Disclaimer: The format of the document should be aligned with the specific contract requirements and the nature of the project. The content provided here highlights key considerations when developing a method statement. Two basic framework formats are included for reference:
Industrial, oil & gas, power plant, or heavy engineering projects
EPC, industrial plant, or infrastructure projects
Please note that these formats should be further customized to suit project needs. Additional elements may be incorporated where applicable, such as a detailed Inspection and Test Plan (ITP) matrix commonly used in oil & gas projects, welding inspection flow, construction workflow diagrams, and quality assurance (QA) forms typically required by consultants.
1.1 SCOPE OF WORK
This method statement covers the fabrication, installation, alignment, welding, inspection, and testing of structural steel members and piping systems including pipes, fittings, and flanges made from carbon steel and stainless steel used in industrial or infrastructure facilities.
1.2 REFERENCES
Works shall comply with recognized international standards including:
ASTM A36 : Structural carbon steel
ASTM A106 Grade B : Carbon steel seamless pipes
ASTM A312 : Stainless steel pipes
ASME B16.5 : Pipe flanges and flanged fittings
ASME B16.9 : Butt-welding fittings
ASME Section IX : Welding qualifications
1.4 PROCEDURE
1.4.1 Material Inspection
Verify material certificates (MTC) and heat numbers.
Confirm compliance with project specifications.
Inspect for damage, corrosion, or deformation.
1.4.2 Structural Steel Installation
Structural members are fabricated off-site or on-site as per approved shop drawings.
Surface preparation and protective coating / galvanizing are applied if required.
Members are lifted using cranes and installed according to grid alignment and elevation.
Connections are completed using high strength bolts or welding.
Final plumbness, level, and alignment checks are carried out.
1.4.3 Pipe Installation
Pipes are cut, beveled, and aligned before welding.
Pipe supports are installed according to piping drawings.
Pipes are installed progressively along the pipe rack or equipment connections.
Fittings and flanges are installed to facilitate direction change and equipment interface.
1.4.4 Welding
Welding is carried out following approved WPS and PQR.
Welders must be certified under relevant codes.
Preheating and post weld heat treatment (PWHT) are applied where required.
1.4.5 Inspection and Testing/QA-QC
Quality control includes:
Visual inspection of welds
Non-destructive testing (RT/UT/PT/MT)
Dimensional verification
Hydrostatic pressure testing of piping system
Inspection hold points should be identified where client or consultant approval is required before proceeding to the next stage (Systems must pass inspection prior to commissioning)
2. MATERIAL SELECTION (Justifications)
Material selection for structural and piping systems is based on strength, corrosion resistance, service conditions, cost efficiency, and maintenance requirements.
2.1 Carbon Steel (Structural Steel and Utility Piping)
Carbon steel is commonly used for:
Structural frames
Pipe racks
Utility pipelines (water, steam, air)
Advantages
High mechanical strength
Cost-effective and widely available
Good weldability
Suitable for non-corrosive environments
Typical Applications
Cooling water systems
Firewater pipelines
Compressed air systems
Structural support members
2.2 Stainless Steel (Process Piping)
Stainless steel is selected for services involving:
Corrosive chemicals
High purity processes
Hygienic or contamination-sensitive systems
Advantages
Excellent corrosion resistance
High durability and longer service life
Resistant to oxidation and chemical attack
Suitable for high temperature environments
Typical Applications
Chemical processing lines
Pharmaceutical or food-grade piping
Acid or solvent transport systems
Offshore or marine environments
2.3 Combined Material Strategy
Using carbon steel for structural support and utility lines while installing stainless steel for corrosive or critical process lines provides:
Optimized cost efficiency
Improved reliability and safety
Reduced maintenance requirements
Longer operational lifespan of the facility
This hybrid material strategy is commonly applied in industrial plants, refineries, power plants, and water treatment facilities.
3. RISK ASSESSMENT (HSE)
(Industrial, oil & gas, power plant, or heavy engineering projects)
3.1 Scope
Coverage of Hazards :
Structural steel erection
Carbon steel & stainless steel piping installation
Welding, grinding, lifting, hydrotesting
3.2 Hazard Identification & Control Measures
A. Lifting & Erection of Structural Steel
Hazards
Falling objects
Crane failure
Working at height
Control Measures
Approved lifting plan & load calculation
Certified crane & lifting gears inspection
Competent rigger & signalman
Full body harness for work > 2m
Barricaded exclusion zones
B. Welding & Cutting Works
Hazards
Fire & explosion
Arc flash & burns
Fumes inhalation
Control Measures
Hot Work Permit system
Fire watch & extinguishers
Welding screens
Proper ventilation
PPE: welding helmet, gloves, FR clothing
Welding qualification in accordance with ASME Section IX.
