Project Title:

PROCESS PIPING OF DKW72,MEM36,SIV,E2,NAOH,SOAP &SAF SYSTEMS

Doc. Title :
Submittal
Method Statement Ref. No

For SS Piping Page no. 1-11

DOC NO-NNSPL/DAT/PTD/004.

METHOD STATEMENT
FOR
SS PIPING

CLIENT : DATWYLER PHARMA PACKAGING IND PVT LTD

PMC : PTD CLEANTECH SOLUTION

CONTRACTOR : NILSAN-NISHOTECH SYSTEMS PVT LTD

This cover page is a record of all revisions of the standard/procedure identified above by number and title.
All previous cover pages are hereby superseded and are to be destroyed.

R Prepared By (NNSPL) Checked & Reviewed By Approved BY(PTDC)

e (NNSPL)
Date Status
v
. Name Signature Name Signature Name Signature

0 11/08/2 Mr. Adil Mr.Roshan

Mr.Nishar
021 ashraf
 CONTENTS
1) TITLE

2) PURPOSE

3) SCOPE

4) AREA OF APPLICATION

5) REFERENCES

6) DEFINITION & ABBREVIATIONS

7) RESOURCES MOBILIZATION

8) CONSTRUCTION EOUIPMENTS

9) PERSONNEL

10) MATERIALS

11) PROCEDURE FOR FABRICATION OF PIPING

12) PROCEDURE FOR ERECTION OF PIPING

13) INSPECTION & TESTING PROCEDURE

14) STATUTORY CONSENT

15) QUALITY ASSURANCE

16) HEALTH & SAFETY PLAN

17) ENVIONMENT POLICY

18) RELEVENT DOCUMENTATION

1. Weld Inspection Report.
2. Hydro test report / Pressure test.
3. Passivation report
4. As built isometrics

19) RISK ASSESSMENT& IIAZARD ANALYSIS:

20) ORGANIZATION CHART

1) TITLE:-

METHOD STATEMENT FOR SS PIPING

2) PURPOSE:

The purpose of this procedure is to provide guidelines to carry out all the activities in a systematic way for
Fabrication and Erection of Piping and to ensure that all concerned personnel have the common
understanding to achieve the highest quality of workmanship and the safe execution of the job.

3) SCOPE:

This procedure describes the stage wise fabrication & erection method of all piping work comes under
NNSPL scope in line with the specification and procedures for Process piping project at Datwyler pharma packaging
ind pvt ltd Shirval,Satara. This procedure may be modified to suit site condition during the fabrication &
Installation of piping work, Testing & Commissioning Procedure & Related quality documentation for taking the execution
quality performance.

4) AREA OF APPLICATION:

This procedure is applicable for common piping. (SS)

5) REFERENCES:
(i) As per Applicable Codes, Standards and Procedures
(ii) As per approved drawings.
(iii) Welding details as per approved WPS , PQR & WPQ.

6) DEFINITION & ABBREVIATIONS:

ASME : American Society of Mechanical Engineers.

IS : Indian Standard.
ASTM : American Society for Testing and Materials.
ANSI : American National Standard Institute.
WPS : Welding Procedure Specification
PQR : Procedure Qualification Record.
WPQ : Welder Performance Qualification
GENERAL:

WELDING:

All welding procedures, welders and welding operators shall be qualified by in accordance with
ASME requirements and job specifications.

Fit up shall be performed by tack weld with Argon gas shall be performed by approved welder.
Cleaning of Piping:

All pipes shall be cleaned prior to fabrication/erection wire brushed to remove all rust and mill scale from
inner surface. The method of cleaning shall be such that no material is left on the inner or outer surfaces of
pipe.

Fabrication:
Pipe welding ends for GTAW (Gas tungsten arc welding) as per relevant standards. To weld the fit-up joints the
welder shall be clears the test before employed for welding.
Pipe Supports:

Prior to installation of pipes, temporary pipe supports shall be installed (If required) or the permanent
supports will be installed as specified in the drawings & technical specification.

Supports permitting pipe movement shall be assembled as specified. Pipe support distance shall be as
per technical specification.

Valves:

Valves may be either with flanged ends, TC end, weld end & threaded ends & should be installed as per
approved drawings and technical specifications.

