Method statement

Stainless Steel Piping

 Building No. 119 Turbo Compressors.
 Building No.118 Biological Reactors.
 All Remaining Stainless Steel Piping Activities.
Table of content
 SCOPE&PURPOSE
 REFERENCE
 RESPONSIBILITIES
 INTERFACING
 RESOURCES
o Equipment
o Manpower
 METHODOLOGY / PROCEDURE
o Site preparation
o Handling & Storage of equipment
o Pre-work
o Sequence / Installation
o Q.C Check
 1. SCOPE & PURPOSE
The purpose of this Method Statement is to describe the Methodology for
installation of Stainless Steel Piping such as Turbo Compressors (Building No. 119) and
Biological Reactors (Building No.118). And to detail the steps to be taken to meet the HSE
requirements specified for the execution of the Abu-Rawash waste water treatment plant.
 The scope of works comprises the following separate operations:
a. Handling and storage of the delivered materials
b. Transportation to site working area
c. Preassembly / preparation and Workshop Activities.
d. Installation
e. Mobilization of required equipment, auxiliaries and personnel.
f. Inspection and Testing of the system.

References
 The following documents define the requirements to be employed to demonstrate
compliance of the works defined in this method Statement
1. Documents
2. Drawings

Responsibilities
 Project Manager
 The Project Manager is responsible for the day-to-day effective
implementation of all activities and that all the relevant staffs are aware of
their responsibilities.
Mechanical Construction Manager
 To ensure that the construction activities are carried out according to the
specification, drawings and planned program.
 To ensure that all the equipment required to carry out the works according
to the construction program are available, in good condition, and provide any
additional equipment that might be required.
 To co-ordinate with the Site Engineer, Lead HSE Engineer, Foreman and
Surveyor for a safe & proper execution of the works.
 Assigning tasks / responsibilities to Senior Site Engineers.

 Senior Site Engineer

 Assigning tasks / responsibilities to Site Engineers.
 Monitoring and controlling execution process with respect to HSE, time,
quality and cost.
  Insuring that the execution process is going in accordance with method
statement.
Site Engineers
 Assigning tasks / responsibilities to supervisor and foreman / subcontractors.
 Monitoring and controlling execution process with respect to HSE time,
quality and cost.
 Insuring that the execution process is going in accordance with method
statement.
 Insure that the execution team aware about all risks before starting the job.
 Surveyors
 Marking points and levelling.

 Lead QA/QC Engineer

 The lead QA / QC Engineer is responsible of the quality of the works executed
in field and, therefore, for the proper application of this field inspection
coordination procedure. He is to be aware of the requirements of CLIENT
Standards and Engineering Procedures and to ensure their implementation in
the field.
 Assigning tasks / responsibilities to QC engineers.
QC Engineers
 Monitoring and controlling execution process.
 Insuring that the execution process is going in accordance with method
statement and standards.
 Check materials and it’s compliance with specification and material
submittals.
 Insure proper handling and storage techniques to avoid material damage.
 Verifying scope of finished work with that of the baseline.
 Handing over finished work to consultant / owner.

 Lead HSE engineer

 Lead HSE Engineer shall ensure implementation of all safety Procedure,
safety measures related to the nature of works being carried out and in
accordance to the HSE Plan.
 Assign HSE officer for close monitoring that the work carried out safely.

2. Interfacing
 Construction Manager:
 Ensure proper coordination between interfacing works.
  Assigning tasks / responsibilities to senior site engineers to facilitate
coordination aspects.
 Senior Site Engineer:
 Ensure proper coordination between interfacing works.
 Assigning tasks / responsibilities to site engineers to facilitate
coordination aspects.
 Site Engineers:
 Coordinate with other site engineers to perform work properly and with
accordance to time schedule, scope and quality.
3. Resources
 Equipment
 Trucks for transportation.
 Lifting accessories.
 Cranes.
 Forklift
 Manpower
 Supervisor
 Foreman.
 Pipe fitters
 Fitters / Fabricators
 Riggers
 Safety Officer
 Welders

