METHOD STATEMENT

WELDING WORKS
Project: Utility Plant & Distribution and East Midfield & Perimeter Roads

Doc. No. Issue Date: Rev.:00

Prepared By: Mr.

Designation: Sign:
QA/QC Engineer
Date:

Approved By: Mr.

Designation: Sign:
Project Manager
Date:
AMENDMENT SHEET

ISSUE PAGE # SUBJECT OF THE AMENDMENT AMENDED BY DATE

1 First Issue

CONTENTS

1. PURPOSE..............................................................................................................................3

2. SCOPE ...................................................................................................................................3

3. ROLES AND RESPONSIBILITIES .....................................................................................3

4. DEFINITIONS ......................................................................................................................4

5. SIGNIFICANT HAZARDS IDENTIFIED ...........................................................................5

6. INTERFACING ACTIVITIES..............................................................................................5

7. PROCEDURES .....................................................................................................................5

8. EMERGENCY PROCEDURES .........................................................................................10

9. HSEQ ...................................................................................................................................10

10. MANAGING CHANGES ...................................................................................................11

11. REFERENCE DOCUMENTS ............................................................................................11

12. ATTACHMENT ..................................................................................................................11

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1. PURPOSE

The purpose of this method statement is to provide standard working procedures for carrying
out Welding Works to ensure that the works and related activities are executed in accordance
with the contract requirements, hazards are analyzed and precautions are implemented and that
all quality assurance / control activities are conducted in a systematic manner, works inspected
and documented.

2. SCOPE
The scope of work relevant to this method statement involves Welding Works for Utility Plant
& Distribution(UP &D) and East Midfield & Perimeter Roads(EMPR)

3. ROLES AND RESPONSIBILITIES

Project Manager

• Bears overall responsibility for timely & Quality execution of works with effective use
of resources & manpower.
• He has overall responsibility to ensure all activities are in accordance with the relevant
Contract specification and the Method statements.
• Responsible for the quality related works to be done according to the PQP and advise
QA/QC Engineer for any change or addition in the PQP and ITP.
• He shall arrange and confirm the date for the testing and disinfection.
• He shall approve all the materials required.
• The Project Manager will have the overall responsibility for safety on the project,
ensuring that all aspects of the HSE plan are implemented and adhered to.
• He will ensure that all reasonably practicable measures are taken to protect and promote
the health and welfare of the workforce and to protect the environment.

Project / Site Engineer

• Responsible to carry out all Quality related activities in accordance to the Project
Quality Plan & originate reports.
• He shall ensure the correct setting out.
• He shall provide necessary information and distribute responsibilities among the teams.
• He is also responsible to originate Inspection requests & Checklists (if applicable) on
completion of each activity as mentioned in the ITP & maintain Inspection & test
reports.
• Responsible to ensure all operations are in accordance with the relevant ADAC contract
specifications and the method statement.
• Responsible to ensure works are carried out as per the project specifications.
• Responsible to ensure approved materials are used for the works.
• Ensure adequate measures are taken for traffic management in applicable areas.
• He shall update the method statement as required.

QA/QC Engineer

• Responsible to monitor the implementation of Project Quality Plan, Inspection test plan
& report forms in the project.

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 • Responsible for inspecting all the measuring equipments, having them calibrated and
records maintained.
• Responsible to monitor the materials and equipments used are approved and certified as
necessary.
• Responsible for notifying the Engineer for inspections & tests.
• All QA/QC documents shall be filed and proper document list shall be made available
for easy access of the same.
• He shall ensure all activities done are in accordance with the relevant Contract
specification and the approved Procedure/Method statements.

HSE Engineer/Officer

• Under the directions of the Project Manager, he will ensure that the HSE plan and other
safety information, along with work methodology is distributed and understood by the
discipline field supervisors.
• Assist for delivering toolbox talks or task specific talks by the supervisor/ foreman to
their teams daily.
• Responsible to conduct HSE induction training to all new employees before assigning to
work.
• He will conduct risk assessments and train the employees for all relevant activities under
their control and record the same.
• Responsible to take appropriate measures to eliminate / minimize or protect against all
identified hazards to ensure protection of workers involved in all tasks.
• Issue permit to works for permit required critical activities (Pressure test) after ensuring
all control measures are in place.
• Ensure adequate personal protective equipments are provided to all the employees.
• Ensure the welfare facilities are provided for the work force.
• Co-ordinate with the Engineer for effective implementation of HSE at site.

