Kerja Republik Indonesia by
approved test procedures using methodology and procedures covered in the ASME
Boiler and Pressure Vessel Code, Section IX, "Qualification Standard for Welding
and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators".
Installation shall conform to ANSI 31.1 "Power Piping".
1. Submit for approval the names, identification, and welder's assigned
number, letter or symbol of welders assigned to this project.
2. The assigned identification symbol shall be used to identify the work of
each welder and shall be indelibly stamped immediately upon completion of
each weld.
3. Welders shall be tested and certified for all positions.
4. Submit identifying stencilled test coupons made by each operator.
5. Any or all welders may be required to retake welding certification tests
without additional expense.
6. When so requested, a welder shall not be permitted to work as a
welder on this project until he has been recertified in accordance with
Kementerian Tenaga Kerja Republik Indonesia.
7. Recertification of the welder shall be made after the welder has taken
and passed the required tests.
8. Where piping 1-1/2 inches and smaller is butt or socket welded, submit
3 samples of test welds for approval.

6.5 TACK WELDING AND WELDING

Weld pipe joints in accordance with recognized industry practice and as follows:
1. Weld pipe joints only when ambient temperature is above 0°F.
2. Bevel pipe ends at a 37.5° angle where possible, smooth rough cuts, and
clean to remove slag, metal particles, and dirt.

METHOD STATEMENT 7
 3. Use pipe clamps or tack-weld joints with 1" long welds, 4 welds for pipe
sizes to 10", 8 welds for pipe sizes 12" to 20".
4. Build up welds with stringer-bead pass, followed by hot pass, followed by
cover or filler pass. Eliminate valleys at centre and at edges of each weld.
Weld by procedures which will ensure elimination of unsound or unfused
metal, cracks, oxidation, blow-holes, and non-metallic inclusions.
5. Do not weld out piping system imperfections by tack-welding procedures.
Refabricate to comply with requirements.
6. At Installer's option, install forged branch-connection fittings whenever
branch pipe is indicated, or install regular T-fitting. Tack welding may be
made directly to the groove of the weld joint or by using bridge (fit up lug).
The fit-up lug to be used shall be of the same composition as the base
metal to be welded.
Tack welds shall not remain on the finished welds and shall be removed by
grinding before the start of permanent welding.
Electrodes or filler metals to be used in tack welding shall be the same as
specified in the applicable WPS.
Preheating in tack welding shall also be applied when preheating is specified in
the applicable WPS.
In order to monitor and control the welding of each joint, a matrix indicating the
below information shall be written near the joint:

METHOD STATEMENT 8
 No welding shall be done if there is impingement of rain, or high wind on the
weld area or when the weld area is wet. Protection from rain and wind shall be
provided in the event of rain or strong wind.
Piping shall be adequately supported prior to welding to avoid distortion
during welding.
Electrodes or filler metals to be used shall be as per applicable WPS.
Welding filler materials/electrodes shall be collectively stored and controlled
at site Welding Electrode Control Room protected from rain and moisture. A drying
(baking) and holding oven shall be provided at site Welding Electrode Control Room
for conditioning/re-conditioning of SMAW or low hydrogen covered electrodes.
All low hydrogen covered electrodes shall be dried (some electrode
manufacturer uses the term re-drying) in the drying oven at required time and
temperature according to the electrode manufacturer recommendation.
Low hydrogen covered electrodes, after drying shall be transferred to the holding
oven at required temperature recommended by the electrode manufacturer.

Each welder shall be issued portable oven or quiver and will use it during
receiving of electrodes from welding consumable controller, during work at site, and
during returning of unused electrodes.

Preheating, when required shall be according to the applicable WPS.

Reinforcements for butt weld joints shall be according to the Table 127.4.2 of
ASME Section B31.1 (refer to the table below), while undercuts shall not exceed 1.0
mm.

METHOD STATEMENT 9
 All socket weld joints require a minimum of two passes and shall have minimum
sizes as indicated in Figures 127.4.4 B and C in Chapter V of ASME Section B31.1.

