Total sheets: 19 sheets (Including cover sheet) Subcontractor’s name : WEC engineer & Contractors Pte LTD. Employer : Nghi Son Refinery and Petrochemical LLC. Contractor :JGCS Consortium Zone : ZONE 1 Projectname : NSRP Complex Project Subcontract No. : €NT-6495-SMP1C-001 Document Title : METHOD STATEMENT & JOB SAFETY ANALYSIS FOR STAINLESS STEEL PIPE FABRICATION Contractor's Doc.No. : VV3160-001-C-107 Revision No.: 0 Issue Purpose to Contractor ( FA,FC): FA Review Result Sticker ( Filled By JGCS) RESULT CODE: A, B, R, F ( ) NEXT STATUS: FA,EC ( ) Re-submission Date: C 7 Responsible Dept./ Person ( ) - Construction HSSE a Checked By (Name, Sign): Result Code: Date: Approved by (Name, Sign): ‘A: Approved without Comment; B: Approved with Comments R: Not Approved; _F: Not Subject to Review Issue Purpose Sticker Issue Purpose to Employer: FA, FR, Fl, FC FR Document Class: Z, X, Others x 13 NOV 2016 NSRP PROJECT ~ EDuecs,) te VEC oenneeeray NGHI SON REFINERY AND PETROCHEMICAL PROJECT | Document Title : METHOD STATEMENT & JOB SAFERY Contractor Doc. No: ran ANALAYSIS FOR STAINLESS STEEL PIPE W3160-001-C-107 FABRICATION METHOD STATEMENT & JOB SAFETY ANALYSIS FOR STAINLESS STEEL PIPE FABRICATION DOCUMENT CLASS: X Issue Purpose For Approval NSRP PROJECT 43 NOV 2018 Dp REGEIVED 0 | 13-Nov-2014] Issue for Approval [~f) U Ay o Wy E Rev. | Date Description Prepared by | Checked by | Approved by Responsible Company Prepared by: Checked by: ‘Approved by: WEC Nguyen Xuan Tung Atienza Victor Atienza Victor Page 1 of 18aces; "4=* VEZ consenrruss | NGHISON REFINERY AND PETROCHEMICAL PROJECT Document Title : METHOD STATEMENT & JOB SAFERY Contractor Doc. No: reve ANALAYSIS FOR STAINLESS STEEL PIPE W3160-001-C-107 FABRICATION _ TABLE OF CONTENTS 1. PURPOSE 3 2. SCOPE 3 3, REFERENCES 3 4, DEFINITIONS & ABBREVIATION 4 5, SAFETY 4 6. PREPARATION 5 61 Quality Control 5 62 Fabrication Area 5 63 Equipment / Tools 3 64 — Material Control 5 7. FABRICATION 6 7.1 Marking 7 7.2 Cutting and edge preparation 7 7.3 Bdge preparation for welds 8 74 Fit-Up 8 75 Welding 9 8. THREADED AND SOCKET WELDS 10 9, TOLERANCE u 10. NDE AND REPAIR OF DEFECTS 12 11, PAINTING 13 12. PROTECTION AND STORAGE OF PREFABRICATED PIPE SPOOLS, 13 13, INSPECTION 13 14, PREPARATION FOR SHIPMENT 13 15. SUPPORT FABRICATION 4 APPENDICES APPENDIX: JSA Page 20f 18ag @ > uees| tte. cONsanerun NGHI SON REFINERY AND PETROCHEMICAL PROJECT Document Title METHOD STATEMENT & JOB SAFERY Contractor Doc. No: ANALAYSIS FOR STAINLESS STEEL PIPE W3160-001-C-107 FABRICATION 1. PURPOSE This procedure describes the general requirements for shop fabrication, pipe spool fabrication and inspection in respect of stainless steel piping materials. In addition to, the information contained in this procedure WEC will carry out fabrication to meet the requirements of drawings, technical specifications, standards and codes, as set out in the contract, should there be any conflict between this procedure and contract document, the later shall govern, 2. SCOPE, ‘This procedure shall be applied for piping steel fabrication work in workshop in Nghi son refinery and petrochemical project. 3. REFERENCES $-000-1670-0006V General requirements for field fabrication of piping = $-000-1520-0107V Supplementry welding requirements to API RP 582. - ASME American Society of Mechanical Engineers = ASMEA240 Stainless Steel Plate - ASMEB31.3 Chemical Plant and Petroleum Refinery Piping Code - ASMEB31.4 Oil Transportation Piping = ASMEB31.8 Gas Transmission and Distribution Piping - ASMEB36.10B Welded and Seamless Wrought Steel Pipe - ASMEB16.25 Butt Welding Ends - ASMEBI65 Piping Flanges and Flanged Fittings - ASMEBI6.9 Wrought Steel Butt Welding Fittings - ASMEBI6.11 Forged Fittings, Socket- Welding and Threaded - ASMEBI6.34 —_Valves- Flanged, Threaded, And Welding End - ASME Section IX Welding and Brazing, Qualifications - ASME Section V_ Non-Destructive Examination - ASTM American Society for Testing and Material - ASTM A312 Standard Specification for Seamless and Welded Pipe Austenitic Stainless Steel Pipes Page 3 of 18uccs, 24s * ae NGHI SON