Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Document name
Document number
Rev. no / Page
SC NO.
REQ NO.
IDENT NO.
ITEM NO.
PNG
PNG LNG Plant Project
CHIYODA-JGC JOINT VENTURE
:
: DW-PIPE-011
: PGLN-YF-KPMTH-90K010-021
Rev.no :
:
A-Reviewed with
No comments
Section :
B-Reviewed with
Comments as noted
Signature :
Date :
B
Doc. name
Doc. no
Rev. no
PGLN-YF-KPMTH-90K010-021
Prepared
by
Checked
by
2
1
0
03 Jan.2011
Issued for
review
C O N T E N T S
1.0
PURPOSE
2.0
SCOPE OF WORK
3.0
4.0
RESOURCES
ORGANIZATION CHART FOR PIPING ERECTION
RESPONSIBILITIES
MANPOWER
TOOLS AND EQUIPMENT
4.1
4.2
4.3
4.4
5.0
GENERAL ACTIVITIES
6.0
6.1
6.2
6.3
6.4
7.0
8.0
TEMPORARY FACILITIES
2 of 20
Rev.
Approved
by
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
9. 0
10.0
11.0
ATTACHMENTS
3 of 20
Rev.
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
1.0
PURPOSE
The purpose of this Work Method Statement is to control installation activities of piping
erection around equipment, especially around E-1411,E-1412,E-1415A/B and AFC
undertaken by SUBCONTRACTOR, and to ensure that the required quality is achieved
to Project Specification Codes and Standards, Russian codes and standard.
2.0
SCOPE OF WORK
This Work Method Statement describes the erection methods for pipes that shall
be erected around equipment except on pumps and compressors of Sakhalin
LNG Project.
3.0
DOC. TITLE
Welding of Metals
Shop and Fabrication of Piping
Piping General Requirement
Process Piping
Technical Specification for General Welding
Requirement
Technical Specification for Prevention of Stainless
Steel Zinc Embrittlement
Technical Specification for Welding-Quality Control
Requirements During Site Construction
Piping Class Summary
Piping Material Specification
Technical Specification for Valve Locking And
Interlocking Devices
Technical Specification for Sequencing Ball Valves
Expansion Joint for Cryogenic Service
Technical Specification for Shop and Field
Fabrication of Piping,
Specification for Piping General Requirements
Material Identification and Traceability
Scaffolding Procedure
Inspection and Test Plan Piping field Erection
Inspection and Test Plan Piping(Adjacent to Rotating
Equipment) Alignment Check
Inspection and Test Plan Installation of Strainer
Element
4 of 20
Doc. name
4.0
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
RESOURCES
4.1
4.2
Responsibilities
Construction Manager is responsible for:
1) Implementation of this work procedure
P/Erection Superintendent is responsible for:
1) Implementation of work activity including preparation of work, delivery of
material, welding, storage, etc.
2)Control of welder and daily welding report and submission to Contractor.
3)Implementation the latest revised drawing and design change.
4) Review of NDE requirements, requisition of NDE and maintenance of NDE
report.
5)The implementation of PWHT, and maintenance of report concerned.
6)Preparation of Material Requisition for field materials
7) Control of storage, handling, preservation of materials received from the
Material Control Team for the process of installation.
8)Clearance of Pre-Test/ Post-Test Punch Items
QA/QC Team Manager is responsible for:
1) Inspection of installation in accordance with relevant ITP.
2) Preparation of inspection record.
3) Handing over QA records to the CONTRACTOR Quality Assurance Manager.
4) Reporting Non-Conformance item(s).
4.3
Manpower
The installation work shall be controlled and coordinated by supervisor.
The basic manpower shall include but not limited to
4.3.1 Pipe Foreman
4.3.2 Pipe Fitter
4.3.3 Pipe Welder
4.3.4 Rigger
4.3.5 Scaffolder
4.3.6 Helper
4.3.7. Equipment Operator
1) Crane Operator
5 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
2) Manlift operator
4.4
5.0
GENERAL ACTIVITIES
Please refer to Attachment #1 in General Work Method Statement
(Doc. No. 7002-E-00-38-P-3101-01-01)
6.0
6.1
6.2
6.2.1
Preparation
6.2.1.1 After release or hand over of the equipment to piping erection group,
depressurization of the purging gas (Nitrogen) thru a valve shall be conducted
under Contractors supervision and control. The pressure cap on the nozzle shall
be removed only immediately before connecting the nozzle to the piping system.
6.2.1.2 To explain how to control do not exceed the nozzle load include back charge for
welding refer to Erection and Installation instruction.
