METHOD STATEMENT – Stainless pipelines CWWTP Vrbas and Kula1.0 Purpose To define method of installation of the following pipelines that has to be made of stainless steel AC-EBR-1100-0450-B30; AC-EBER-1200-0450-B30; AC-EBR-1300-0450-B30; AC-EBR1400-0450-B30; BB-EID-1000-0080-B30; BB-EBR-1000-0800-B30; BB-EBR-2000-0800B30; HD-APR-1100-0450-B30; HDP-APR-1200-0450-B30;HD-APR-1300-0450-B30; HDAPR-100-0600-B30; HD-APR-1000-0400-B30; HD-APR-2000-0400-B30; DA-APR1001—0350-B30; DA-APR-2001-0350-B30; DA-APR-1002-0300-B30; DA-APR-20020300-B30; DA-APR-1003-02500-B30; DA-APR-2003-0250-B30; DA-APR-1004-0200B30; DA-APR-2004-0200-B30; DA-APR-1005-0150-B30; DA-APR-2005-0150-B30; DEBBI-1100-0080-B30; DE-BBI-1200-0080-B30; DE-BBI-1300-0080-B30; DE-BBI-30000125-B30; DE-BBI-1100-0500-B30; DE-BBI-1200-0500-B30; DE-BBI-1300-0500-B30; DE-BBI-1400-0500-B30; HB-EID-1000-0200-B30; HB-EID-2000-0250-B30; GA-EPO1000-0020-B30 2.0 Scope The method is applicable for stainless pipelines in CWWTP Vrbas and Kula Municipalities. 3.0 Method General Check all pipes and fittings to be used for joint are free from defects, dents or deformities and are straight. Remove pipes and fittings with defects and replace with acceptable materials. Remove foreign matter or dirt from inside of the pipe and fittings before fit up. For longer work breaks, place suitable stoppers to prevent debris, earth or water from entering pipe open ends. Welding electrodes shall be stored and handled as per Manufacturer’s instructions. Pipe Joint Preparation Cut the pipes to the required length using an appropriate pipe cutter, or profile cutter, allowing for provision of pipe fitting later. Works shall be carried out in accordance with the approved shop drawings. The pipes shall be checked by the assigned foreman for its squareness and straightness, after being cut to the correct angle and site requirements, as per sample of welding details in Figure 1 shown below. Figure 1 – Sample of Welding Details . . Place the spirit level over both pipes as shown on Figure 2 and maneuver until both pipes are leveled. Adjusting the pipe support can easily do this. Remove the adjustable bolt stoppers after fit up and grind flush all tack welded points making sure that there is no over grinding of the base metal. with each pipe ends aligned near each other using adjustable bolt stopper as shown on Figure 2 below. Repeat the same procedure. Rotate the pipes 90°.Pipe to Pipe Fit Up • Lay the two (2) pipes on top of the pipe stand or adjustable support. a welding electrode of 2. It is recommended to weld adjustable bolt stoppers (small piece of plate about 12 mm thick with an M-16hexagon bolt and nut welded at one end as shown in Figure 2) for perfect and easy alignment. In normal practice.4 mmØ size. removed of its covering and bent in the middle at an angle of 30° is inserted between the two pipes to obtain a perfect welding gap. Tack weld at the top and bottom. Bring lengths together leaving only small welding gap. Figure 2 –Pipe to Pipe Fit Up Level one length of pipe using spirit level. Ensure that there is no high-low situation or misalignment between the two outside surfaces. 45° Elbow to Pipe Fit Up Layone (1) pipe on top of the adjustable pipe support.3 for Pipe to Pipe fit up. similar to item4.3. Tack welds in place both the pipe and the elbow. Place a 45° spirit level on the face of the elbow until bubble is centered and ensure that there is no high-low situation or misalignment Between the two outside surfaces. Place the 45° elbow to the end of the pipe leaving a small welding gap. Level the pipe using spirit level. Figure 3 -45° Elbow to Pipe Fit Up . 90° Elbow to Pipe Fit Up Layone (1) pipe on top of the adjustable pipe supports. Figure 4 -90° Elbow to Pipe Fit Up . Level the pipe using spirit level. Place the 90° elbow to end of the pipe leaving a small welding gap the same as item4.3. Tack weld in place both the pipe and elbow. Place a spirit level on the face of the elbow and maneuver the elbow until it is leveled and ensure that there is no high-low situation or misalignment between the two outside surfaces.3 for Pipe to Pipe Fit up. 3. Figure 5 -Tee to Pipe Fit Up . • Place the tee at the end of the pipe leaving a small welding gap the same as item4.Tee to Pipe Fit-Up • Layone (1) pipe on top of the on the adjustable Pipe supports. • Level the pipe using spirit level. • Place a spirit level on the face