REFINERY AND PETROCHEMICAL PROJECT | METHOD STATEMENT & JOB SAFERY Contractor Doc. No: | REV-0 Document Title : ANALAYSIS FOR STAINLESS STEEL PIPE 'W3160-001-C-107 FABRICATION - ASTM A790 Standard Specification for Seamless and Welded Fertitic/ Austenitic Stainless Steel Pipes - MSS: Manufacturer Standardization Society - MSS SP 97 Integrally Reinforced Forged Branch Outlet Fittings- Socket Welding, Threaded, and Butt Welding Ends - AWS American Welding Society 4. DEFINITIONS AND ABBREVIATION wes: Welding Procedure Specifications POR: Procedure Qualification Record wae: Quality Assurance / Quality Control NDI/NDE: Non-Destructive Testing/ Non- Destructive Examination RT: Radiographic Testing MPI: Magnetic Particle Inspection DPE: Dye Penetration Inspection PWHT: Post Weld Heat Treatment Fabrication team: a body, who has responsibility to fabricate pipe works 5. SAFETY Fabrication team shall ensure that all fabrication activities on safe, effective and timely operation in strictly compliance with Project HSE Plan Fabrication team shall work closely with HSE personnel to ensure the safe, effective performance of the activities by all members To ensure a safe working environment forall personnel through the whole of the project period including sub-contractors, equipment vendors All personnel working at fabrication site shall participate weekly HSE meetings and Superintendents and/or Supervisors shall conduct tool-box. meeting daily for direct workforces to ensure safe performance of fabrication activities of pipe works. All equipment, tools used for fabrication works shall be valid calibrated certificates in accordance with Project safety rules and all lifting equipment with suitable color code. To Page 4 of 18sccs) B4s* | WEL consenrrur | NGHISON REFINERY AND PETROCHEMICAL PROJECT Document Title METHOD STATEMENT & JOB SAFERY Contractor Doc. No: REV-0 ANALAYSIS FOR STAINLESS STEEL PIPE WV3160-001-C-107, FABRICATION | censure equipment, tools shall be calibrated and inspected periodically in accordance with Equipment Protection & Preservation Procedure 6. PREPARATION 6.1.Quality Control WEC will provide all supervision and inspection of fabrication works mandatorily to ensure ‘compliance with specification requirements and the relevant codes and standards. Supervision and inspection will meet in accordance with the approved inspection procedure for process piping. All procedures, certificates such as WPS, Material control procedure etc... shall be available at fabrication area or in hand prior to commencement of the works. 6.2, Fabrication Area Stainless steel will be fabricated in the Pipe Fabrication Workshop. Stainless steel will be fabricated in an area separate from that used for carbon steel. 6.3. Equipment/Tools Preparing consumable, required tools/equipment list including hand tools, electrical/ mechanical tools and welding machines etc... that shall be used for fabrication works. Make sure that all tools, equipment shall be valid identification tag and those tools I equipment shall be calibrated periodically in compliance with Equipment Protection & Preservation Procedure 6.4, Material Control All material shall be fully inspected upon receipt to be ensured that the correct grade of material has been supplied and that identification, dimensions, material quality and preparation are in accordance with the requisite standards and specifications. Material found to be defective or incorrectly marked shall be immediately placed in a ‘quarantine area separate from accepted material with sufficient safeguards to preclude it being used and should be marked with QA "HOLD" label. All flange faces including gasket grooves in ring joint flanges shall be protected by plastic cap, plywood or equivalent method before fabrication stage or relocating. After completion of weld, flange face shall be protected again by Rubber, plastic caps or plywood or multi-size canvas bags All materials, whether loose or prefabricated will be stored as per the Material Control Procedure. Materials which have been damaged or found to have defects will not be used