Majnoon Oil Field

Mechanical, Electrical &

Instrumentation (ME&I)
General Services
Project

MASTER DOCUMENT REGISTER FOR ME&I PROJECT

Sign Sign Sign

001 Issued For Review 08-11-2022 Abdullah Farhan

Rev. Reason for Issue Date Author Checker Approver

Rev.
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001
Master Document Register For ME&I Project Majnoon Field Development

Revision History
Revision Revision
Approver Summary of Changes
Date Number
08-11-2022 001 Issued For Review

Holds
Hold Ref. Description / Reason for Hold Ref. Section
HOLD 1 xxxxxxxxxxxxxxx
HOLD 2
HOLD 3

Reference Documents
Ref. Document Number Rev. Document Title
1 xxxxx xxx xxxxxxxxxxxxxxxxx.
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Table of Contents
REVISION HISTORY 2

HOLDS 2

REFERENCE DOCUMENTS 2

TABLE OF CONTENTS 3

1.0 PURPOSE OF THIS DOCUMENT 4

2.0 ABBREVIATIONS 4

3.0 REFERENCE OF DOCUMENT 4

3.1 Document References 4
3.2 Code and standards 4

4.0 RESPONSIBILITIES 6
4.1 Project Manager 6
4.2 Construction Manager 6
4.3 QA/QC Manager 6
4.4 QA/QC Engineer 6
4.5 Safety Manager 6
4.6 Safety Engineer 7
4.7 Site Engineer 7
4.8 Surveyor 7
4.9 Foreman 7
4.10 Technician 8

5.0 RESOURCES 9
5.1 Workforce 9
5.2 Tools and Equipment 9
5.3 Materials 10

6.0 SEQUENCE OF THE WORKS-METHOD STATEMENT FOR FIBERE OPTIC CABLE

INSTALLATION 11
6.1 Delivery of Materials, Storage, and Handling-Optical Fibre Cables and Accessories 11
6.2 Site Execution 13

7.0 METHODOLOGY 14
7.1 Pre-requisites 14
7.2 Site Access 14
7.3 Pre-installation 14
7.4 Trench Installation 14
7.5 Procedure of Conduit/Sleeve Installation 15

8.0 TESTING OF INSTALLED FIBRE OPTIC CABLE SYSTEM 17

9.0 QUALITY CONTROL-METHOD STATEMENT FOR FIBER OPTIC CABLING 18

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9.1 Quality Records 18

1.0 PURPOSE OF THIS DOCUMENT

The scope of this method statement is limited to pre-fabrication, erection and testing procedure
followed for carbon steel piping.

2.0 ABBREVIATIONS

3.0 Abbreviation Description R

E
MFD Majnoon Field Development
F
ASME American Society of Mechanical Engineers
API American Petroleum Institute E
ISO International Organisation for Standardization R
QHSE Quality Health, Safety and Environment E
QA/QC Quality Assurance/Quality Control
N
PPE Personal Protective Equipment
HSE Health Safety and Environment C
HSSE Health, Safety, Security and Environment E
IMS Integrated Management System
ASTM American Society for Testing & Materials
BS British Standard
ACI American Concrete Institute
RA Risk Assessment
MS Method Statement
IFC Issued for Construction
OF DOCUMENT
3.1 Document References
Document Number Document Title
Project Execution Plan
Quality Assurance/Control Management Plan
Health, Safety, security, and Environment Management
Plan
Project Engineering and Built Procedure
Document Control Procedure
Project Organization and Management Plan
Project Management Plan
Materials Management Plan
Project Specification for site preparation
3.2 Code and standards

CODE AND STANDARD DESCRIPTION

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Typical Installation for Cabling

Specification for Electrical Requirement for Packaged
Specification for Power and Control Cables.
Typical Installation for Cabling

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4.0 RESPONSIBILITIES
4.1 Project Manager
 will be responsible for managing, execute complete and handover the construction
activities within approved resources in compliance with requirements as specified in
project specifications. He will be overall in charge of implementing this method
statement for fibre optic cable installation per QA/QC and HSE requirements.

 Responsible for controlling the project’s entire activities & for the overall coordination
with COMPANY.

 Ensure that adequate welfare facilities and equipment are provided to the project to
avoid injury, health impairment, or damage & to ensure providing quality works within
the planned time scale.

 All responsibilities stated in the Project’s Quality Assurance Plan.

4.2 Construction Manager

 Organize the site so that work is carried out to the required specifications with
minimum risk to men, equipment, and materials.

 Coordination with different functions with the project.

 Expediting area of concern to achieve project schedule.