6.6 PIPE SUPPORTS AND PERMANENT ATTACHMENTS

Supports and other permanent attachments designed to be directly welded to
pipe (such as pipe shoe, pipe chair, or dummy pipe) shall be installed before
pressure test of piping.
Pipe supports shall be installed according to its type and location indicated in
the drawing.
The support assemblies shall not be used for attachment of rigging to hoist the
pipe into place. The piping shall be securely held in place by other means until the
pipe support is completely assembled and attached to the pipe and the building
structures. The rigging shall be removed in such a manner so as not to impose a
sudden load on the pipe support.
Spring supports shall not be used during hydrostatic testing of piping systems
unless they are pinned or blocked to act as rigid support. Piping that has supports
that are not pinned or blocked shall be held securely in place by other temporary
means throughout the testing. After successfully passing the hydrostatic test, the
pin or blocking device shall be removed.
After start-up of a piping system, all supports shall be checked for proper
operation and any adjustments required shall be made.

7 TESTS AND INSPECTION

7.1 FIT UP INSPECTION

The Reference Documents, Codes and Standards, and Reference Acceptance
Criteria shall consist of but not limited to the following:
A. This procedure
B. Approved ITP
C. ASME B31.1 Paragraph 127.3
D. Reference drawing
Items to be checked and verified during Fit Up Inspection are but not limited to
the following:
A. Material specification

METHOD STATEMENT 10
 B. Joint number
C. Piping and components orientation according to the drawing
D. Cleanliness of the pipe internal and external
E. Cleanliness of weld edge preparation
F. Groove angle, root gap and internal
G. Straightness and squareness of piping assembly
H. Electrode or filler metal used in tack welding
I. Inspection matrix written near the joint

7.2 WELD VISUAL INSPECTION

The Reference Documents, Codes and Standards, and Reference Acceptance
Criteria shall consist of but not limited to the following:
A. This procedure
B. Approved ITP
C. ASME B31.1 Paragraph 127.4
D. Approved WPS
E. Approved welding control procedure
F. Reference drawing

Items to be checked and verified during Weld Visual Inspection are but not
limited to the following:
A. Material specification
B. Joint number
C. Applied WPS
D. Applied preheat temperature (if required)
E. Electrode or filler metal used in welding
F. Inspection matrix written near the joint
G. Name of welder
H. Cleanliness of the joint
I. Surface of welds shall be sufficiently free from coarse ripples, grooves,
overlaps, abrupt ridges, and valleys and shall meet the criteria listed in
ASME B31.1 Paragraphs 127.4.2 to 127.4.8., and Paragraph 136.4.2

METHOD STATEMENT 11
7.3 Liquid Penetrant Examination Procedure

7.3.1 Scope
This procedure details the techniques to be applied for Visible (Colour
Contrast) Solvent Removable Liquid Penetrant Examination (PT), to find the defects
open to surface on all types of non-porous metals and non-metals including welds,
pipes, tubes, forgings, fittings and other wrought products when such examination is
required by the construction Code and/or material specification.

The extent of examination shall be as specified in the drawing and test plan.

This procedure requires qualification by demonstration for all the applicable

essential variables when specified by construction Codes or specification. The
demonstration shall be carried out on a flawed specimen. NDE Level III shall certify
that this procedure has been demonstrated for capable of producing interpretable
examination results to the satisfaction of AI as per Article I Para T-150 of ASME
Code Sec V.

Any change in a variable identified as an essential variable in this procedure

shall require re-qualification by demonstration. Any change in a variable identified as
non-essential variable does not require requalification or demonstration however, a
revision to the procedure shall be required.

Based on the contract specific customer requirements, an annexure to this

procedure can be issue. Any change in the essential variable shall however require
qualification and demonstration.

The applicable essential and non-essential variables are identified on the

Qualification and Demonstration record, which is attached and forms part of this
procedure.

7.3.2 APPLICABLE CODES & SPECIFICATIONS

a) ASME Code Section V Article 6

b) ASME Code Section VIII, Div. 1 - Appendix 8

c) ASME Code Section VIII Div. 2 - Clause 7.5.7

d) ASME Sec. IX

METHOD STATEMENT 12
e) ASME B31.1 & ASME B31.3

f) ASME Sec. 1

g) Applicable SA/SB material specification

7.3.3 SURFACE PREPARATION

As welded, as forged or machined condition is acceptable. Grinding or
machining may be done on irregular surfaces which could mask indications of
unacceptable discontinuities.