Foremen/ Supervisor

• Co-ordinate with the project engineer for work activities and ensure they are done in
accordance with the relevant Contract specification and the approved Procedure/Method
statements.
• Ensure all equipments used for the work in good condition and have the valid documents
including test certificates.
• Inspect their teams P.P.E.s to ensure it is appropriate to the task at hand and replace any
damaged or expired items and conduct task specific tool box talks daily before start of
shift.
• Deliver the task specific tool box talk and record attendance of the crew prior to start the
activity in each shift.
• Participate in hazard identification within their work area, report any protectively
hazards and ensure all persons under their control are aware of these hazards and of the
measures needed to eliminate, minimize or protect against them.
• Maintain all accident preventive measures in place and report any incidents as required.
• Ensure adequate warning/ instruction signs are posted at relevant locations.
• Report work progress on daily basis to the project engineer and QA/QC Engineer.

4. DEFINITIONS
CLIENT -

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 ENGINEER -

PQP - Project Quality Plan

ITP - Inspection Test Plan

PPE - Personal Protective Equipments

PTW - Permit to Work

5. SIGNIFICANT HAZARDS IDENTIFIED

➢ Fire and less chance of explosion
➢ Electrocution
➢ Fall of person/ materials
➢ Slip/trip hazards
➢ Chemical hazards
➢ Mishandling of hand tools
➢ Manual handling
➢ Ergonomically hazards.
➢ Working near road traffic
➢ Working unsafely too close to the public
➢ Extreme Environmental conditions such as high temperature and humidity
➢ Dust

6. INTERFACING ACTIVITIES
Interfaces with existing utilities if any will be identified at all locations and NOC, PTW,
etc. will be obtained from HLG. The identified activities shall be carried out only under
the supervision of competent person.

7. PROCEDURES
7.1 WELDING PROCESS
• Only mentioned below welding processes to be used under this procedure.
• The allowable welding process are indicated in the Welding Procedure Specification
(WPS)
• The WPS shall be in accordance to the requirements of the ASME Sec. IX Code.
• The acceptable welding process.

o Shielded Metal Arc Welding (SMAW)

• The above process may be used in combination, but the PQR must be in accordance
with requirements in paragraph QW -200.4 ASME Sec. IX Code.

7.2 WELDING EQUIPMENT

• Welding machines shall be direct current (DC) Type.

• Any DC Welding power source capable of sustaining a stable area over the range of
current prescribed in the welding procedure may be used with this procedure.

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 7.3 FILLER MATERIAL

▪ All Filler materials shall be selected regarding the mechanical and

chemical requirements of the base material to be jointed.

▪ All electrodes shall be purchased in a hermetically sealed container. Low

Hydrogen electrodes removed from containers shall be baked for 1 hour
at 300o C, or as per manufacturer recommendation, before transfer to a
holding oven at a temperature of 110o C to 150oC.

▪ On issue to the welder, electrodes shall be transferred directly into the

welders holding box maintained at a temperature of 70oC until use.

▪ Electrodes not used by the end of shift shall be discarded.

▪ All Electrodes and Welding wire shall conform to the WPS.

▪ For each type of filler material which shall be in fabrication or erection,

certificates with chemical and mechanical analysis shall be available.

▪ Electrodes and Filler wire must be readily identifiable and each type kept
separate from all other type of different consumables.

▪ All Filler Material must clean, dry and properly stored according to the
manufacturer recommendation.

▪ Filler material which may have become contaminated or cannot be

positively identified or have not certificate shall not be used and must
be discarded.

7.4 SHEILDING GAS

• Shielding and purging gases employed in welding shall have a nominal composition
and purity according to according to the indication of the WPS.

7.5 WELD JOINT PREPARATION

• Preparation type of welding joint shall be performed in accordance with the WPS.

• Weld bevel may be made by machining, grinding or flame cutting that surface shall
be reasonable smooth and true. Flame cut surface shall be grounded back 1.5mm
minimum to remove heat affected zone and oxides, dross etc.

