Pipeline Engineering Documents – Onshore Oil Facility
1. Method Statement for Fabrication and Installation of Piping
Scope:
This document outlines the step-by-step process for the fabrication and installation of
piping at an onshore oil facility.
Preparation:
- Review issued-for-construction (IFC) drawings and specifications.
- Conduct site survey and material take-off.
- Prepare tools, lifting equipment, welding machines, and PPE.
Fabrication:
- Cut pipes to required lengths based on drawings.
- Bevel pipe ends and clean surfaces.
- Fit-up using pipe clamps and supports.
- Perform visual inspection before welding.
Installation:
- Transport prefabricated spools to site with caution.
- Align and support pipes using proper hangers and clamps.
- Conduct fit-up, welding, and NDT (RT, UT, or MPI).
- Install supports and ensure stress-free alignment.
- Carry out flange tightening to recommended torque.
Commissioning:
- Perform pressure tests.
- Flush lines using air, water, or chemical flush.
- Insulate and paint if required.
- Final walk-through with client/inspector.
2. Welding Procedure Specification (WPS)
Welding Process: SMAW (Shielded Metal Arc Welding)
Base Material: ASTM A106 Grade B / API 5L Gr B
Filler Material: E7018 Electrodes
Joint Design: Butt weld – single or double V-groove
Preheating Temperature: 50°C minimum
Interpass Temperature: ≤ 150°C
Welding Parameters:
- Root Pass: 90-110 Amps, 2.5mm electrode
- Fill/Cap Passes: 120-150 Amps, 3.2mm or 4.0mm electrode
Post Weld Heat Treatment (if required): As per project specs
Testing:
- 100% Visual
- 10% Radiographic or Ultrasonic (or as per project requirement)
3. Hydrotest Procedure for Flowline Testing
Scope:
Hydrostatic testing will confirm the integrity of newly installed flowlines.
Preparation:
- Ensure all welding is complete and accepted.
- Clean the inside of the pipeline (flushing and drying).
- Install calibrated pressure gauges and vents.
Filling:
- Fill line with clean water (treated where needed).
- Remove all air pockets using vent valves.
Pressurization:
- Raise pressure gradually to 1.5 times design pressure.
- Hold for minimum 30 minutes (or as specified).
Acceptance Criteria:
- No visible leaks or pressure drop.
- Re-test if failure occurs and rectify issues.
Draining:
- Drain water safely and dry pipe with air blower or nitrogen.
4. Health, Safety and Environmental (HSE) Plan
HSE Objectives:
- Zero incidents and injuries
- Environmental compliance
- Safe work culture
HSE Measures:
- Daily toolbox talks and safety induction
- Use of full PPE (helmet, gloves, coveralls, goggles, boots)
- Confined space entry protocols
- Permit-to-work system enforced
- Firefighting and first aid stations at site
Environmental Protection:
- Spill kits at designated points
- Proper waste disposal and segregation
- Dust and noise mitigation
Emergency Response:
- Fire drills and evacuation plans
- Emergency contact list available at all times
5. Quality Management Plan (QMP)
Quality Objectives:
- Meet project technical specifications
- Deliver work right the first time
- Ensure client satisfaction
Quality Control Procedures:
- Inspection and Test Plan (ITP) to govern all tasks
- Material test certificates (MTCs) for all incoming materials
- Fit-up, welding, and NDT inspection records maintained
- Hydrotest records and QA documentation compiled in final dossier
Reporting:
- Daily quality checklists and inspection reports
- Non-conformance reports (NCR) and corrective actions
6. Security Plan
Security Objectives:
- Protect personnel, materials, and site assets
Measures:
- Access control points with sign-in registers
- 24/7 manned security at entry/exit points
- Perimeter fencing and warning signs
- Surveillance cameras in critical zones
Incident Response:
- Log all security breaches or suspicious activity
- Immediate report to site manager and local authorities
- Emergency lockdown procedures for serious threats
Personnel:
- Security guards trained in emergency protocols
- ID badges for all workers and visitors