The surface to be examined and all adjacent area within at least 1 inch
(25mm) shall be dry and free of all dirt grease, lint, and scale, welding flux, weld
spatter, paint, oil and other extraneous matter.

7.3.4 BRAND OF PENETRANT CONSUMABLES

The following brands of PT consumables are approved for use. All
consumables shall be used within the expiry date specified by the
manufacturer.
Intermixing of consumables from different families or manufacturers is not
permitted.

Table 3 Brand of penetrant consumable

7.3.5 CLEANING
The surface to be examined shall be cleaned using solvent cleaners before liquid
penetrant examination.

Minimum drying time after cleaning shall be 1 minute. Drying shall be by natural
evaporation.

METHOD STATEMENT 13
7.3.6 TEMPERATURE OF THE TEST SURFACE
The temperature of the test surface shall be between 40oF (5oC) and 125oF
(52oC) throughout the examination period. Local heating or cooling is permitted to
maintain the required surface temperature.

7.3.7 APPLICATION OF PENETRATION

The penetrant may be applied by aerosol spray cans of wiped with brush. For
the minimum dwell time refer Table 1. The surface shall remain wet with penetrant
during the dwell time. Re-spray is permitted.

7.3.8 EXCESS PENETRANT REMOVAL

The excess penetrant shall be removed completely using cloth or absorbent
paper, repeating the operation until the traces of penetrant have been removed. The
remaining traces shall be removed by lightly wiping the surface with cloth or
absorbent paper moistened with solvent.
Flushing the surface with solvent, following the application of the penetrant
and prior to developing is prohibited.

7.3.9 DRYING AFTER REMOVAL OF EXCESS PENETRANT

Following the removal of excess penetrant, the surfaces shall be dried by
normal evaporation for a minimum of 1 minute and a maximum 20 minutes. Refer
Table 1.

PERMESIBLE DWELL TIME

After penetrant
MATERIAL After initial Penetrant removal and Interpretation
cleaning application before Time
Developer
Application
WELD Min 1mnt Min 5mnt Max 20mnt Min 10mnt
Max 20mnt Max 30mnt

PLATES, Min 1mnt Min 20mnt Max 20mnt Min 10mnt

FITTING, Max 20mnt Max 30mnt
PIPE, AND
OTHER
WROUGHT
PRODUCT
METHOD STATEMENT 14
7.3.10 DEVELOPER APPLICATION
The developer shall be applied uniformly to the surface being examined to obtain
a coating of even thickness over the entire surface by spraying. Only wet non-
aqueous developer in aerosol spray shall be used.

7.3.11 EXAMINATION
Developing time for final interpretation begins immediately after the
application of developer, as soon as wet developer coating is dry. Final interpretation
shall be made not less than 10 minutes nor more than 30 minutes after the coating is
dry. See Table 1.

If the surface to be examined is large enough to preclude complete

examination within the prescribed or established time in Table 1, the examination
can be performed in increments.

The area under inspection shall be illuminated adequately by natural or

artificial light of minimum 1000 lux to enable interpretation of the results accurately.
220V/100 W lamps at a maximum distance of 0.5 meter gives the required light
intensity. This has been verified by demonstration using light meter.

If false indications are suspected, re-examination of the area shall be carried

out.

7.3.12 EVALUATION OF INDICATIONS

An indication of an imperfection may be larger than the imperfection that
causes it, however the size of the indication is the basis for acceptance or rejection.

An indication is evidence of mechanical imperfection. Only indications with

major dimensions greater than 1/16 inch (1.5mm) shall be considered relevant.

A linear indication is one having a length greater than 3 times the width. A
rounded indication is one of circular or elliptical shape with the length equal to or less
than three times the width.

Any questionable or doubtful indications shall be re-examined to determine

whether or not relevant.