 Adhere to the project-specific quality management program and HSE requirements.

4.3 QA/QC Manager

 Responsible for the work of entire quality assurance, quality control & inspection
programs.

 Produce all quality-related documents & reports necessary as requested by

COMPANY.

 Provide written procedures & coordinate in formalizing the Method Statement for fibre
optic cable installation with the Project Manager/ Construction Managers/Site
Engineers to describe the job-specific work for each stage/activity.

 All responsibilities stated in the Project’s Quality Assurance Plan.

4.4 QA/QC Engineer

 Responsible for the work of entire quality assurance, quality control & inspection
programs.

 Produce all quality-related documents & necessary quality reports as requested.

 Provide written procedures & coordinate in formalizing the method statement  for fibre
optic cable installation with the Construction Manager/Site Engineers to describe the
job-specific work for each stage/activity.

4.5 Safety Manager

 Manage Safety Engineers and Safety Officers to be in strict conformance with project
policies and procedures.

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 Must ensure safe work method as stated here and risk assessment is fully
implemented during activity.

 Responsible for controlling HSE personnel for effective monitoring of work.

 Oversee site safety orientations/inductions, toolbox talks, safety training certifications,

job site inspections, working at heights, scaffolding tagging systems are fully
functional, rigging, etc.

 Report to Project Manager all personal injuries and near-miss incidents (aligned with
Safety Engineers/Officers) as well as property damages immediately. Produce
investigative reports and summaries to senior management.

4.6 Safety Engineer

 Ensure that all workers have a safe place of work, advise a safe system of work, and
provide adequate instructions, training, and supervision to enable employees to work
safely.

 Carry out site surveys on daily basis to ensure that the HSE methods of working are
in operation & that all regulations are being observed.

 Report, determines & analyses the cause of any accident or dangerous occurrence
and recommends measures for preventing recurrence.

4.7 Site Engineer

 Adheres to the project-specific Method Statement for fibre optic cable installation,
procedures, inspection programs & HSE instructions to get the activities performed to
client satisfaction with full coordination with the HSE & quality personnel.

 Responsible to ensure that correct drawings, materials, tools, and equipment are
provided on-site.

 Liaising with sub-contractors, supervisors, planners, quantity surveyors, and the

general workforce involved in the project.

 Responsible for planning the work and efficiently organizing the plan and site facilities
in order to meet agreed deadlines.

 Site engineer is responsible to coordinate with QA/QC team engineers/ inspectors,

and handover daily site progress works reports/highlighted drawings & present during
inspection/site visit with QA/QC inspectors & consultant/client.

4.8 Foreman
 Performed the activities that were instructed by the Supervisor/Engineer at the site
and follow the safety procedures to make it safe for his workers.

 In charge to lead the work execution send the focal point in coordinating with the site
Supervisor/Engineer related to overall site activity, materials, tools, and equipment.

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5.0 RESOURCES
This resource and manpower are not limited as above mentioned but will be increased and
improved as project requirement to implement the work without delay, with quality control and
safety of personnel.

5.1 Workforce
Manpower Required

 Site Engineer

 Welder Foreman

 Chargehand Supervisor

 HSE Engineer/officer

 Lifting supervisor

 Skilled labour as per the required work

 Welder

 Grinder

 Scaffolders

5.2 Tools and Equipment

Operators of the equipment will be certified by 3rd party and have valid license/registration
issued by the traffic department.

 Mechanical tools

 Mobile Crane

 Forklift

 Hiab

 Manual and Pneumatic torque wrench

 Oxy-acetylene cutting machine

 Welding machines

 Grinding machines

5.3 Materials
 Consumables Discs

 Electrode Consumables

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6.0 PROCEDURE
The engineering drawings and documents received from COMPANY shall be clearly
understood to find out the service, material specification, size, thickness, PWHT requirements,
NDT requirements, Painting and Coating requirement, piping routings quality etc, line wise and
area wise.

6.1 Materials receiving and storage

 Materials requisition from prepared by supervisor shall be forwarded to the material
controller who shall collect the piping materials as per the piping specifications and
drawings from COMPANY, respecting the material issue procedure of COMPANY.

 Handling and transportation of piping materials shall be done with utmost care to avoid
any damage.

 Separate area shall be assigned for the storage of carbon steel piping materials. Pipes
shall be stored in open area resting on wooden sleepers and small pipe fittings, bolts,
nuts, and gaskets shall be stored in shelved containers. Storage & issue procedure of
piping materials shall be in time with the requirements of COMPANY.

 Documents shall be maintained by the material controller till the end of the project.

