METHOD OF STATEMENT

FOR
FABRICATION AND PAINTING WORK

Rev Date Status Prepared Checked Approved

0
 Table of Contents

1 Purpose 03

2 Scope 03

3 Reference 03

4 Abbreviation 04

5 Responsibilities 04

6 Material Control 06

7 Method & Sequence of work 06

8 Welding 08

9 Blasting 10

10 Coating Application 13

11 Packing & Shipping 14

12 Health & safety Environment 17

13 Inspection Test plan 17

14 Organization Chart 18

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
1. Purpose

This document describes the work method that Petrolynx Industries & Projects
LLC Shall adapt while executing the fabrication, welding and painting works.
This method statement provides a summary and explanation of the fabrication
methods, welding processes, Painting process and intended sequencing of
operations.

2. Scope:

Fabrication, welding and Painting of

▪ Steel structures
▪ Piping
▪ Pressure Vessel
▪ Heat Exchanger
▪ Storage Tank
▪ Other Oil & gas Equipment’s.
3. References:

3.1 Codes and Standards

AWS D1.1-- Structural steel code.

ASME SEC II --Materials
ASME SEC V-- Non-Destructive examination
ASME SEC VIII--Rules for construction of pressure vessel
ASME SEC IX-- Welding & Brazing Qualification
ASME B31.3 -- Process piping
ASME B31.1-- Power Piping
AWWA D100-- Welded carbon steel water storage tank
API 650-- Welded carbon steel oil storage tank
API 1104-- Welding of Pipelines & Related Facilities
SNT-TC-1A-- Personnel NDT qualification

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
4. Abbreviations

QA - Quality Assurance
QC - Quality Control
PPE - Personal Protective Equipments
ITP - Inspection and Test Plan
WPS - Welding Procedure Specification.
RFI -Request for Inspection.
RA - Risk Assessment
UT -Ultrasonic test.
MPI -Magnetic particle test.
LPT -Liquid penetration test.
MTC -Material Test Certificate.

5. Responsibilities:

5.1 Project Manager

The Project Manager is responsible for the proper implementation of this procedure.

5.2 Production Manager

The Production Manager is responsible for the implementation of this procedure at

fabrication shop and plan the weekly work schedule and controlling all the structural
works.

5.3 Safety Engineer

The safety Engineer / Supervisor will make sure that all the safety requirements are
fulfilled prior to start of the job. Risk Assignments shall be prepared and shall be
strictly implemented.

5.4 Fabrication Supervisor

The Fabrication Supervisor will be directly involved in the planning and execution of
the activities involved in the fabrication works. He will be responsible to carry out as

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
 per the project plan and He should raise Request for Inspection (RFI’s) to the QC
dept. at appropriate stages of the work as detailed in the ITP.

5.5 Foreman

The Foreman will be responsible for the direct execution of works involved in the
fabrication process according to the plan and will directly control and issue
instructions to the working personnel. He will provide instructions to welders that
cover the fundamental requirements of the Welding Procedure Specification (WPS).
He will also ensure that works are performed with proper tools/equipment and good
housekeeping around the working area.

5.6 QC Engineer

The QC Engineer will be responsible for the necessary inspections and tests to be
carried out for all the activities involved in the fabrication works as per the
Inspection Test Plan (ITP) and IFC drawings.

5.7 QC Inspector

QC Inspector is responsible to inspect all the materials and dimension check prior to
fabrication. He inspects the fit up and dimension, then giving clearance for welding.
He is also responsible for calibration of all instruments/machines using for
fabrication works.

5.8 Welding Inspector

The Welding Inspector inspects the joint after fit-up and give clearance for welding.
Once welding is completed, visual inspection shall be conducted by welding
Inspector.

5.9 Planning Engineer

Planning engineer will receive all the drawings from engineering department and
also ensure that the same will be kept updated as per the last revision. Preparation of
weekly, monthly and overall planning shall be schedule. Production progress shall be
monitored on a daily basis. Job cards and drawing from engineering department shall
be issued for fabrication engineer through planning engineer.

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6. Materials & Control

6.1 Material

▪ The quality & grade of materials should be according to client specifications and
drawings.
▪ The Material shall be checked for dimension, thickness, visual and to be free from
loose mill scale, surface defects pitting, ovality and surface condition.
▪ All steel supplied shall be stored in a safe condition with proper care taken during
storage to ensure that no damage occurs.
▪ The identifying and marking system shall be established.
▪ Substitution if any, on sizes or quality shall be implemented only after obtaining
approval from the client.