6.2.1.3 Arrange the order for pipe installed around heat exchanger, the crane location and
capacity as well as arrangement of workers shall be checked. (Refer erection and
installation construction to the Doc. No. 7001-E-14-21-P-0317)
6.2.2
Scaffolding
6.2.2.1 Scaffolding work shall be done in a position that are essential for rigging and
welding work and fully concerned with safety and shall be approved for use and
inspection by safety manager.
6 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
6.2.3
Fabrication of pipe spools
6.2.3.1 Pipe spool shall be fabricated in accordance with order of pipe installation and
construction schedule of heat exchanger and all related inspection shall be
completed
6.2.4
Permanent and Temporary Support Installation
6.2.4.1 All pipe support shall be fabricated and installed and be completed inspection from
the top before pipe spool installation
6.2.4.2 When installation of temporary support inevitably, installation in concerning with
safety and damage shall be recovered after removal
6.2.5
Rigging
6.2.5.1
Pipe spool shall be arranged around heat exchanger and pipe spool storage on
the wood, and touch-up painting shall be done if there is a damage in pipe surface
6.2.5.2
6.2.5.3
Rigging should be done by using sling belt according to weight for pipe spool
Crane for rigging shall be set in safe place and appropriated capacity of crane
shall be used by calculating height of heat exchanger and weight of pipe spool
6.2.5.4 Arrange a skilled rigger and set rigger in place for pipe spool installation and near
crane
6.3
6.3.1
6.3.2
6.4
6.4.1
6.4.2
6.4.2.1 Surface of flange gasket face shall be free from rust, weld spatter, scars, paint,
7 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
6.4.3.1.1
6.4.3.1.2
below:
1) The line that shall be developed by connecting the two uppermost points of two
opposite bolt holes equidistant from flanges vertical centerline shall neither develop
an angle of depression nor an angle of inclination
2) The four projected lines tangent to the four quadrant points of flange face, and
parallel with pipe or spools horizontal line shall be of equal distances when
measured perpendicularly using an L-square from pipe/spools outer surface
3) When pipe/spools centerline is at zero degree from the horizontal, the x and y-axis
of the flanges face shall also be at 0 and 90 degree, respectively. Otherwise, the
flange is not aligned and squared.
6.4.3.1.3
Gasket Setting
6.4.4.1.1
Prior to fabrication of gasket, an inspection shall be conducted to check
its size, dimension, and ratings that it conforms to its required specifications.
6.4.4.1.2
Gasket shall be handled very carefully, and inspected from any signs
and/or occurrences of corrosion and damage. Gasket they could prejudice quality,
8 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
safety and integrity of the piping installation shall be rejected and promptly
replaced.
6.4.4.1.3
Order of Flange Bolt Tightness, Refer to procedure for bolt up attachment
#10.3
7.0
7.1
inside surface of the vessel. Once the purging process is completed the nozzles of the
vessel shall then be sealed tightly with pressure caps to prevent the gas from
escaping into the atmosphere. These pressure caps shall only be removed at a time
prior to connecting the vessels nozzle to the piping system. Exposure of the vessel
inside walls/chambers to open atmosphere shall be kept as short as possible.
Duration to nozzles being open shall be kept as short as possible , i.e. cut the cap,
inspect and weld the piping consecutively whenever possible. The pressure caps,
protection or cover, on nozzles shall be remove only immediately before the
connection of nozzle to the piping system. Removing of blankets is only allowed
after depressurizing the connecting chamber from nitrogen-over-pressure by
installed gauge / valve.
Refer to Nitrogen let down procedure(7001-E-14-21-P-0311) for safety aspects
To avoid ingress of swart it is recommended that the pressure caps shall be cut at
horizontal Nozzle position.
During all work around the vicinity of an open nozzle, care must be taken that no
particles like slag, scale, rust, welding residues, oil, grease, salt, or moisture etc. can
get into the nozzle and thus inside the CWHEs. In case that particles get into the
nozzle, it is necessary to remove them (e.g. with vacuum cleaner). The CWHEs are
accessible via manholes and visible via handholes according to Dimensional Outline
9 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
Drawings.
If the CHWEs are installed in the plant, but not yet completely piped, all open
nozzles have to be covered by ply wood. And Foil is not sufficiently secure to ensure
avoidance of ingress. Securely fitted blind or other secure means should be used.
This is important for nozzle open to the top. In any situation the CWHEs have to be
protected from ingress of moisture (rain!) to avoid freezing during operation!