of the tee and maneuver the tee until leveled and ensure that there is no high-low situation or misalignment between the two outside surfaces.3 for Pipe to Pipe fit up. • Tack weld in place both the pipe and tee. Bring the flange at the end of the pipe leaving a small welding gap the same as item4. If a slip-on type of flange is to be used.Flange to Pipe Fit-Up Layone (1) pipe on top of the adjustable pipe support. insert the pipe to the flange bore up to 5mmdepth from the flange face to give enough space for a fillet weld.3 for Pipe to Pipe fit-up (In case a Weld neck type of flange is used).3. Align the top two (2) holes of the flange with the spirit level. Figure 6 -Flange to Pipe Fit Up . Tack weld in place the pipe and flange. Level the pipe using spirit level. TYPICALDETAILS OFADJUSTABLE BOLT STOPPER USE FOR PIPE FIT UP and ALIGNMENT Figure 7 . . Figure 7 – TIG welding After welding process passivation procedure of welded joints has to be done as it follows.Welding of stainless will be performed in TIG technology in protective layer of inert gas. Brief individual worker the roles and responsibilities of each. Ensure all tools to be used have been inspected and tag by Safety Dept. Ensure designated hoisting area is cleared of obstruction. . Pipe Lifting Ensure safe work procedure for lifting operation is observed. and well versed on the job at hand with the latest revised drawing/s. Pick up and dispose wastes & other debris prior to leaving site area. Housekeeping Maintain cleanliness and orderly stocking of materials & tools. Ensure all workers assigned are involved in its particular task. Ensure that equipment to be used are properly tagged and checked.0 Health. Ensure pipe support systems are installed accordingly as required. Ensure transporter route is cleared of obstruction. Nylon String Line.with the correct equipment are used. with the correct PPEs. Ensure the pipes are firmly placed on the designated location before releasing the hoisting hook. Brief individual worker the roles and responsibilities before start work.EQUIPMENT AND TOOLS Boom truck Chain blocks (1Ton – 5Ton Cap. Ensure all workers involved in the hauling operation put on PPEall times. The lorry transporting the pipes will be guided to the designated hoisting area and released all the latching belts only after the lorry parked firmly. Coordinate with Construction Department for Pipe Hoisting area. Ensure work areas are clearly marked to restrict access to authorized personnel only. Coordinate with Safety Department for delivery trucks access routes. Safety and Environment Measures RISK ASSESEMENT Preparation Notify all concerned in site for the date of material delivery.) A-frame(steel fabricated) Nylon sling or straps(New and tested) Set of shackles Adjustable bolt stopper Adjustable pipe supports Spirit level Alignment Tools (Plumb Bob. Chalk line. Ensure that welders are qualified. Felt Tip Marker) Welding Personnel Protective Equipment Hand tools Steel measuring tape Angle & Straight Grinders Welding Machines Steel Scaffolding and Ladders 4. Ensure workers at all times to be in proper gear where required. During Site Execution Ensure workers are distributed to each designated place. Ensure proper lifting method . Remove safety yellow tape or other warning devices that were used to control access to the work area. Ensure the pipe lengths to suit site routes into designated work area. 5 Safety Inspections It shall be responsibility of the Supervisor to routinely inspect the physical areas under their control in pipe welding works. supports. 5. and if the job site is cleaned up after the day’s work. equipment and unused materials properly at the end of the workday. This inspection shall include determining if pipes. scaffolds and ladders are appropriately installed and/or use. Enclosures: VRB-S01-MAI-000 (Delivered to Supervisor) VRB-S02-MAI-000 (Delivered to Supervisor) VRB-S03-MAI-000 (Delivered to Supervisor) VRB-S04-MAI-000 (Delivered to Supervisor) VRB-S05-MAI-000 (Delivered to Supervisor) VRB-S06-MAI-000 (Delivered to Supervisor) VRB-S07-MAI-000 (Delivered to Supervisor) VRB-S08-MAI-000 (Delivered to Supervisor) VRB-S09-MAI-000 (Delivered to Supervisor) VRB-S10-MAI-000 (Delivered to Supervisor) VRB-S11-MAI-000 (Delivered to Supervisor) VRB-S12-MAI-000 (Delivered to Supervisor) Subcontractor’s welding technologies Attestations for welders . Store tools.