End Caps:

All Screwed or welded end caps are to be installed as specified in the drawings or as per Eng. Request. .

Testing:

The hydro test shall be performed after completion of pipeline in all respects. The test pressure will be as
per technical specification. The hydro test shall be taken in confidence of client.

7) RESOURCES MOBILIZATION:

Sufficient Material, manpower with necessary tools and equipment’s, as required, for safe and timely
completion of the work shall be deployed and these will consist of but not limited to the following.

1. Engineers & Supervisors.

2. Safety Personnel.
3. Skilled workers.(Fitter welder)
4. Unskilled workers. (Foremen, helper)
 8) CONSTRUCTION EOUIPMENTS:

All major lifting equipment’s tools and accessories listed below for the fabrication/erection will be arranged
by our site Engineers. Our engineer will reserve its right to select and use the appropriate tools, equipment and
accessories on based on actual site condition and as per requirement.

1. Hydraulic Crane 5. Welding machine 9. Welding torch

2. Hand tools 6. Grinding machine 10. Spirit Level
3. Hydro Testing Pump 7. Argon Gas cylinder 11. Measuring tape etc…
4. Hammer 8. Safety belt

9) PERSONNEL:

The Staffs & Manpower (PM, ENGR, QA/QC etc.) will be identified for to complete the particular job
and each staffs & manpower job responsibility will be identified and defined. Only trained and certified
personnel will be allowed for to complete the target.

10) MATERIALS:

All materials will be identified for particular job. Piping, Valves & specialties will be as per approved
technical data sheet. All material will be identify by as per specification and requirement & stored item wise
separately.

11) PROCEDURE FOR FABRICATION OF PIPING:

1. Pipe will be identified by Dia & grade and before starting the fabrication, pipe will be cleaned on
the inside. SS pipe will be either 304 or 316 L grade.
2. Pipe length will be marked as per approved drawings/Isometric drawings and cut by using hack
saw cutter & Grinder
3. Pipe level will be checked before welding and will be done as per approved groove angle.
4. Joint fit-up will be done as per approved WPS/Specifications (GTAW).
5. Depending on site conditions, assemble the piping into manageable lengths on the floor. Using
welded jointing as applicable.
6. Joint welding to be done by qualified welders as per approved WPS.
7. After completion of welding joint to be cleaned by wire brush.
8. Joint inspection will be done as per standard boroscope SOP and reports to be maintained.
9. Please refer attached chart for detail procedure
10. Refere attached SOP for orbital welding.
12) PROCEDURE FOR ERECTION OF PIPING:

1. Pipe Spools will be identified before installation of pipe.

2. As per approved drawing temporary or permanent support will be installed before erection of Pipe
Spools. Supports distance will be maintained as per specifications.
3. Before installation of pipe spools support painting to be done as per specification/ approved data sheet.
4. Pipe spools to be erected as per approved drawing using by proper handling equipment.
5. Align and level the piping as per approved drawings.
6. Joint fit-up will be done as per approved WPS/Specifications.
7. Joint welding to be done with GTAW (Gas tungsten arc welding) by qualified welder as per approved WPS.
8. After completion of welding joint to be cleaned by wire brush.
9. On surface of all welding joints, K2 paste solution to be used to avoid joint blackness.
10. Valves shall be installed as per approved drawing.
11. Permanent supports will be fixed as per approved drawing.
12. Install drain points at lowest level and install vent point at highest level in main line.
13. Joint inspection will be done as per require %boroscopy/videoscopy.
14. Line inspection will be done before given clearance for pressure test and report to be maintained.

13) INSPECTION & TESTING PROCEDURE:

After installation of piping as per approved drawing final line inspection will be done before
pressure test of piping. Weld inspection report and erection checklist to be completed before Hydro test
pipe as per approved SOP.