All piping has to be carefully cleaned by purging and dried before connecting to
CWHEs. Due to the small pipe diameters the CWHEs may easily be blocked through
ingress of slag. This can result in in safety problems due to blocking of the free
passage to the safety valve and in operation problem because the heat transfer
surface would be partly inactive.
To avoid ingress of the soil particles during start-up and operation it is recommended
To install strainer in the let pipes to the CWHE
7.2
7.2.1 Check and record that no pressure in inside the nozzles / chamber.
7.2.2 Removal of pressure caps shall be done only by using a cutting disc. At no instance
shall the surface temperature of the cap, measured at its heat-affected zone,
exceed 350 degree for 30 minutes (for Asahi Transition Joints) to minimize heat
transfer by conduction, or the development of an excessive thermal gradient on the
base metal of vessels connecting nozzle.
7.2.3
For the limitation of temperature at the transition joint there are the following
possibilities.
-. Continuous cooling during welding with cooling water and application of a spray
protection sleeve (Ref: Welding Procedure Specification No.:TW 108 Rev.5 in
Appendix 3)
-. Early interruption of welding before the temperature comes up to the maximal
tolerated values. Inter-cooling with pressure air (oil free!) down to a temperature
of approx. 40
7.2.4 Only medium size grinders using medium size cutting disc shall be used during the
cutting or removal of pressure caps.
10 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
cutting line
DETAIL A
7.2.4.2 Cutting and grinding has to be done very carefully in order not to damage transition
joint stub. The following shall the steps that shall be followed to avoid slag and fine
cuttings from entering into the bore of pipes.
1. Cutting shall be performed in such a manner that the penetration of cutting discs
shall be gradual, uniform, and evenly distributed throughout the outside
circumference of the cap and inwardly towards the center of its axis. Cutting discs
penetration shall proceed until 80% of caps total thickness shall be removed.
2. At 0.20 t remaining, cutting shall be done more gradually, uniformly and
tangentially until the cutting disc shall be able to penetrate the entirety of the caps
thickness.
3. After removal f the cap, the inside surface of the nozzle shall be cleaned of the
fine cuttings by using a clean and dry cloth. Cleaning shall be done thoroughly and
completely.
4. The nozzle, removed of its cap, shall be sealed tightly with plastic or wooden
covers to prevent incursion of dusts and other foreign particles that could be a
cause to corrosion.
7.2.5 Check that the transition joint are not damaged after cutting the pressure caps.
7.2.6 Paint on the surface must be removed before welding.
11 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
7.2.7 Edge preparation at the pipe for welding according WPS(by other)
Inspect and report cleanliness of pipe internal.
7.2.8 Welding of the pipe of the transition joint stubs.(Doc.No.7001-E-1421-P-0317
Appendix 3)
After completion of welding NDE(PT,RT,UT) as require by local rules and
By Contractor has to be performed.
7.2.9
Alignment and perpendicularity between the vessels nozzle and the connecting
piping component shall be thoroughly checked and measured. Forced fit-up shall
not be allowed at all times. Any misalignment that shall be discovered during fit-up
of the connection shall be rectified immediately and appropriately in order to make
the vessel free from excessive external stresses after welding.
7.3.2
Only a pneumatic test with dry and oil-free air shall be carried out due to difficulties
to remove hydraulic test liquid after installation. Residual test liquid might freeze
during operation and cause severs damage.
7.3.5 The pressure test shall therefore be carried out under supervision of a responsible
12 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
person by observing the local applicable protective labor and safety regulation. And
contractor procedure for pneumatic pressure testing(7000-E-00-10-S-0431-01)
7.3.6 In there are any indications for a leak in the CWHEs, Vendor has to be informed
immediately.
7.3.7 Testing Pressure shall be recorded as per contractor procedure(7000-E-00-10-S0431-01) recording /chart record No. withness persons / calibration sheet
8.0
TEMPORARY FACILITIES
Refer to General Work Method Statement
9.0
10.0
- The area of lay down shall be prepared separately as LTCS pipe, SUS pipe,
13 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
3.
Handling of Material
- Good access of equipment to work site shall be secured.
- Speed Limit shall be kept during driving.
- Pipe should be stacked on wood on firm and horizontal ground/place and
shall be anchored by using tri-angled wood.
4.
Manual Handling
Manual handing shall be minimized during loading and unloading, if possible.
In case of manual handling, worker shall keep good postures(keeping arm
close to the body, correct grip/hold, chin in, head up, use of check the heavy
load body weight), check rough surface and be careful to crushing.
Workers shall wear PPE, especially long-sleeved coverall and hand gloves.
Worker shall be trained before work.