• All surface to welded shall be free of point, oil dirt, scale, oxides and all other
foreign matter they may be determined to weld quality.

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 7.6 WEATHER CONDITIONS

• In the case of wind or dust is present, proper protection shall be provided for
the parts to be welded. Without proper protection of welding area, welding
is not allowed.
• Should the surface to be welded be we, welding can be performed only after
drying up the joints.

7.7 PREHEATING

• Depending of the type of material and the wall thickness, preheating shall
be performed according to the WPS.

• Oxy-acetylene welding or cutting torches shall not be used for

preheating.

• Once welding has commenced it shall continue until the weld is

complete.

• On commencement of welding on a partially completed weld, preheating

shall be applied as stated in the WPS.

• The specified temperature shall be maintained during welding and

checked by temperature indication crayon or digital thermometer or one
equivalent method.

7.8 WELDING PROCEDURE SPECIFICATION (WPS)

• WPS shall be performed as per ASME Sec, IX Code- Last Edition, for Procedure
Qualification Record test and for production welds.

• WPS is written to show the methods, techniques and essential variables to be used
during welding.

• WPS for production shall be formulated from the information records on PQR,
specifying the limits of the essential variable as defined by the code and PQR.

7.9 PROCEDURE QUALIFICATION RECORD (PQR)

• PQR is record of the Welding Data used to weld a test coupon. It also contains the
mechanical and chemical test result of the tested specimens.

• PQR shall be performed in accordance with ASME Sec. IX Code.

• The PQR shall be approved by one authorized company ( Loyds, Bureau Veritas, TUV,
DNV Etc)

7.10 WELDER PERFORMANCE QUALIFICATION (WPQ)

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 • The performance qualification intended to determine the ability of welders to make
sounds welds.

• The WPQ shall be approved by an authorized company in accordance with ASME

Sec. IX Code.

• The qualification of welders shall be in accordance with WPS.

• The record of WPS shall include all requirements in accordance with ASME Sec IX
Code.

• Each welder shall be assigned an identifying number which shall be used to identify
the Welder.

• Each welder who welds under this procedure shall be qualified by visual
examination and radiographic examination.

• The radiographic technique and acceptable criteria shall be as per ASME Sec. IX or
Sec. V Code.

7.11 WELDING

• Welding shall be performed in such a way as to ensure complete fusion of welding filler
metal and the base material to achieve a homogeneous bond over the entire cross
section.

• The GTAW process may be used for Butt and Socket joints. All fillet welds shall have a
minimum of 2 passes.

• The root pass for butt welds shall be made travelling upward

• Each and every welding shall be performed by qualified welders using the source type
techniques as for root pass welding.

• Tack welds shall be provided in sufficient number. Tack welds shall be completely
removed by grinding before welding or ground to a feather edge and inspected before
welding.

• During welding or austenitic stainless steel material, preference shall be given to bridge
tacks ( outside the root area) which shall be removed by grinding.

• Where larger wall thicknesses are being used the root and hot pass may be deposited
using GTAW, the all subsequent passes shall be deposited using the SMAW process.

• For SMAW process, pass sequence will be established during welding procedure
qualification and sketched or the WPS.

• The actual number of passes and layers will vary with inter-pass grinding , welding
position and material thickness.

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 • Arc strikes and stops

• The arc shall be established in the weld groove to start each weld.

• Accidental arch strikes on the base metal outside the joint preparation shall be
avoided.

• Arc strikes on the base metal shall be removed by grinding and NDT carried out. The
minimum design thickness, including corrosion allowance shall not be reduced.

• All stop and start shall be visually examined, before applying a subsequent weld pass.

• All welds shall be identified by a weld number marked on the parent material

• All welders shall mark the weld with their identification number marked on the parent
material welder completes the weld they should indicate which portion to the weld is
attributed to each welder.

• When welding low alloy or austenitic stainless steels, purging shall not be removed until
after completion of the second (hot) pass.

7.12 WELD REPAIRS

• Unacceptable discontinuance shall be completely removed by chipping, gouging

or grinding.

• Repairs to correct weld, defects shall be made using the same procedure used for
the original weld.

• No crack shall be removed without the authorization of the welding engineer.