Testing procedure:
1. All debris shall be removed from the pipes.
2. All necessary welds shall be completed & randomly tested by 5% radiography.
3. Make sure flangeTC clamp joints are all tightened.
4. All necessary valves shall be installed and opened.
5. Make sure that sufficient drain points & vent points provided.
6. Calibrated pressure gauges shall be used for pressure test.
7. All instrumentation shall be isolated.
8. Vents points necessary to prevent air entrapment during filling shall be opened if required.
9. Make temporary tapping provisions for filling and draining of pressure testing water.
10. Test Water will be filled using temporary provisions.
11. Using pressure pump required pressure as per specification or 1.5 times of design pressure to be
raised for retaining time as per Desingn data sheet.
12. All welding joints & flange/TC clamp joints shall be checked for any leakages.
13. If any leakages are found, water shall be drained and leakage will be rectified.
14. Again pressurize the system using pressure pump.
15. During pressurization observe the joints and entire piping system for leakages and raise the
pressure up to required testing pressure.
16. If no leakages are found hold the pressure up to specified/approved time.
17. Inspection report to be maintained.
18. All safety precaution to be taken during hydro testing.
14) STATUTORY CONSENT:

All piping’s installation to be ensure for protection till commissioning.

15) QUALITY ASSURANCE:

We are the ISO 9001:2015 & ISO 45001:2018 certified company. Scope of Integrated Management System;
Nilsan Nishotech offers integrated and customized solutions, comprising right from Design, Engineering,
Manufacturing, Installation and Commissioning for Process Plant and Equipment in areas of Sterile Process Piping,
High Purity Water Systems and Separation Technologies

We will provide Quality Control persons at site to maintain the Quality as per customer requirement

16) HEALTH & SAFETY PLAN:

Please refer Attached HSE PLAN

The safety plan as given below,

Sr.No ACTIVITY PERFORMER FREQUENCY REMARKS

1 Safety committee meeting PMC As per approved To be attended by

manual the Site safety
In charge and as
required.
2 Safety induction for workers and Site Safety In Prior to engaging All personnel to be
for the Staff members charge the workers / staff engaged for
for site activity site activity should
under go
safety induction
Compulsorily.
3 Conducting tool box talk on daily Site Safety In Daily morning
basis at Site. charge /prior to new
activity.
Site Safety In As required Project engineer in
4 Tools and equipment inspection Charge. frequency coordination with
the safety in-charge
shall carry out
Inspection activity.
Site Safety In Completion of Site in charge shall
5 Inspection of the Scaffolding and charge erection and prior identify the
temporary structure for working to use and after competent person
At height. any change in the
Work condition.
Site Safety In Once in every 15 Electrical Engineer in
6 Electrical safety inspection charge Days checked & coordination
tagged by client with the Safety
every 3 months in charge shall carry
out inspection
activity & tags to be
Attached.
 Site Safety In
7 Inspection of fire Extinguisher. Every three month
charge
Inspection of First aid facility Safety In charge During site audit
8

9 Safety Inspection Safety In charge During site audit Concerned person

should accompany the
project engineer.
10 Certification of all equipment Project Engineer When the equipment
Project engineer in
first enter the site
coordination with the
and before start
site safety in charge
using equipment shall carry out
inspection activity.
11 Safety statistical report Site Safety In
Man Hours worked
charge Every month can be calculated at
actual basis.
Competent person Once in a year Project engineer in
12 Third party inspection of the as per the factories coordination with
lifting tools and tackles act, Safety in the safety in-charge
charge, QA/QC shall verify the
jr.engr certificate prior to
hire the cranes etc.
Separate gang &
13 House keeping Site engineer As required timings

17) ENVIONMENT POLICY:

1. The generation of waste should be avoided or minimizes wherever possible.

2. The worksite and premises shall be maintained in a healthy, clean and sanitary condition.
3. The walkways and roadways shall be maintained clean.
4. Special attention shall be given to remove the slipping and tripping hazards.
5. Stack or place material, tool and other equipment in such way that no hindrances to occur in actual work area.
6. Remove trash and debris daily from the worksite and premises including nails & welding stubs.
7. Remove combustible scrap at regular intervals.
8. Separate housekeeping person to be engaged depending the site requirements and environment will be checked on
daily basis by our safety persons.

18) RELEVENT DOCUMENTATION:

As per attached Annexure.
1. Weld Inspection Report.
2. Hydro test report/SOP.
3. Passivation report/SOP.
4. As built Isometrics.
19) RISK ASSESSMENT& IIAZARD ANALYSIS:
Please refer Attached JSA

20) ORGANIZATION CHART :

Please refer Attached Project organogram.