4. Methodology / Procedure

 Site preparation
o Mobilization of laydown area.
o Preparation of material storage area with good and safe access.
List of Piping
1. Turbo Compressor Piping
1.1.Compressor piping
1.1.1. Stainless Steel DN900
1.1.2. Stainless Steel DN250
1.2.Air collection header and piping
1.2.1. Stainless Steel DN900
1.2.2. Stainless Steel DN1800
2. Biological Reactors Piping
2.1. Mixed Liquor Recirculation
2.1.1. Stainless Steel DN1200
2.2. Air Piping
2.2.1. Main Header
2.2.1.1. Stainless Steel DN1800
2.2.1.2. Stainless Steel DN1600
2.2.1.3. Stainless Steel DN1400
2.2.1.4. Stainless Steel DN900
2.2.2. Reactor Distribution header
2.2.2.1. Stainless Steel DN900
2.2.2.2. Stainless Steel DN800
2.2.2.3. Stainless Steel DN700
2.2.2.4. Stainless Steel DN600
2.2.2.5. Stainless Steel DN500
2.2.2.6. Stainless Steel DN400
2.2.2.7. Stainless Steel DN300
2.2.2.8. Stainless Steel DN200
2.2.3. Down Comers (Drop Leg)
2.2.3.1. Stainless Steel DN250
2.2.3.2. Stainless Steel DN200
Fabrication Workshop to be prepared on site containing all the related
equipment, tools and Manpower required for accomplish the pre installation,
pre fabrication, supports fabrication, gathering and classification of material
prior to installation. This workshop will be under supervision of construction
and quality control departments.
 Some Joints will be selected as shop weld joints and others will be
considered as field weld joints and these joints will be marked as weld map.
 Temporary Supports to be fabricated and welded in this workshop.
The following graph shows the workshop area relative to the site map.

Figure 1
1. Turbo Compressor Piping
1.1. Work shop activities:

Figure 2

Figure 3
 1.1.1. Compressor piping
1.1.1.1. Stainless Steel DN900
1.1.1.2. Stainless Steel DN250
 This line is typical for each one of the 10 turbo compressor
 Each line to be separated as pipe spools, as an example this line to be as three pipe
spools as shown
o 045-AIR-1001 Sp.1
o 045-AIR-1001 Sp.2
o 045-AIR-1001 Sp.3

Figure 4

Each spool to be fabricated, welded and inspected as one part as follow:

o Fittings to be checked as material, condition and even dimensions
o Pipes to be cut as the drawing using stainless steel grinding/cutting disks
o Fitting and pipes to be assembled by means of tack welding (According to WPS)
o Fit-up to be check by QC Representative on site in order to release it for welding
 o Joints to be welded according to WPS by a qualified welder
o Welding to be inspected by QC Representative

1.1.2. Air collection header and piping

1.1.2.1. Header
1.1.2.1.1. Stainless Steel DN900
1.1.2.1.2. Stainless Steel DN1800
 This header is to collect compressed air from every 5 turbo compressors that means
we’ve two headers for each compressor building
 Each header to be fabricated as follow:

Figure 5

1.1. Fittings to be checked as material, condition and even dimensions

1.2. Pipes to be cut as the drawing using stainless steel grinding/cutting disks
1.3. DN1800 branch in the header DN1800 to be marked
1.4. The marking to be checked
1.5. Branch Pipe DN1800 to be assembled to the header DN1800 by means of
tack weld (according to WPS)
1.6. Fit-up to be checked by QC representative
1.7. Joint to be welded (according to WPS)
1.8. Welding to be checked by QC Representative on site
1.9. Flanges to be assembled to pipes DN900 and DN1800 by means of tack
weld (according to WPS)
1.10. Fit-up to be checked by QC representative
1.11. Joints to be welded (according to WPS)
1.12.Welding to be checked by QC Representative on site
1.13.Braches connections DN900 to be marked on the pipe DN1800.
1.14. These markings to be checked and released for cutting
1.15.Cutting will be done using stainless steel grinding disks.
1.16. Pipes DN900 to be fit-up one by one to the header pipe DN1800 by
means of tack welding (According to WPS)
1.17.Fit-up to be check by QC Representative on site in order to release it for
welding
1.18. Joints to be welded according to WPS by a qualified welder
1.19. Welding to be inspected by QC Representative
1.20. Reinforcements to be fabricated and assembled to the welded
joints
1.21.Assembly to be check by QC representative in order to release it for
welding
1.22. Reinforcement to be welded to the pipe DN1800 and pipe DN900
1.23. Welding to be inspected by QC representative
1.24. Repeat for the 5 DN900 branches
 1.1.2.2. Piping DN1800
1.1.2.2.1. Line 045-AIR-1021