6.2 Material Identification and Traceability

▪ After receipt of raw material store shall verify the material and forward the
material report and RFI to Petrolynx QC.
▪ Petrolynx QC Engineer will inspect the raw material and verify the heat number
correlation and material specification as per MTC.
▪ The stacking of materials shall be done with respect to the job number and type of
materials etc., stacking the materials in such a way that the identification mark
stamped on it shall be visible enough to locate the material quickly.
▪ Request for Inspection was raised to client for approval & further proceedings.

7. Method & Sequence of the work

7.1 Fabrication - Structural

▪ The fabrication of steelworks, piping, oil & gas Equipment’s shall

be carried out as per approved drawings.
▪ The nesting plan shall be prepared for all material before commencement of
fabrication work. Material item number shall be provided for easy identification.
▪ Marking shall be carried out as per nesting under the guidelines of foremen, and
subsequently verified by the Fabrication engineer prior to cutting.

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
 Necessary items shall be carefully and accurately marked in accordance with
approved shop drawings or templates.
▪ The edges of all plates shall be perfectly straight and uniform throughout. All
corners shall be shaped so as to be notch free, sheared or cropped edges shall be
dressed so that they are free from distortion and burrs.
▪ All steel material shall be straight and free from bends or twists. If the sections
are distorted or twisted during transit, storage, etc. they shall be straightened
and/or flattened before delivered to site.
▪ The bending of plates and sections to specially required shapes shall be done on
appropriate machine.
▪ Punching and or drilling shall be done accurately as per the drawings and burrs
removed effectively.
▪ Where several parts are to be connected to very close tolerances, such parts shall
be first assembled, tightly clamped together and drilled through.
▪ Build up beam structure shall be assembled in jigs or on suitable surface plates
with proper layouts as per the Drawing. Butt weld in flange plates and /or web
plates shall be completed before the flanges with web fit-up Assembly. The Flange
Plates shall be fit up with web plate, for correct alignment and held in position by
use suitable devices or by tack welds until welding is completed to assure the
most suitable welding position and accurate assembly. After completion of
Flanges and Web joint fit-up, Petrolynx QC shall check the fit-up and release for
welding.
▪ Structures shall be assembled in jigs or on suitable surfaces plates with proper
layouts. The members to be welded shall be held in the correct position by bolts,
clamp and wedges where practicable. Any wedges used to space root gaps shall be
removed from the root gaps immediately after tack welding and before making
the root run. After completion of joint fit-up, Petrolynyx QC will check the fit-up
and he will release the joint for welding.
▪ The fabricated components shall be assembled in such a manner that they are
neither twisted nor otherwise damaged. In order to minimize distortion in a
member the components shall be positioned by using clamps, clips, jigs and other
suitable manner and fasteners shall be placed in a balanced pattern.
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 ▪ If necessary, items like roof trusses shall be trial assembled as per approved
assembly drawing keeping in view the actual site conditions prior to dispatch to
site for erection, so that, they can be conveniently pre-assembled before erection.
Necessary match marks shall be made on these components before disassembly
in the shop and dispatching.

7.2 Fabrication – Piping, Oil & Gas Equipment

▪ Visual and dimensional check shall be performed by the QC Inspector after each
stage of pre-fabrication (like cutting, rolling, edge preparation, marking, etc.) for
all piping, oil & gas equipment as per the approved shop fabrication drawings.
▪ Material traceability to be verified by the QC Inspector during this activity.
▪ Butt-welded end preparation shall meet the requirement of client specification.
▪ Surfaces for welding shall be clean and shall be free from paint, oil, rust, scale, or
other material which is detrimental to welding.
▪ Recording the required material traceability information using methods such as
material tabulations or as built sketches which assure identification of each piece
of material during fabrication and subsequent identification in the completed
parts may also be used alone or in parallel with the stamping method.
▪ Handling, storage and inspection of Welding Consumables shall be as per
approved Procedures
▪ Visual and dimensional check shall be performed by the QC Inspector after each
stage of fabrication (fit-up assembly, preparation for welding, etc.) for all items as
per the approved shop fabrication drawings.
▪ During fit-up of butt-welded joints, alignment shall be checked and maintained as
accurate as practicable. If pipe components do not exactly match, the difference
shall at least be equally spaced over the circumference.
▪ Recording the required material traceability information using methods such as
material tabulations or as built sketches which assure identification of each piece
of material during fabrication and subsequent identification in the completed
parts shall be used.