except where there are only minor surface marks, in which case WEC will obtain approval from Client The materials shall Page 5 of 18gees, Bvae* WEL falallebatadicheheste NGHI SON REFINERY AND PETROCHEMICAL PROJECT Document Title : METHOD STATEMENT & JOB SAFERY Contractor Doc. No: REV-0 ANALAYSIS FOR STAINLESS STEEL PIPE 'WV3160-001-C-107 FABRICATION bbe dressed provided the min wall thickness is not reduced and the manufécturing tolerances defined in ‘the appropriate material or purchasing specification are compiled with. Radial grooves or scratches on flange faces are not allowed. Re-facing/ machining will require Client's approval Any re-facing that reduces the flange thickness to less than the minimum thickness allowed by the relevant code or standard is rejected. Edge thickness of flange will be checked after re-facing. 7. FABRICATION ‘Spool Fabrication Sequence Flowchart Page 6 of 18JGCcs B“9 g > NGHI SON REFINERY AND PETROCHEMICAL PROJECT VEC | Document Title : METHOD STATEMENT & JOB SAFERY Contractor Dos. No: REVO ANALAYSIS FOR STAINLESS STEEL PIPE W3160-001-C-107 FABRICATION 7.1 MARKING Marking shall be marked for identification and traceability purposes for each process till completed pipe spool as following: Traceability and Identification shall be identified specifically as matrix table below MARKING MARKING | MARKING CONTENTS. ae FREQUENCE | METHOD MARKED Cua Offent piece Engraving or | Sheet No. a Marker pen Material grade Allocetd joint No, Welds on Marker pen welder / welding pipe spool Each weld Colour band | operator ID Number Marker Pipe spool Each marking components | Component colourband | Spool Number or Tagging Bach spool or | Colour band | Isometric Number ee Sub spool Tagging Spool Number pipe spool me Note: Tag plate shall be made of stainless steel sheets attach to complete fabricated spool and secure by Stainless steel wire. 7.2 CUTTING AND EDGE PREPARATION Stainless steel shall be cut by methodology of flame cutters, high speed cutter, grinders or band saw machines. Stainless steel shall be cut by a high speed cutter, grinders or band saw machine, All cutting tools shall be compatible with stainless stee! materials to avoid any contamination. All materials cut by a flame or are shall. have the edge ground back to clear the affected zone. ‘The grinding wheel is marked by an impregnated red dye inthe make-up of the disc, which denotes chloride and sulphur free material when used for stainless steel and high alloys steel. Page 7 of 18JGCcs | B43 o> VED censenrrum | NGHISON REFINERY AND PETROCHEMICAL PROJECT Document Title : METHOD STATEMENT & JOB SAFERY Contractor Doc. No: REV-0 ANALAYSIS FOR STAINLESS STEEL PIPE 'W3160-001-C-107 FABRICATION _ Wire brushes with stainless steel bristles will be used, dedicated to stainless steel and high Alloy materials. Files for use on stainless steels and non-ferrous alloys shall be NEW and dedicated toa particular alloy only. All edges shall be accurately maintained as per design requirement with a smooth even surface with all slag removed. Bevelling will be performed with a bevelling machine or grinder. Separate bevelling machine or grinder will be used for stainless steel and stainless steel. Preparation will be in accordance with the approved WPS. 7.3. EDGE PREPARATION FOR WELDS The preparation of edge for welding shall be done by machining or grinding. Edge preparation shall be performed in accordance with the approved WPS & ASME B 31.3. The surfaces of the edge preparation shall be free from tears, grease, oil slag, scale or internal burrs. Stainless steel and high alloy pipe shall be bevelled by a grinding or bevelling machine only. Separate bevelling machine or grinder will be used for carbon steel and stainless stec! 7.4 FIT- UP ‘Alignment forthe fit-up of the piping components shall be executed For stainless steel and high alloy spool fabrication the floor on the fitting tables will be covered with wooden planks or rubber. All stands will be insulated with clean rubber sheeting to prevent contamination of the stainless steel and high alloy pipe spools. Under no