Figure 6

1.25. Line 045-AIR-1021 to be separated by means of pipe spools as follow

(AS SHOWN IN GRAPH)
1.25.1. 045-AIR-1021-SP01(HEADERS)
1.25.2. 045-AIR-1021-SP02
1.25.3. 045-AIR-1021-SP03
1.25.4. 045-AIR-1021-SP04
1.25.5. 045-AIR-1021-SP05
1.25.6. 045-AIR-1021-SP06
1.25.7. 045-AIR-1021-SP07
1.25.8. 045-AIR-1021-SP08
1.26.For each spool the following to be done:
1.26.1. Fittings to be checked as material, condition and even dimensions
1.26.2. Pipes to be cut as the drawing using stainless steel grinding/cutting disks
 1.26.3. Fittings to be assembled to the pipes by means of tackwelds (according to
WPS)
1.26.4. Fit-up to be checked by QC representative
1.26.5. Joint to be welded (according to WPS)
1.26.6. Welding to be Inspected by QC Representative on site

1.1.2.2.2. Line 045-AIR-1021

Figure 7

1.27. Line 045-AIR-1021 to be separated by means of pipe spools as follow

(AS SHOWN IN GRAPH)
1.27.1. 045-AIR-1022-SP01(HEADERS)
 1.27.2. 045-AIR-1022-SP02
1.27.3. 045-AIR-1022-SP03
1.27.4. 045-AIR-1022-SP04
1.27.5. 045-AIR-1022-SP05
1.27.6. 045-AIR-1022-SP06
1.27.7. 045-AIR-1022-SP07
1.27.8. 045-AIR-1022-SP08
1.27.9. 045-AIR-1022-SP09
1.28. For each spool the following to be done:
1.28.1. Fittings to be checked as material, condition and even dimensions
1.28.2. Pipes to be cut as the drawing using stainless steel grinding/cutting disks
1.28.3. Fittings to be assembled to the pipes by means of tackwelds (according to
WPS)
1.28.4. Fit-up to be checked by QC representative
1.28.5. Joint to be welded (according to WPS)
1.28.6. Welding to be inspected by QC Representative on site
1.2.Site installation activities:
1.2.1. Header
1.2.1.1. Using telescopic long/low bed trailer the two headers to be transported from the
fabrication workshop to the area for assembly and preparation for lifting as shown
1.2.1.2.Unload the headers one by one
1.2.1.3.Prepare the headers for lifting

Figure 8
 Figure 9

1.2.1.4. Before lifting the header, the permanent supports to be lifted and installed as
follow:
1.2.1.4.1. 045.65.SPT-102
1.2.1.4.2. 045.65.SPT-103
1.2.1.4.3. 045.65.SPT-104

Figure 10
Figure 11

Figure 12

Figure 13
 1.2.1.5. Pipes to be cleaned
1.2.1.6. The header to be lifted and fixed on possition rested on the supports
1.2.1.7. The second header to be lifted the same manner
1.2.1.8. Suitable scaffold to be built inside the turbocompressor building
1.2.1.9. 4 lifting lugs per one turbocompressor to be welded to the embedded plates in
the building roof
1.2.1.10. Using a suitable trailer transport the compressors’ piping into the turbo-
compressor building one by one
1.2.1.11. Pipes to be cleaned
1.2.1.12. Inside the tubo compressor building the maulal butterfly valve DN900 and the
check valve DN900 to be assembled to the pipe DN900
1.2.1.13. The manual buterfy vale DN250 to be assembled to the pipe DN250
1.2.1.14. The assembled the branch DN900/DN250 to be lifted one piece using chain
blocks hanged to the prewelded lifting lugs in the building roof as shown

Figure 14

1.2.1.15. Support 05.65.SPT-101 to be installed on possition

1.2.1.16. The pipe to be adjusted to the support and fixed to the turbo compessor flange
1.2.1.17. Space for the expanion joint DN900 to be checked and adjusted and kept locked
using spacer between the two flanges DN900 between the Header and the pipe
DN900
1.2.1.18. Scaffold to be removed
1.2.1.19. The rest of 9 tubo compressor to be lifted by the same manner
1.2.1.20. Recheck the position of the header DN1800 and adjust if required
 Line 045-AIR-1021
1.2.1.21. The following supports to be installed as shown in figure 15
1.2.1.21.1. 05.65.SP-103
1.2.1.21.2. 05.010.STT-103
 Figure 15