7.13 INSPECTION

Visual Inspection

• Prior to welding the end preparation, Fit-up and clearance dimensions shall meet
the requirements as specified on the welding procedure (WPS).
• During welding each weld shall be inspected and repaired in necessary before the
root process is deposited. Each layers of deposited weld metal shall be inspected.
• After welding the completed weld joint shall be visually inspected.

Liquid Penetrant Inspection.

• All liquid penetrant inspection ( PT) shall be in accordance with the ASME Sec.
V code or as per project specification.

• Percent of PT inspection shall be as per project specification.

Radiography Examination

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 • All radiographic examination shall be performed in accordance with the ASME
Sec.V Code or as per project specification.

• Percent of Radiography inspection shall be in accordance with project

specification.

• Acceptable standard of welds that are shown by radiography, shall be in

accordance with project specification.

Personnel Qualification

• Personnel performing NDT shall be qualified in accordance with the latest

edition of American Society for NDT recommended practice SNT-TC-1A and or
equivalent internationally acceptable certificate.

• Only individual qualified for NDT level 1 and under the supervision of a level
2 or individual qualified for NDT Level 2 may perform NDT.

8. EMERGENCY PROCEDURES
In case of any HSE incidents requiring an emergency response, the procedures as stated in
the HSE plan shall be followed. Third party trained first aiders and fire fighter shall be
available to respond for any emergency situation may arise during the works. The
emergency contact numbers will be communicated to all employees. The risk assessment for
the activity shall be communicated to employees.

Emergency Contact Nos:

Police -999
Fire -997
Ambulance -998

9. HSEQ
In-order to achieve the targeted objective ‘zero lost time injury’ the work crew will be provided
awareness training to follow the safe work procedures. The method statement and risk
assessment shall be in place of the work and shall be strictly followed without any short falls.
Tool box talk training shall be provided to the work team prior to start the works. Personal
protective equipments requirements shall always be in compliance with and all personnel
involved in works shall wear company's coverall, safety helmet& safety boot. In addition to the
above PPEs respiratory masks, ear protector equipment, safety goggle, etc. shall be used as
necessary. It shall ensure that all safe practices are adhered to, as per ADAC rules and
regulations while carrying out all activities. In-addition to the above control measures, the
following points shall be considered:

➢ Continues supervision shall be ensured.

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➢ The testing area shall be barricaded and unauthorized entry shall be prevented.
➢ A work permit shall be obtained prior to start any pressure testing work.
➢ Adequate warning signs such as “RESTRICTED AREA” shall be displayed.
➢ All the equipments used shall be inspected prior to use and must be in good condition and
necessary certificate shall be available.
➢ All chemicals shall be carried in labeled container and MSDS shall be available.

The works shall be carried out in line with the contract specific requirements and the Inspection
test plan for the work will be followed. Inspection Test Procedures shall be according to the
attached Inspection & Test Plans (Refer to the Annexure-I).

10. MANAGING CHANGES

Any changes for the work plan needs to be well communicated with all work crew. Any
changes for the method statement need to be approved prior to apply for the work.

11. REFERENCE DOCUMENTS

▪ ASME Boiler and Pressure Vessel Code Sec.IX

▪ ASME Boiler and Pressure Vessel Code Sec. II, Par C

▪ ASME Boiler and Pressure Vessel Code Sec.V

▪ American Society of Mechanical Engineers (ASME)- B 31 Series

▪ AWS Standard for Welding Terms and Definition- A.W.S A 3.0

▪ Contract Drawings

▪ Contract Specifications – ADAC

▪ Project Quality Plan

▪ Project HSE Plan

12. ATTACHMENT

1. DRAWINGS

2. PQR

3. WPS

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 APPENDIX –A

PREPARATION OF WELD EDGE AND FIT-UP PROCEDURE

CONTENT

1. Scope
2. Reference Documents
3. Responsibilities
4. Weld End Preparation
5. Cleaning and Weld Ends Protection Requirements
6. Fit – up Procedure
6.1 General
6.2 Fit- Up Procedures for Piping 2” and Below

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 1. SCOPE

This procedure covers the requirements for weld edge preparation for Carbon Steel, Low
Alloy Steel and Stainless Steel Pipes and Plates.