5.
Rigging
1) Suspended load and Falling material
- Rigging work shall be done by skilled and trained riggers, erectors,
banks-man and crane operator under the control of supervisor.
14 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
Scaffolding Works
1) Damage on scaffolding structure due to improper installation
-
15 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
- All workers who install pipe spool at work at height shall wear full body
harness and fix it to hand rail or structure during the work, if the platform or
scaffold is not inspected and permitted by competent person. In case of
permission, full body harness is not mandatory to every body. But, every body
should wear full body harness in case he works outside platform and scaffold.
- Worker shall pay attention to prevent of falling material such as tool, working
material from platform and scaffold. To prevent falling down of material, worker
16 of 20
Doc. name
8.
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
shall have a good house keeping on, platform and scaffold, minimize the
volume and store material inside apart from platform and scaffold in case of
storing material on platform and scaffold.
Do not throw down any material to ground from platform and scaffold.
Lay down material from platform and scaffold by trolley.
Gas inside the equipment shall be removed and then tested by gas tester
before commencing work.
Equipment piping shall be installed from top to down direction.
Welding work, flange bolting and other work shall be done on equipment
platform or scaffold. In case the using of platform or scaffold for equipment
erected by other contractor, the work shall be done by using man lift or
additional scaffold.
Band pipe spool tightly by using web sling before erection of pipe spool to
prevent pipe spool from slipping down to ground
Web sling is a good measures for non-slip of material from banding condition
and protection of pipes surface.
Rig spool after rigger confirm the tightness of banding beam by using web
sling.
The sling shall be inspected by CTSD and color coded before using and user
shall check the condition of sling before using every times
Signalman(banksman) with signal jacket shall be nominated to control the
crane operation and rigging work.
Before work commence, install barricade and warning tape around working
area.
Equipment shall be protected from falling material by covering equipment with
plywood and etc.
Grinding and Welding
1) Fire by spatters
- Flammable materials around cutting area shall be not kept.
- Fire blanket shall be used for flammable materials.
- Fire extinguisher shall be prepared beside working area.
- Watch man shall be nominated and check the working condition
carefully.
2) Injuries by grinding machine
- Only qualified, trained and skilled worker only shall carry on that job.
- Worker shall wear adequate PPE, especially full face shield, retardant
clothes and leather glove.
- The change of grinding disc shall be done by competent person.
- Grinding machine shall be quarterly inspected, color coded. And it shall
17 of 20
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
4) Electric shock
- Electric machine and generator shall be equipped with ELCB and shall
be earthed by 1 m earth stake or to scaffolding
- Welding cable shall be kept dry and free from grease and oil to prevent
breakdown of insulation.
- Welder and fitter shall wear dry coverall, dry safety shoes and dry
gloves.
- Earth cable lines shall properly earthed and well be arranged under
scaffold, platform, working area or arranged 2 meters over from ground
or platform to prevent cable from damage and workers tripping.
5) Toxic Fume
- Adequate exhaust ventilation shall be provided.
- In case adequate exhaust ventilation is not possible, welding should be
carried out by wearing suitable respiratory protection.
6) Bad weather condition
- Secured ladders/man lifts shall be used for main access at heights for
staging.
- SUBCONTRACTOR shall check weather forecast everyday in order to
check the working condition.
9.
-
Back Purging
After welding, the back purged gas shall be removed by compressed air.
Nobody shall enter into the back purged pipe without removing back
purged gas and gas testing.
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
2) High temperature
- Heat area should be barricaded and protected round working area.
- Worker wear adequate PPE, especially gloves around working area.
- Not allow to keep farmable materials around cutting area.
- Prepare fire extinguisher beside working area.
- Do not use damaged PWHT cables and heat band.
3) Fire by over heat
- Not allow to keep farmable materials around cutting area.
- Prepare fire extinguisher beside working area.
- Do not use damaged PWHT cables and heat band.
11.Non Destructive Examination
1) Exposure to radiation
- NDE bunk shall be covered and isolated completely from workers.
- Do not access NDE work area and source.
Permit to work(PTW) of NDE shall be permitted.
The schedule of NDE shall be informed and announced to every
workers in advance.
- NDE work shall be scheduled and executed especially at night or no
work time after workers finish works and go out after work.
- Warning lamp, warning sign and warning tape shall be installed outside
work area before commencing NDE work.
- The source shall be kept well in well protected container if possible far
from working area after operation.
-
11.0
ATTACHMENT
Doc. name
Doc. no
PGLN-YF-KPMTH-90K010-021
Rev.
20 of 20