special circumstances stainless stecl, high alloy & non-ferrous materials shall be allowed to come into contact with stainless steel. Pipes shall be properly supported at least 1 meter off the ground and aligned by jigs or clamps in order to eliminate strains prior to tack welding. Where jigs or clamps are used for stainless steel and high alloy pipe spool fabrication, these items will be lined with clean rubber or stainless steel material to eliminate the possibility of contamination with other material. ‘The number of welds in a spool shall be minimized as less as possible. Minimum spacing of circumferential welds between center line shall not be less than four (2) times the pipe wall thickness, or at leat 40mm which is greater. Circumferential butt welds closer than the limits described above shall be brought to the attention of the Company for approval Branch nozzle and other pressure attachment welds shall not be close than ¥/(Dxt) mm to adjacent pressure welds. Any case which fails to meet this criterion shall be brought to the attention of the ‘Company for approval prior to commencement of fabrication / welding. Longitudinal welds of adjacent pipes shall be staggered by 30° or 75mm in circumferential length of pipe whichever is greater. Page 8 of 18,sees; 542” VEZ eae NGHI SON REFINERY AND PETROCHEMICAL PROJECT Document Title : METHOD STATEMENT & JOB SAFERY Contractor Doc. No: REV-0 ANALAYSIS FOR STAINLESS STEEL PIPE 'W3160-001-C-107 FABRICATION The bolt holes of flanges shall straddle the normal horizontal and vertical centerline of pipe. Holes for attachment of weldolets and nippolets shall be made by using cutting torch or drill sand all burrs shall be removed. 7.5 WELDING All welds shall be performed in accordance with the approved WPS, which shall be displayed on a notice board close to the work. Welding activities shall be done by qualified welders. ‘The welding grooves shall conform to the ASME 831.3, ASME 816.25 and the approved WPS. All edges of surfaces to be welded shall be cleaned to a bright metal finish, in a manner suitable to remove any oxides, scale, grease, oil, or contamination due to heating torch or machining. Oil, paint ‘and dirt shall be removed from the pipe surface at least 25mm from bevel. Stainless steel wire brushes shall be used for all other metal materials except stainless steel and low alloy steel. No sealing or back-up rings shall be used. ‘Any cracks, blowholes, cold laps, unusual irregularities, slag, flux, or other impurities that appear onthe surface of any welding bead shall be removed by grinding or chipping before depositing the next successive bead. ‘The requirement of the finished weld reinforcement for all materials should comply to ASME B31.3 specification for piping. ‘Two welders may be required on pipe o6 inches and above, if necessary , pipe to be marked with welder's ID. No. for area welded. Ifare strike occurs, this shall be removed by grinding followed by MPUDPL. For new piping , the acceptable wall thickness is the thickness as calculated inclusive manufacturing tolerances, corrosion and erosion allowances. If pipe is on ground severely to repair, the damaged part of the pipe shall be removed. - No undercut or overlapping (cold lap) is permitted. = Weld projection and depression. ‘The specification for weld projection and depression should be in accordance to ANSI B31.3, Table 341.3.2, as applicable. - Preheating and inter pess shall be maintained as per the approved WPS. - Peening and hammering of weld runs is prohibited. - Branch connections and outlets: Page 9 of 18uccs, 4=* Wer consonrrym — | NGHISON REFINERY AND PETROCHEMICAL PROJECT Document Title : METHOD STATEMENT & JOB SAFERY Contractor Doc. No: REV-0 | ANALAYSIS FOR STAINLESS STEEL PIPE W3160-001-C-107 | FABRICATION a. Welded branch connections shall be jointed to the header with full penetration welds. b. Stub-in connections shall be set-on type as per ANSI B 31.3, Fig. 328.5.40. Reinforcement pads or saddles required by specifications and drawings shall be of the same material as the main pipe (unless specified otherwise) and