2. REFERENCE DOCUMENTS

• ASME B31.1
• 2.2 ASME B31.3
• 2.3 ASME Sec. IX
• 2.4 Welding Procedure Specification (WPS)

3. RESPONSIBILITIES
3.1 Piping Supervisor /Foreman is responsible to follow strictly the requirements for weld
edge preparation.
3.2 Pipe Fitters shall align and fit-up the pipes/ plates in accordance with the applicable
provisions of this procedure.
3.3 For their work they are responsible to the piping and welding foreman.

4. WELD END PREPARATION

4.1 The weld edges on stainless Steel material shall be prepared by machining, cutting with
a cutting disc and grinding.

4.2 The grinding and cutting discs used shall be segregated and used for Stainless Steel
only.

4.3 The weld edges shall be cleaned free from all grease and oil or any other carbon acetous
materials employing solvents.

4.4 The weld edges on Carbon Steel material shall be prepared by thermal cutting,
machining, cutting with cutting disc and grinding.

4.5 Piping of nominal size 2” or below shall have weld edge preparation for Butt or Socket
weld according to the approved WPS.

4.6 Piping having nominal diameter over 2” shall have end preparation for butt weld only,
in accordance with standard and approved WPS.

5. CLEANING AND WELD ENDS PROTECTION REQUIREMENTS

5.1 Prior to fit- up all surface 50mm on each side of the weld ends shall be from mill seal,
sand, paint or dirt of any kind.

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 5.2 Cleaning may be done by machining, wire brushing, sand blasting or grinding.

5.3 Cleaned weld ends shall be protected against dirt by use of plastic cups or adhesive
tapes. The protection shall be removed just before commencing of the fit-up.

6. FIT-UP PROCEDURE

6.1 General

6.1.1. The inside diameters of piping to be jointed shall be aligned accurately,

within the allowable drawing tolerances on diameters; wall thickness and
roundness as per applicable standard and approved WPS.

6.1.2. Alignment shall be preserved during welding. Internal misalignment exceeding

20mm shall be tap-bored to 30mm max. ( 1 to 4 chamfer). The remaining wall
thickness shall not be less than minimum design thickness including corrosion
allowance. The root opening shall not differ from the shown in the WPS unless
permitted by Engineer.

6.1.3. Clamps, tack welds or other appropriate means shall be used to ensure
alignment. Tack welding shall be in accordance with the approved WPS. Tack
welding shall only be carried out by an approved welder. Tack weld shall be
grounded to a feather edge and inspected or shall be removed prior to
commencement of the root pass.

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APPENDIX –B

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 WEID JOINT INSULATION USING SLIP ON SLEEVE

CONTENT

1. Scope
2. Reference Documents
3. Responsibilities
4. Preparation and Procedures

SCOPE

This procedure covers the requirements of weld joint insulation using slip on sleeve for
Carbon Steel, Low Alloy Steel Pipes and Fittings.

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 REFERENCE DOCUMENTS

• Contract Specifications – ADAC

• Manufacture Recomentation.

1.RESPONSIBILITIES

Trained Supervisor /Foreman is responsible to follow strictly the requirements for

insulation by slip on sleeve.

Trained Workers shall align and fit-up the sleeve in accordance with the applicable
provisions of this procedure.

For the work they are responsible to follow the manufacturer recommendation.

2. PREPARATION AND PROCEDURES

2.1 Insulate using slip on sleeve (tube) jacket placed over field joint and insulated with
polyurethane foam.
2.1The type of Heat-shrink jacket tube is as recommended by manufacturer.

2.2 Polyurethane foam chemicals (2 components) poured in a heat shrink tubular sleeve fixed
around joint.

2.3 0.1 % of heat shrink tubular sleeves, selected at random, Pressure-test to 0.2 bars.

2.4. Prior to insulation, grit blast external surfaces of core pipe and fittings.

2.5 Coat blasted external surfaces of core pipe and fittings by airless spray using self-priming
polyamide/polyamide epoxy coating to minimum DFT of 150 microns and average DFT of 200
microns.
2.6 Keep 50 mm bare, uncoated from both pipe ends for jointing.

2.7Coating system selected shall be compatible with applied insulation.

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