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 ▪ The butt joints shall be free from slags and spatters from tack welding, fouling, rust,
scales, grease, earth, paint, varnish or lacquer as well as from any possible local
irregularities.
▪ Root spacing or root opening shall be as per the approved WPS.
▪ Metal tag, hard stamped with the spool number or drawing number, is the
preferred method to identify a spool and shall be securely tied.

8. Welding
▪ Welding and welding procedure qualifications shall be done in accordance with
applicable Code & standards as per the client specification.

8.1 Type of Welding Process

▪ All Welding activities shall be carried out as per the approved Welding procedure
specification (WPS).
▪ The following Welding Process shall be used in Fabrication works.
▪ FCAW Process
▪ SMAW Process
▪ SAW Process
▪ GTAW Process

8.2 Welding Process

▪ The following practices shall be used for welding.

▪ Prior to welding filler material shall be checked.
▪ Prior to welding root opening, groove angle and the crucial dimensions shall be
checked and groove face shall be free from oil, water and dirt.
▪ Prior to welding the welding current shall be measured the most appropriate
welding condition (current & voltage) shall be maintained.
▪ If necessary, additional protection may be required like Fire blankets. All joints
are to be dried before welding in damp climatic condition.
▪ During welding work, the most appropriate arc length, angle and welding speed
shall be maintained so that welding defects shall be avoided and arc energy
requirements are satisfied.

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
 ▪ All reinforcement shall blend smoothly into the plate surfaces with transition
areas free from undercut.
▪ Chipping and gouging shall be used, provided grinding follows them.
▪ In the case of multi pass welding, each pass shall be cleaned with wire brush or
chipping hammer prior to starting the next pass welding to avoid slags and
spatters.
▪ All craters shall be filled to the full cross section of the welds.
▪ Preheat, inter pass temperature, welding electrical characteristics, gas flow rate
& purging shall be monitored by Welding foreman & Qc inspector as per
approved WPS.
▪ Post weld heat treatment, NDT, hydrotest, PMI, Ferrite test shall be conducted
and reports Submitted to client for approval.
▪ Only approved WPS with supporting PQR and other documents shall be used
during the welding of the fabricated items.
▪ Welders with approved WPQ will only be allowed to weld and tack.
▪ Personnel Qualified to AWS QC 1, CSWIP-W1-6: Standard for Qualification and
Certification of Welding Inspection shall be used for visual examination of
welds.
▪ Welding Inspector shall verify the following during the welding stage:
▪ Availability of WPS on shop floor
▪ Calibration Sticker for the Welding Machines and Holding Ovens
▪ Welder ID on welded joints
▪ MTC for the Welding Consumables used is available
▪ Baking & drying of electrodes / fluxes prior to use
▪ Welding log summary shall be generated to provide details (welder ID, weld
process, NDE carried out, etc.) on a particular weld joint. Marking of weld ID
near the weld joint shall be verified and checked by the welding inspector.
▪ Acceptance Criteria for the visual examination shall be as per Project

Specification or Standard.

▪ As-welded surfaces are permitted; however, the surface of welds shall be

sufficiently free from coarse ripples, grooves, overlaps, abrupt ridges, and
valleys. The surface condition of the finished welds shall be suitable for the

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
 proper interpretation of nondestructive examinations when nondestructive
examinations are required
9. BLASTING

9.1 Pre – Startup

▪ All coating materials shall be delivered to the job site in the original and
unopened containers plainly marked with the proper designation of the
product, as well as the name of the manufacturer.

▪ Verify and record batch numbers, shelf life and general condition of materials.

▪ Assure that the coatings are stored at all times in a cool dry place as per
manufacturer’s instructions.

▪ Check all equipment to be operational, compressors to yield required oil – free

pressure and spray equipment to be according to specifications.

▪ Verify that welds are continuous, free from sharp projection or pinholes and
free from spatters and slag.

▪ Verify and record ambient conditions, surface temperatures and dew point to
be within product specification requirements.

9.2 Surface Preparation

Surface preparation will be done as per client specification or Manufacturers
Data Sheet.

9.3 Material
Abrasive will be Garnet with 30/60 mesh size / Copper Slag grit HD 0.2-
2.4mm to achieve the specified blast standard of SSPC – SP10 and, profile
amplitude. Average profile height shall be 40 – 80 microns.

