1.0 PURPOSE
2.0 SCOPE
3.0 APPLICABLE DOCUMENTS
4.0 RESPONSIBLITIES
5.0 TOOLS AND EQUIPMENTS
6.0 METHOD/PROCEDURES
7.0 QUALITY CONTROL
8.0 SAFETY PRECAUTIONS
9.0 ATTACHMENT
REPAIR OF UNSUCCESSFUL SECOND WELD REPAIR PROCEDURE
1.0 PURPOSE
This method statement provides the specific guidelines and methodology to carry out the repair of unsuccessful second weld repair of any piping material without replacing with a new section of pipe and/or fittings at Plants and refinery projects.
2.0 SCOPE
2.1 This method statement covers piping materials with size 36 and above.
2.2 This method statement also cover the following general activities:
- Preparatory Works.
- Removal of Weld Defects.
- Welding.
- Non Destructive Examination.
3.0 APPLICABLE DOCUMENTS
3.1 Saudi ARAMCO Project Specification and Standards
3.1.1 SAES-W-011 – Welding Requirement for On-plot Piping
3 .1.3 Schedule Q Project Quality Requirements
3.1.2 SAEP-1160 Tracking and Reporting of Welding, NDT and Pressure Testing for Capital Projects
3.1.4 Saudi ARAMCO Construction Safety Manual
3.2 Inspection and Test Plan
3.2.1 ASME Sec IX Welding and Brazing Qualification
3.2.2 ASME B31.3 Process Piping
3.2.3 01-SAMSS-010 Fabricated Steel Piping
4.0 RESPONSIBILTIES
4.1 Project Manager shall be the over-all responsible for the implementation of this method statement and for all the task and functions concerning construction activities.
4.2 Safety Officer shall ensure that all works to be carried out should meet the Project’s Health, Safety, Environment (HSE) and Security standard.
4.3 QC Inspector shall be responsible of the inspection of the work in accordance to Saudi ARAMCO Project Standards and Specification. He will be also responsible to re-examine or to have the required testing done and to ensure that satisfactory results have been obtained.
4.4 Welding Supervisor & Foreman shall directly control, organizing and planning the repair activities. Responsible at site for the implementation and compliance with the method statement.
5.0 TOOLS AND EQUIPMENTS
5.1 Tools and Equipments needed should be in good condition and must be checked by Welding Supervisor/ Safety Officer prior to use in the construction area. This include but not limited to:
5.1.1 Welding Machine
5 .1.2 Portable Grinder
5.1.3 Pencil Grinder
5.1.4 Measuring Tape
6.0 METHODS/ PROCEDURES
6.1 Preparatory Works
6.1.1 Notify DEC/JGC & PIO prior to start of the activity.
6.1.2 Prepare all materials, tools & equipment and manpower needed for the job.
6.2 Removal of Weld Defects
6.2. I The repair area shall be marked off using a tracer card of a particular radiographed.
6.2.2 The area shall be excavated using portable grinder on the marked up location. Refer to Figure I for the illustration.
6.2.3 Grind smoothly the defective area within the marked up location of the joint.
6.2.4 After the excavation, the Liquid Penetrant Test shall be performed to determine the defective area. This will be repeated until sound metal has been reached.
6.2.5 The excavated locations shall be free from cracks/defects after applying the Liquid Penetrant Test.
6.3 Welding
6.3.1 Welding shall be done using the same Welding Procedure Specification (WPS), welding process, consumables, preheat and PWHT used for original weld joint.
6.3.2 All welding process shall be protected from wind, rain and other harmful weather conditions that can affect the weld quality.
6.3.3 Selected qualified welder with good record on RT repair rate will be assigned to perform the welding on joint.
6.3.4 Welding works shall be performed only on the identified portion/location of the joint.
6.3.5 Cleanliness shall be maintained after welding is completed. All stubs, rods, flux, slag and foreign material shall be removed from the vicinity of the working area.
6.3.6 Apply necessary NOT after welding repair work is completed. Refer to Para. 6.4.
6.4 Non Destructive Examination
6.4.1 After the repair work has been completed, the area shall be tested with Liquid Penetrant Test to ensure sound metal.
6.4.2 For with PWHT requirement initial RT will be performed after completing the repair works and before endorsing it to final RT.
6.4.3 The intent of initial RT is to evaluate the weld quality prior to PWHT (if any) so any unacceptable discontinuities can be repaired prior to PWHT.
6.4.4 Initial RT report shall be considered for information only and not final acceptance. Such RT reports shall be submitted to Saudi Aramco.
7.0 QUALITY CONTROL
7.1 Sub-contractor QC Inspector will be assigned to do quality control and quality assurance requirement of this job.
7.2 Sub-contractor QC Inspector shall be responsible to conduct all the required documentation and to ensure that all applicable requirements, codes, and standards are complied with.
7.3 All Quality Control Inspection shall be performed as required in accordance with Saudi ARAMCO Standards and Specification.
8.0 SAFETY PRECAUTIONS
8.1 Approved work permit shall be obtained prior to start any activities as required.
8.2 Work execution shall be carried out in accordance with the method statement and project safety specifications.
8.3 Toolbox meeting shall be conducted prior to start the activities.
8.4 Workers should wear their PPE’s needed for the job.
8.5 Proper housekeeping must be maintained in the duration of works.
8.6 Continuous monitoring and inspection shall be implemented to detect and correct unsafe practices while performing the work activities.
8.7 To ensure adequate precautionary measures and protection of the nearby existing structures and services either aboveground or underground during the work execution.
8.8 Ensure provision of mandatory and prohibition safety sign boards.
9.0 ATTACHMENT
9.1 Attachment 1 Job Safety Assessment