 Waste materials and other piping fittings and rejected materials shall be stored as per
waste management procedure in separate area.

6.2 Pre-Fabrication
6.2.1 Cutting and bevelling
 Prior to initiation, welding map shall be issued to organize and opt the better plan for
piping system erection.

 Cutting of piping, edge preparation, joint alignment, and fit-ups as per WPS.

 The edge cleaning and bevelling shall be done using abrasive grinding disc/bevelling
machine.

 Line number, spool numbers, and joints numbers are to be clearly identified and
marked on the spools with the welding identification for each joint.

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6.2.2 General requirements

All welding activities shall be as per contract specification, qualified PQR and approved WPSs.
A copy of the approved WPSs shall be on site for any reference and clarifications. Quality
personnel shall monitor all welding activities at all stages to ensure all welding activities are as
per Client/Eni approved procedure and specifications. Quality Personnel shall conduct a toolbox
to welding supervisor and welders to impart the requirements of WPSs, all welding shall be
carried out strictly in accordance to the approved WPSs. In case of GTAW process and Piping,
the use of high frequency arc ignition devices is recommended Joints ''Welded, socket,
threaded '' shall be identified, marking, inspected/ tested and controlled at shop and on the field
site. Tack welds, if forming part of the root pass, shall have the start and stop ends ground
smooth to blend into the root. Tacking shall be done by qualified welder on bevel ends of pipe
fittings. All defective tack welds shall be removed completely during root pass welding as
feasible. Flange face shall be protected adequate prior to commence any welding and
throughout the completion. All surfaces subject to weld shall be free of moisture, rust, oil,
impurities etc., in order to avoid any deterioration to the weldment.

 Each layer of deposited weld metal shall be thoroughly cleaned prior to subsequent
weld deposits. When necessary, the deposited metal shall be ground to ensure
proper toe blend.

 On completion of root pass the welding supervisor shall ensure compliance in

accordance with NDT requirement at root if any.

Fillet welds used for attachments shall be carried out by qualified welders using electrodes and
preheat as per approved WPS.

 Fillet welds shall have proper fusion and penetration at the root of the joint.

 Fillet welds shall fuse gradually into the pipe and be free from marked irregularities,
convexity/concavity and undercut.

All temporary attachment such as cleats, bridges and tacking pieces to pipe work shall be the
same material.

 During removal of temporary attachment, care shall be taken to avoid any parent
metal ripping or damage.

 Removal of temporary attachments by hammering and/or bending shall not be

permitted.

Each weld joints shall be uniquely identified with a joint number as per the IFC drawings.

 Prior to visual inspection, the weld number and welder identifications shall be marked
at a near distance adjacent to the weld by paint marker or Indelible crayons.

 This identification shall remain on the pipe till the completion of all NDT for any
verification by quality personnel and/or COMPANY representative.

6.2.3 Fit-up and tack welding

 Fit-up assembly shall be carried out by using locally prepared couplers. All the required
pipe holding work benches. Assembling brackets, U bolts etc. would be made in house
to suit the pipe sizes.

 For butt welds a uniform root opening as specified shall be maintained as per WPS.

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 For all socket weld joints the pipe end shall be free from cutting burrs. A clearance shall
be made between the end of pipe and bottom of socket as per WPS.

 Internal misalignment shall be limited to a value specified in the WPS.

 The pipes shall tack welded in three equidistance positions. Tack weld shall be done as
per approved WPS by qualified welder.

6.2.4 Welding
 Welding procedures and welders shall be qualified as per project specifications and
relevant codes, prior to start of the welding.

 Edges shall be free from dirt, rust, oil, grease, paint etc.

 Welding shall be done as per approved WPS for the particular piping. Preheating and
welding consumables shall be checked before starting of welding.

 Each weld layer shall be cleaned before starting to weld next layer. The cleaned area
shall be free from slags. Any visual defects like cracks, pores, spatters weld shall be
removed by grinding at tack points of each weld. Any possible weld excess layer shall
be removed by grinding.

 Appearance of finished weld shall be as even as possible and free from spatter, under-
cutting, cracks, excess reinforcement etc.

 All the welding activity shall be monitored by QC inspector to ensure the procedure and
WPS being applied carefully. And maintain the inspection at all levels of welding
process to establish the quality of welding and, mitigate the occurrence of welding
defects that could happen during the activity.

6.2.5 Post Weld Heat Treatment

The post weld heat treatment (PWHT) of the piping spools shall be carried out as per the
procedure.

6.2.6 Non-Destructive Examination

 The extent of NDT will be in accordance with project general specification for different
piping systems. The acceptance criteria shall be in accordance with ASME B31.3.