C. Piping Installation & Hydrotest
Hazards
Line burst during hydrotest
Stored energy release
Slips/trips
Control Measures
Calibrated pressure gauges
Test barricade & warning signage
Gradual pressurization
Pressure relief valve installed
Controlled access during testing
D. Handling Stainless Steel
Hazards
Cross-contamination from carbon steel tools
Sharp edges
Control Measures
Dedicated SS tools & brushes
Segregated storage area
Edge protection gloves
4. INSPECTION AND TEST PLAN (ITP)
5. QUALITY ASSURANCE
5.1 Pre-Construction
Approved IFC drawings
Approved WPS / PQR
Welder qualification records
Material approval from client
5.2 During Construction
Heat number traceability maintained
Fit-up inspection prior to welding
Bolt tightening sequence followed
Proper segregation of CS and SS materials
Surface protection applied
5.3 Post-Construction
NDT completed and accepted
Hydrotest completed
Punch list closed
As-built drawings updated
Final QA dossier compiled (included in the Project Quality Plan or Project Execution Plan (depending on role in the project whether a contractor/sub-contractor/consultant)
6. MATERIAL TRACEABILITY
6.1 Objective
To ensure full traceability of structural steel, pipes, fittings, and flanges from delivery to final installation.
6.2 Procedure
A. RECEIVING (INCOMING) INSPECTION
Verify Mill Test Certificates (MTC)
Check heat number stamped on materials
Assign internal tracking number
B. STORAGE AND SEGREGATION
Separate carbon steel and stainless steel materials
Store stainless steel away from contamination
Tag materials with identification code
C. FABRICATION/INSTALLATION
Heat number transferred to cut pieces
Weld map prepared for piping system
Welding recorded in weld log
D. DOCUMENTATION
Maintain:
Material Receiving Report (MRR)
Weld Traceability Log
NDT Reports
Hydrotest Reports
Final Material Dossier
7. ENGINEERING RATIONALE
The integration of:
Carbon steel for structural and non-corrosive utility service
Stainless steel for corrosive or critical process service
ensures:
Structural integrity
Operational reliability
Cost optimization
Regulatory compliance
Long-term asset durability
(EPC, industrial plant, or infrastructure projects)
1. RISK ASSESSMENT (HSE)
Risk assessments must comply with occupational safety requirements such as ISO 45001 and project safety procedures.
Mandatory Personal Protective Equipment (PPE)
Safety helmet
Safety shoes
Welding shield
Fire resistant gloves
Safety goggles
Full body harness for work at height
Emergency procedures must include first aid availability, fire extinguishers, and evacuation plan.
2. INSPECTION AND TEST PLAN
Inspection activities follow engineering standards including ASME B31.3 for piping systems.
Inspection hold points should be identified where client or consultant approval is required before proceeding to the next stage (Systems must pass inspection prior to commissioning)
3. QUALITY ASSURANCE
A quality checklist ensures compliance with project specifications.
Pre-Installation
Approved shop drawings available
Material certificates verified
Welding procedure approved
Welder qualification valid
Inspection tools calibrated
During Installation
Pipe alignment verified
Correct fittings and flanges installed
Welding parameters monitored
Bolt tightening sequence followed
Structural members properly aligned
Post Installation
NDT inspection completed
Pressure testing completed
Surface coating / painting completed
Final inspection signed by QA/QC team
4. MATERIAL TRACEABILITY
Material traceability ensures that every component installed can be traced back to its origin.
Each material must have:
Material Test Certificate (MTC)
Heat number identification
Manufacturer details
Batch or lot number
Common traceability practices include:
Stamping or tagging heat numbers on pipes
Marking structural steel members
Traceability tags attached to fittings and flanges
Material logs maintained by QA/QC department
4.1 Records
The following records should be maintained:
Traceability records are essential for future maintenance, audits, and regulatory compliance.
4.2 Project Documented Information
Project documentation should include:
Method Statement
Risk Assessment
Inspection & Test Plan
Welding Procedures (WPS/PQR)
NDT Reports
Hydrostatic Test Reports
Material Traceability Records
Final Acceptance Certificate
All documents should be compiled into a Project Quality Dossier for submission to the client. (included in the Project Quality Plan or Project Execution Plan (depending on role in the project whether a contractor/sub-contractor/consultant)
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