PIPING FLANGE ALIGNMENT PROCEDURE & METHOD STATEMENT

This article is about Piping Flange Alignment Procedure or method statement for Heating on Weldment.

1.0 PURPOSE
2.0 SCOPE
3.0 APPLICABLE DOCUMENTS
4.0 RESPONSIBILITY
5.0 MANPOWER
6.0 TOOLS & EQUIPMENT
7.0 METHODS/PROCEDURES
8.0 QUALITY CONTROL
9.0 SAFETY PRECAUTION
10.0 ATTACHMENTS.

PIPING FLANGE ALIGNMENT PROCEDURE & METHOD STATEMENT

1.0 PURPOSE

1.1. This Piping Alignment Procedure & method statement shall provide minimum guidelines to carry out the heating on the piping weldment for alignment for Plants and refinery projects. In accordance with contract scope of work and project specification.

2.0 SCOPE

This method statement covers the heating of the piping weldment for construction on all rotating equipment flanges for final alignment for Plants and refinery projects.

3.0 APPLICABLE DOCUMENTS

3.1. Project Specification and Standard

3.1.1. S-000-3160-002 Specification for Piping Construction Work in Field

3.2. Saudi Aramco Standard

3.2.1. SAES-W-011 Welding Requirements for On-Plot Piping.
3.2.2. SAES-L-350 Construction of Plant Piping.
3.2.3. SAES-L-310 Design of Plant Piping.
3.2.4. SAEP-352 Welding Procedures Review and Approval.
3.2.5. SAEP-324 Certification Review and Registration of Project Welders.

3.3. Industry Codes Standard

ASME B31.3 Process Piping.
API RP 686 Recommended Practices for Machinery Installation and Installation Design.

3.4. Applicable SATIP/SAIC/SATR

SATIP-W-011-01 Welding of On-Plot.

4.0 RESPONSIBILITY

4.1. Construction manager responsible for implementing HSE and shall study, analyze and schedule all construction activities with his department to include manpower and equipment line up as well as other possible resources required for the successful implementation of the construction work activities. Study all aspects of work procedure as per Technical Scope of Work.
4.2. Piping Superintendent shall assist Construction Manager in the overall construction activities. Receives and carries out directives and strategies of Construction Manager in various phases of duties assigned by this immediate Supervisor.
4.3. Piping Supervisor shall be directly reporting to the Piping Superintendent and responsible in the implementation and control of all site activities per Technical Scope of Work and latest approved construction drawings. He shall coordinate with other discipline to visualize possible conflicts in the drawing as well as in the schedules to provide other options in preventing unnecessary delays and obstructions.

4.4. Piping foreman shall be responsible for the direct work supervision at site and ensure that the work is performed in accordance with JV Technical Scope of Work and specification.
4.5. QC Inspector shall be responsible to verify the work and ensure that the work is being performed.

4.6. Safety Supervisor officer shall be responsible in monitoring safety aspects and ensuring that the work is done in accordance with Safety Standard Procedure. He shall discuss to the piping supervisor the characteristics of related materials and status of work area giving reminders as an additional point to work safely.

5.0 MANPOWER

5.1. The Piping Superintendent shall control the overall air blowing activity. The basic manpower under him shall consist but not limited to the following:

5.1.1. Piping Supervisor.
5.1.2. Piping Foreman.
5.1.3. Pipe fitters.
5.1.4. Permit Receiver.
5.1.5. Helpers.
5.2. Safety Engineer/Officer.
5.3. QC inspector.

6.0 TOOLS, EQUIPMENT AND TEMPORARY MATERIALS

6.1. Tools and equipment needed should be in good condition and must be checked by Piping Supervisor / Safety Officer prior to use in the construction area.

These includes but not limited to the following:

1. Hand Tools(Wrenches).
2. Power Tools.
3. Calibrated welding machines.

7.0 PIPING FLANGE ALIGNMENT PROCEDURE

7.1. After pressure testing some piping lines are misaligned to equipment nozzle where it affects the parallelism between flange of equipment and pipeline.
7.2. Check both flange from nozzle of equipment and flange of pipelines. Verify and study where the best spot to align the nozzles.
7.3. Always consider not to stress equipment side.
7.4. The piping flange bolts must be loose from the machine flange before partial excavation and recapping. This allows the end of the piping to move as the piping cools after partial excavation and recapping.

7.5. After studying the lines, select joint to recap and partially excavate. Where it is one (1) option to align pipe line nozzles to equipment nozzles.
7.6. Remove capping and partially excavate on filler metal portion only by means of grinding. After grinding, construction to apply additional weld with filler wire on the excavated and capping point. Align both piping and equipment as per requirement tolerances during welding process.
Refer to the below typical figure.

7.7 After welding work, construction shall prepare DWR (Daily Welding Report) and QC shall conduct internal visual inspection.

7.8 MT shall be done on the re-capped and excavated welds of carbon steel piping. PT and PMI shall be done on the re-capped and excavated welds of stainless steel. Re-capped joint previously radiograph shall be subjected to 100% RT and if previously not selected no RT required.

8.0 QUALITY CONTROL

8.1 QC Inspectors to ensure that no stress on both equipment and pipelines is present
8.2 All inspections shall be conducted as per applicable SATIP, SAIC and SATR

9.0 SAFETY PRECAUTION

1. Construction Manager / Piping Supervisor / Foreman shall be responsible for the implementation of this procedure and the required orientation necessary for the work force.
2. Safety Supervisor/ Officer shall monitor compliance of the entire working crew regarding safety procedures until the work is fully completed.
3. The necessary manpower inclusive of supervisory staff, tools, equipment, materials and other resources required must be made available and ready to use.
4. Provide warning sign and sufficient barricade on working areas to avoid unauthorized entry. Only assigned personnel shall be allowed in the area.
5. All workers shall wear mandatory PPE and additional PPE if required.
6. Sufficient lighting shall be provided if working in the night.
7. Only trained personnel are allowed to work in this activity.
8. Good housekeeping must be maintained for the duration of work.
9. Job Safety Analysis of this procedure shall be disseminated and explained to all involve personnel for safety awareness.

10.0 ATTACHMENT

Attachment 1 Job Hazard and Risk Assessment (JHRA)