shall be formed and countered to provide a good fit to both main and branch pipe. d, Branch reinforcement pads or each segment there of shall be provided with a minimum 3.0 mm drilled and/or tapped hole prior to fitting to the pipe, so ensuring leak detection, venting and testing facilities. Whenever possible, pad should be made in one piece before fitting onto pipe. ¢. Attachment welds of non-pressure parts by welds which cross existing main welds or for which the distance between the attachment weld toe and existing main weld is less than ‘50mm should be avoided. If unavoidable, the area to be welded over shall be subject by 100% radiographic or MPI as directed by WEC and witnessed by Client. After welding the welds and adjacent area shall be similarly examined, Qualification of welders and welding operators. a. All welding procedures, welders & reference to be used shall be qualified in accordance with ASME B31.3 in paragraph 328.2 Welding Qualification b. Performance qualifications will be carried out for all welders and welding operators in accordance with the requirement of ASME IX. c. All welders should always keep their identification cards at all times with their name and number plus a photograph, signed by WEC. 4. The qualification limits and ranges for WPS/ PQRs and welders will to be based on ASME IX. e. The acceptability of the test weld shall be judged as follows. Visual inspection by inspector. Root bead and surface of weld. Burn thru during application of hot passes and subsequent passes, after visual acceptance, is cause for immediate disqualification. Radiographic examination or bend test in accordance with ASME B31.3. Stainless Steel after welding shall be picked and passivized in accordance with approved procedure. 8, THREADED AND SOCKET WELDS Threads shall be concentric with outside of pipe, per ASME 831.3, tapped and cleaned out. All surfaces of threaded joints shall be carefully examined damages of thread and continuity of thread before connection, and any dust, oxide and grease shall be removed and shall be rejected if not in conformance with ASME 81.20.1 or other applicable standards When socket weld fittings are used, pipe shall be spaced approximately 1/16 inch (1.6mm) away from the "bottom" of the socket. Minimum gap to be 3/64 inch (12mm) and Page 10 of 18gGes| "42 * WEL gewsontrve | NGHISON REFINERY AND PETROCHEMICAL PROJECT [Document Title : ] | METHOD STATEMENT & JOB SAFERY | Contractor Doc. No: Rev ANALAYSIS FOR STAINLESS STEEL PIPE | wv3t60-001-c-107 FABRICATION maximum to be 1/8 inch (3.2mm) in accordance with ASME B31.3. Use gap-a-let (washer-ring) for socket joint instead of RT. - All threaded joints, where no seal -welding is provided, shall be packed with fiber reinforced gasket-seal compounds (Loctite 567 or 577 or equal). - Screwed connections subject to seal welding shall be made without the use of sealing compound. - Seal welding of threaded connections, when specified, shall include the first block valve, cover all threads and be done with electrodes not to exceed 1/8" inch (3.2 dia) in diameter. = The joint shall be cleaned of all cutting oil and other foreign material and made up dry to full thread engagement before seal welding. 9. TOLERANCE The dimensional tolerance should be in accordance with figure below. Page 11 of 18gecs ae VEL powsaneryn NGHI SON REFINERY AND PETROCHEMICAL PROJECT Document Title METHOD STATEMENT & JOB SAFERY Contractor Doc. No: ANALAYSIS FOR STAINLESS STEEL PIPE 'W3160-001-C-107 FABRICATION. (Ke eee amet et Isbrooose oo gineering litte get SERS 8 BIER ES ShecattE ER Ree 6 teste sce sal st devote frome 2 ONG US Whats Ge Rosas oe” Hebets Beaton 10. NDE AND REPAIR OF DEFECTS. - Extent of welding test shall be examined in accordance with drawing indicated. - All final examinations shall be performed after any required post weld heat treatment. - Root concavity is not permitted. (Too restrictive - follow ASME B31.3 table 341.3.2, as applicable) ~ Undercut shall be limited to 0.5mm occasional, intermittent. No internal undercut is allowed. - NDT and visual inspection