9.4 Equipment
Mobile air compressors will supply compressed air and the air will be dry and
oil free with a nozzle pressure of 100 PSI. 200ltr mobile blast pots with
remote control handles (dead man) will be used. Equipment will be earthed

and hoses will be carbon impregnated to prevent static electricity build up.
Venture shaped, tungsten carbide lined nozzles will be used and replaced
when wear reaches 50% of its original diameter.
HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
9.5 Pre-Start Inspection
Prior to starting surface preparation all items will be checked for faults that
could be deemed to be detrimental to the paint coating i.e. rough welds, burrs,
weld splatter, laminations etc. Faults will be rectified before surface
preparation commences
9.6 Repair After Welding
The affected area of sections will be rectified by the following method:

a. Abrasive blasting of welded area to Swedish standard SA 2.5.

b. Cleaning and de-dusting of blasting area.
c. Re-Paint the affected area as per required thickness &
specifications.
9.7 Degreasing
Any oil or grease will be removed by scraping off heavy deposits, brushing on
degreaser or emulsion cleaner followed by high – pressure portable (less
chlorides) water washing. The use of solvents for degreasing of large areas
cannot be considered a safe practice however, solvent swabbing may be
considered for removing small spots of oil or grease.

All chemicals to be used must have proper MSDS.

9.8 Environmental Conditions

Thick plastic sheet will be installed all around the area to be blasted.

The used grit laying on the plastic sheet will then be collected in plastic bays
and safely disposed appropriately in accordance with environmental approved
waste disposal agencies.

▪ Blast cleaning will not take place under the following conditions:
▪ Rain, fog, mist, airborne dust or sand or if there is moisture on the
surface.
▪ Steel temperature is less than 3° C above the dew point.
▪ Ambient air temperature is below 4° C.
▪ Relative humidity is greater than 85%.
▪ If there is a possibility of the above occurring within 2 hours or less.

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
 9.9 Blast Cleaning
Experienced blasters will perform abrasive blast cleaning and the standard will
conform to the requirements of the relevant systems specified herein and,
manufacturer’s data. Any defects uncovered by blasting will be rectified and re-
blasted to standard.

9.10 Cleaning
After blasting the surface will be thoroughly cleaned by one or more of the
following methods:
▪ Clean dry air blowing
10. Coating Application

10.1 Materials
One Manufacturer will supply all paint materials and thinners. Multiple coat
systems will be of a different colour for each coat.

10.2 Storage
All paint materials and thinners should be stored in an air- conditioned
container, according to the manufacturer’s recommendations and data
sheets. Special attention will be paid to the safety aspect of storing paints.
The following will be monitored and recorded:

a) Shelf life.
b) Batch numbers.
c) Labelling of tins.
d) Condition of tins i.e. broke seals or damaged tins.
10.3 Equipment
Airless or conventional spray pumps with paint manufacturers recommended
nozzle sizes and pressures will be used. Brushes and rollers will be used for
stripe coating, touch up and areas that may be inaccessible to the spray gun.
All equipment will be thoroughly cleaned before and after use with
manufacturers recommended cleaner/thinner. Wet film combs will be used to
control the uniformity of film thickness.

If there is a risk of any of the above occurring during the application or

surface drying of the coating.

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
 10.4 Mixing
Paint will be checked before mixing for any deterioration during storage. Any
doubts about the integrity of the material will be brought to the attention of
the manufacturer and advice will be sought on the course of action. Thinning
will only take place according to manufacturer’s recommendation and to them
specify maximum volume. Only a volume of paint, will be mixed, that can be used
within the pot life and paint that has exceeded the pot life will not be used. Paint will
be thoroughly mixed using mechanical power stirrers.

10.5 Inspection
All inspection and testing will be carried out as per section 7.0 by qualified
and experienced personnel. A manufacturer’s Technician shall be available
as and when required.

10.6 Environment Conditions

▪ Application will not take place under the following conditions:
▪ Rain, fog, mist, airborne dust or sand or moisture on the surface.
▪ Steel temperature is within 5°C of the dew point.
▪ Steel temperature is below 10° C.
▪ Steel temperature is above 40° C.
▪ Relative humidity is greater than 85%.
11. Packing & shipping

▪ All materials shall be cleaned and dried internally and externally to remove
foreign materials such as weld slag, scales, rust, cuttings, filings, moisture,
liquids, oils, films, fluids and other such excesses.

▪ Critical wear/polished surfaces and stressed parts shall be cleaned using a

suitable solvent.

▪ Protective primer undercoats and finish coats shall be applied as specified on

the fabrication drawings.

▪ Ladders, cages, etc. may be shipped attached to columns, drums, air coolers,
or shipped separately.