METHOD STATEMENT 15
7.3.13 ACCEPTANCE STANDARDS
These acceptance standards shall apply unless other more restrictive
standards are specified by contract and specified in drawing and / or test plan. All
surfaces to be examined shall be free of following.

a. Relevant linear indications.

b. Relevant rounded indications greater than 3/16 inch (5.0 mm).

c. Four or more relevant rounded indications in line separated by 1/16 inch (1.5mm)
or less (edge to edge).
d. Crack like indications, irrespective of surface conditions are unacceptable.

7.3.14 REPAIR REQUIREMENTS

Unacceptable imperfections shall be repaired and re-examined to ensure
removal or reduction to an acceptable size. Whenever an imperfection is repaired by
chipping or grinding and subsequent repair by welding is not required, the excavated
area shall be blended into the surrounding surface to avoid sharp notches, crevices
or corners. Where welding is required after repair of an imperfection, the area shall
be cleaned, and welding performed in accordance with a qualified welding
procedure.

Any indications which are believed to be non-relevant shall be regard as an

imperfection unless it is shown by re-examination by the same method or by the use
of other non-destructive methods and/or by surface conditioning that no
unacceptable imperfection is present.

After a defect is thought to have been removed and prior to making weld
repairs, the area shall be examined by suitable methods to confirm the defect has
been removed or reduced to an acceptable size of imperfection.

After repairs have been made, the repaired area shall be blended into the
surrounding surface so as to avoid sharp notches, crevices, or corners and re-
examined by the liquid penetrant method and by all other methods of examination
that were originally required for the affected area, except that, when the depth of
repair is less than the radiographic sensitivity required, re radiography may be
omitted.

METHOD STATEMENT 16
7.3.15 POST EXAMINATION CLEANING
The area after examination will be cleaned using dry/wet cloth or water
washed. Other special cleaning if required shall be specified on Inspection & Test
Plan.

7.3.16 INSPECTION REPORT

The results of the examination shall be reported on the Form

8 APPENDIX
1. APPENDIX 1 Welding Procedure Specification (WPS)
2. APPENDIX 2 Permit to Work (PTW)
3. APPENDIX 3 Job Safety Analysis (JSA)

METHOD STATEMENT 17
APPENDIX 1 Welding Procedure Specification (WPS)

METHOD STATEMENT 18
METHOD STATEMENT 19
METHOD STATEMENT
APPENDIX 2 Permit to Work (PTW)

METHOD STATEMENT 2
APPENDIX 3 Job Safety Analysis (JSA)

Form No. JSA-HSE-01

Revision
JOB SAFETY ANALYST
Date
Disetujui
Nama Pekerjaan / Task Title Oleh / HSE Officer
Approved By
JSA No. / No. JSA Supervisor Client
Project
Alat Pelindung Diri (APD) yang harus dipakai / Required Personal Protective Equipment ( PPE )
Helm Pengaman, Kacamata, Sepatu Pengaman, Sabuk Pengaman, Sarung Tangan/ Hard Hat, Safety Glass, Safety Shoes, Body Harnest, Safety Gloves
Urutan Dari Langkah-langkah Pokok Tugas Bahaya-Bahaya Potensial Tindakan atau Prosedur Direkomendasikan
Sequence Of Critical Steps Of The Task Potential Hazards Reccomended Action Or Procedure

Petunjuk Umum/General Guidelines

1. Sebutkan Secara berurutan hanya langkah-langkah pokok tugas yang harus dikerjakan. Gunakan kalimat aktif secara jelas dan singkat/ Describe in sequence
only the main steps of the task to be performed. Use active sentences
2. Gunakan Frasa Singkat untuk mendeskripsikan Bahaya-bahaya Potensial, Seperti : Terjepit di antara daun pintu dan kerangka Mesin, dll. / Use Simple phrases
to describes identified potetial hazards, such as: Pinched between the door and machine, etc.
1. 6. 11.
2. 7.
3. 8.
4. 9.
10.
5.
3. Jika ada perubahan dengan isi dp JSA ini harus dengan sepengetahuan dan persetujuan HSE Manager DME / When any changes of this JSA's content have to
acknowledge and
approved by Manager HSE DME
4. Wajib disosialisasikan oleh supervisor kepada crew tau teamnya dan menandatangani tanda bukti kehadiran/ Its Mandatory to socialize by supervisor to his crew or
team and to sign off at the attendance list.

METHOD STATEMENT 2