 If PWHT is applicable for any piping system, NDT shall be carried out after completion
of PWHT.

 Welding record shall be maintained with proper identification of joint, welder etc. for all
joints.

 NDT shall be carried out as per approved procedure and the results shall recorded
properly.

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6.2.7 Repairs of welded joints

All discontinuities considered as unacceptable on the basis of specification must be removed by
using a procedure qualified by the Company Before starting any work the Contractor
responsible for welding operations shall submit to the Company, for approval, a detailed
procedure for repairs. The above procedure must clearly indicate the modalities of removal of
the defective sections and the performance of welding. The proposed procedure must be
qualified by simulating the real working conditions which may occur in the field and by
performing suitable test joints.

If the defects to be removed are located in the root pass and if the repair is permitted, the root
pass shall be carried out by using a welding process capable to ensure a regular and consistent
penetration of the repaired section.

All the detected defects shall be marked at location by the quality personnel. Minor surface
imperfections may be removed by grinding provided that the wall thickness is not reduced
locally by more than 12.5% of the nominal value specified or the minimum design thickness
whichever is greater and the minimum wall thickness is maintained. Any minor repair or repair
involving welding, the ground area shall be dressed to uniform to obtain smooth profile.

 If planer defects such as cracks etc. are to be repaired, every effort shall be made to
prevent the propagation of defect during its removal.

 Visual Inspection shall carry out to ensure the defects have been completely
removed.

Repair work shall be recorded and reported to the COMPANY repair work shall not proceed
without approval. Defect shall be removed by grinding and verify the removal by VT, upon the
through verification repair weld shall be carried out.

After completion of weld repair, weld visual inspection shall be carried out and recorded in
Repair Welding Inspection Report.

Repaired weld shall be subjected to 100% visual examination followed by NDE at the same
degree and techniques used for the original examination.

 The acceptance criteria shall be the same as for the original welds. Accidental arc
strike or arc burn on the pipe surface outside the weld shall be smoothened by
careful filing.

 The filed area shall be blended with the adjoining pipe surface by smooth transition
and shall avoid notches and stress concentration.

 The residual thickness shall meet the tolerance limits specified by the respective
material specification.

 MPI or DP examination shall be carried out on the surface after removal of Arc Strike.

The welds containing cracks shall be completely removed.

 Unacceptable defects shall be removed by grinding. Company shall be informed of

the cracks and the reason for the same.

All weld repairs shall be carried out in accordance with the approved WPS for butt welding of
pipes. Company shall be informed of defects which are unacceptable. Only 2 attempts to repair
for carbon steel welds shall be permitted.

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6.3 Piping erection

 The pre-fabricated spools shall be identified by spool and line numbers before and after
priming.

 Care shall be taken while handling and stacking of spools to prevent any possible
damage.

 Open ends of spools shall be covered by caps after thorough cleaning.

 Erection of spools shall be carried out area by area as per piping layout drawing and
isometric drawings.

 Scaffolding and temporary platforms shall be arranged to carry out fit up and welding of
field joints at elevated positions.

 Pre-fabricated spools shall be shifted to site carefully as per daily erection plan.

 Before erection of spools, an insurance on the thorough cleaning of the spools and their
items.

 Erection the spools in position shall be using suitable crane or other lifting equipment.

 Supports to be welded on to the pipe (shoes or saddles) shall be done before erection.

 Piping supports shall be detailed in the piping layout drawings and isometric drawing for
location and type.

 Joints shall be aligned and complete the fit-up / welding as per applicable and approved
WPS.

 NDT and other inspection shall be completed for the field joints and recorded properly.
If PWHT required, PWHT shall be carried out first.

6.4 Mechanical clearance, Inspection, & Pressure Testing

 The test loops for the completed line system wise shall be identified.

 Upon obtaining mechanical clearance, Hydrostatic test shall be carried out as per
project specification.

 Equipment & devices such as high-pressure pump, chart recorder device, calibrated
pressure gauges, and test medium shall be arranged.

 Blind flanges shall be installed on all required locations and, items which as not to be
included in pressure testing, shall be isolated.

 Water shall be filled and vented properly before pressurising.

 Line shall be pressurised to the required pressure of that piping class and hold the
pressure till the inspection is completed.

 Pressure test shall be witnessed by COMPANY representative.

 On satisfactory completion of test, pressure shall be released and line is to drained off
completely.

 Reinstating the line with all the permanent items shall be carried out after.

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6.5 Inspection Test quality records

Inspection, testing and recording shall be in accordance with the approved inspection & test
plan.

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