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
 ▪ All flexible connections subject to possible damage during shipment shall be
disconnected, clearly marked for installation location, and safely packed
separately within the same package. Loose ends are to be adequately
supported and protected to prevent damage.

▪ All threaded, bevelled, and machined areas shall be lubricated/greased and

protected as necessary from damage, corrosion, handling, etc.

▪ Stainless steel materials shall be crated or suitably protected, and stored only
below deck on a vessel.

▪ Items subject to damage by water, humidity or moisture shall receive

additional protection as defined on the drawings.

▪ Flanged openings bolted on, shall be protected with appropriate plywood or

plastic covers. Apply plastic cover with plastic secure tape

▪ Unconnected pipe threads used in normal operation shall be completely

protected and covered with plastic plugs or caps

▪ Desiccant crystals, vapor inhibiting oil, vapor phase inhibiting powder or

silica gel shall be used where appropriate for I & E or moisture sensitive
equipment.

▪ Equipment shall be held in a fixed position by chocks, bracing, bolts or

packing materials to prevent movement or vibration during transport.

▪ All vessel internals not installed in the vessel shall be crated or boxed for
protection from damage or loss in transit. Internal bolting and gaskets for
service operation shall be boxed separately for later installation.

▪ Structural steel shall be securely strapped and tagged

▪ Marks on small bundles will be applied to permanently tags.

▪ Suitable anti-corrosive substance coating shall be applied to all materials.

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
 ▪ Flanged openings shall be sealed against the ingress of dust, dirt, sand and
water by securing wooden, plastic or metal covers to the openings. Threaded
connections will be protected by caps and small threaded connections can be
wrapped.

▪ 5” OD and below: Wooden case or crate required

▪ 3/4” - 6” OD: Single random length: sufficient strong bundle with minimum
five wire ties

▪ Machined and bevelled edges of pipes shall be protected from damage with
metal or plastic caps.

▪ Large OD fittings and flanges shall be palletized, utilizing plywood separators

so as to not allow metal to metal packing. At least two steel bands and four
when necessary, of sufficient strength shall criss-cross pallet.

▪ Large OD elbows can be double or triple tiered on pallets, with plywood

spacers between tiers and on top. Banding shall be secured around the
circumference of package as well as inserted through elbows.

▪ Flanged faces, screwed, socket weld ends and other machined surfaces shall
be plugged, sealed and protected with a suitable anti-corrosive material to
prevent damage and/or corrosion prior to installation/operation.

▪ Waterproof plastic shall be used to line tops, ends and sides of all waterproof
crates.

▪ Lengthy materials, structural steel, pipe, etc. which are not likely subject to
transit damage are allowed to be shipped bare in bundles.

▪ Bundles shall be securely tied with steel wire or steel bands at the centre and
each end, at minimum

▪ Protective material shall be placed between wires/banding and materials, to

prevent damage/corrosion

▪ Bundled material ends shall be capped and/or protected as necessary to

prevent damage or loss.

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
 ▪ Forces imposed on packages during transit, handling and environmental
conditions encountered during storage, shall be considered in the design and
in the selection of packaging methods.

▪ No material or equipment shall ship from our premises to the Fabrication

Yard and site with an outstanding Non-Conformance without prior written
approval from client.

▪ We will follow project specific punch list system, unless otherwise agreed
with client, all punch lists shall be closed at the contractor works place prior
to dispatch of items to client location or Site

▪ External surface of the all items has been preserved by painting as per
approved painting procedure.

▪ Appropriate care will be taken to avoid any damage of our packed &
delivered condition

12. Health, Safety and Environment

▪ The Sub-contractor Workshop safety procedure shall be strictly followed by
all Sub-contractor Personnel’s.
▪ Tool box talk shall be conducted on daily basis to inform the workers of the
recent safety issues and incidents and to get feedback of any unreported unsafe
acts. Feedback will then be processed and resolved.
▪ This method of statement will be carried out in conjunction with HSE Plan and
Risk assessment.
13. Inspection and Test Plan
▪ Approved Inspection and test plan shall be implemented during each and
every stage of fabrication, to ensure the work is carried out with full
compliance drawings and specification. The Inspection and approving parties
as per ITP shall ensure the quality of work at every level.
▪ All non-destructive testing shall be performed by the Petrolynx Quality control
team in accordance with the requirements of the applicable standards and
project specifications. NDT shall be performed as per approved ITP and
procedures.

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.
14. Organization Chart

HOLDER OF ASME – ‘U’, ‘U2’ & NBIC - ‘R’ STAMPS ACCREDITED. ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 CERTIFIED.