should be performed in accordance to ASME B 31.3 and ASME. Section V for piping. ~The surface of repair welding will be cleaned thoroughly before welding in accordance with applicable W.P.S. - All repairs shall meet the inspection requirements and acceptance standards for the original ‘material. Major repairs shall be inspected by Company who shall be notified at least one day in advance of starting the repair. The definition of a major weld repair is to be taken as either a removal of more than 50% of the wall thickness or a length of more than 150mm in one or more Page 1201 18] = segs), 242 * VEL NGHI SON REFINERY AND PETROCHEMICAL PROJECT | Document Title : ] | METHOD STATEMENT & JOB SAFERY | Contractor Doc. No: Reve | ANALAYSIS FOR STAINLESS STEEL PIPE 'W3160-001-C-107 FABRICATION | directions or a total surface area of all repairs exceeding 20% of the total casting surface area. Prior to repair welding, preheating around the repair area will be as per the approved WPS. Repair welding shall be performed in accordance with repair procedure. Temperature of preheating for Stainless steel repairs shall be in accordance with the approved welding procedure 11. PAINTING ‘A protective coating will be applied in accordance with the Specification and Painting procedure. Before installation, all piping spool welded joints, which carried out at the painting shop shall be fall coated with specified paint system except field welding areas. During transferring of spools from paint yard to pipe stock yard and subsequently to the deck for installation, handling and preservation shall be exercised carefully to prevent damage to paint coating using soft slings and canvas 12, Protection and storage of prefabricated pipe spools Upon delivery of prefabricated pipe spools, checks by visual shall be made to ensure that all ‘end covers are in place to prevent ingress of dirt and moisture and no welding defects and damages found. After final completion and acceptance of pipe spool fabrication and NDE activities, stainless steel pipe spools will be transferred to the painting area. Before transfer to painting area, pipe spools shall be attached stamped stainless steel tags and blown thru or internally swabbed to remove contaminants and providing with rubber end covers. After completion of painting, the painted pipe spools shall be stored on pallets as per the pallet control system. After completion of fabrication, the stainless steel, high alloy pipe spools are transferred to the pipe stock yard directly and segregated from stainless steel spools for protection and storage or transferred to painting area if required in accordance with project procedures Spools for yard installation: All pipe spoot ends will be protected by caps, plywood or equivalent methods attached to flanges. All male/female threads should be protected using waterproof tape or equivalent materials to prevent damage to the threads. 13, Inspection Inspection will be done in accordance with the Project specification and the approved inspection procedure for process piping. 14, Preparation for Shipment Stainless steel & Low-alloy ferrite steel Page 13 of 18JGGS cONsaRTINM ag @ P as ¢ > | WEL NGHI SON REFINERY AND PETROCHEMICAL PROJECT Document Title : | METHOD STATEMENT & JOB SAFERY | Contractor Doc. No: REV-0 ANALAYSIS FOR STAINLESS STEEL PIPE | W3160-001-C-107 FABRICATION ~ Stainless steel flange face, including gasket grooves in ring joint flanges, shall be cleaned of all mill scale, rust etc and shall be coated with rust inhibitor to prevent rust formation. = Stainless steel spools with beveled or grooved ends shall be thoroughly cleaned and coated with rust inhibitor to prevent rust fabrication. ~ Stainless steel, High alloy & non-ferrous material. = All beveled and grooved ends shall be prepared as per the paragraph 10.0 above, except that ends do not require the rust preventive coating 15, Support Fabrication In general, all support fabrication works shall be in accordance with approved support drawings and pipe support standard. 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