1.2.1.22. Using suitable trailer transport the fabricated piping spools of line 045-AIR-1021
to the ground near the turbocompressor building
1.2.1.23. Assemble the spools together as follow:
1.2.1.23.1. In a clean leveled area 045-AIR-1021-SP-02 and 045-AIR-1021-SP-03 to be
arranged together for assembly
1.2.1.23.2. Conneting joints to be cleaned and ready for assembly
1.2.1.23.3. Spools to be assembled together by means of tackweld (according to the
WPS)
1.2.1.23.4. The joint to be ispected by QC representative in order to released for
welding
1.2.1.23.5. Welding to be done (according to the WPS)
1.2.1.23.6. Welding to be inspected by QC representative
1.2.1.24. 045-AIR-1021-SP-04 to be assembled to the previosly assembled spools as follow:
1.2.1.24.1. In a clean leveled area 045-AIR-1021-SP-04 and the previosly assembled
spools to be arranged together for assembly
1.2.1.24.2. Conneting joints/pipes to be cleaned and ready for assembly
1.2.1.24.3. Spools to be assembled together by means of tackweld (according to the
WPS)
1.2.1.24.4. The joint to be ispected by QC representative in order to released for
welding
1.2.1.24.5. Welding to be done (according to the WPS)
1.2.1.24.6. Welding to be inspected by QC representative
1.2.1.25. Now we have the assembly of 045-AIR-1021-SP01,02 abd 03 assembled as shown
in figure 16
Figure 16

1.1.1.1. Pipes to be cleaned

1.1.1.2. Using crane the assembled piping to be lifted and rested on its supports 05.65.SP-103
and 05.010.STT-103
1.1.1.3. The joint to 045-AIR-1021-SP-01 to be assembled as follow:
1.1.1.3.1. The joint to be cleaned and ready for assembly
1.1.1.3.2.Pipes to be assembled together by means of tackweld (according to the WPS)
1.1.1.3.3.The joint to be ispected by QC representative in order to released for welding
1.1.1.3.4. Welding to be done (according to the WPS)
1.1.1.3.5.Welding to be inspected by QC representative
1.1.1.4. Now the line 045-AIR-1021 is as shown in figure 17
Figure 17

1.1.1.5. Spools 045-AIR-1021-SP-05, 06,07,08 to be assembled together (total length will be

20,172) as follow:
1.1.1.5.1. Spools 045-AIR-1021-SP-05 and 06 to be arranged on the ground for assembly
1.1.1.5.2.The joint to be cleaned and ready for assembly
1.1.1.5.3.Pipes to be assembled together by means of tackweld (according to the WPS)
1.1.1.5.4. The joint to be ispected by QC representative in order to released for
welding
1.1.1.5.5.Welding to be done (according to the WPS)
1.1.1.5.6. Welding to be inspected by QC representative
1.1.1.5.7.Spools 045-AIR-1021-SP-07 and the assembled spools to be arranged on the
ground for assembly
 1.1.1.5.8. The joint to be cleaned and ready for assembly
1.1.1.5.9. Pipes to be assembled together by means of tackweld (according to the
WPS)
1.1.1.5.10. The joint to be ispected by QC representative in order to released for
welding
1.1.1.5.11. Welding to be done (according to the WPS)
1.1.1.5.12. Welding to be inspected by QC representative
1.1.1.5.13. Spools 045-AIR-1021-SP-08 and the assembled spools to be arranged on
the ground for assembly
1.1.1.5.14. The joint to be cleaned and ready for assembly
1.1.1.5.15. Pipes to be assembled together by means of tackweld (according to the
WPS)
1.1.1.5.16. The joint to be ispected by QC representative in order to released for
welding
1.1.1.5.17. Welding to be done (according to the WPS)
1.1.1.5.18. Welding to be inspected by QC representative
1.1.1.6. Now the spools are weled together as shown in figure 18

Figure 18

1.1.1.7. Scaffold to be built under the end of the previosly lifted pipe
1.1.1.8. Pipes to be cleaned
1.1.1.9. Using crane the assembled spools to be lifted on position
1.1.1.10. The joint to be arranged for weldingas foloow:
 1.1.1.10.1. The joint to be cleaned and ready for assembly
1.1.1.10.2. Pipes to be assembled together by means of tackweld (according to the
WPS)
1.1.1.10.3. The joint to be ispected by QC representative in order to released for
welding
1.1.1.10.4. Welding to be done (according to the WPS)
1.1.1.10.5. Welding to be inspected by QC representative
1.1.1.11. Now line 045-AIR-1021 has been installed completely as shown in figure 19

Figure 19
  Line 045-AIR-1022
1.1.1.12. Pipes to be cleaned
1.1.1.13. Spool 045-air-1022-SP-02 to be lifted and fixed temporarly by means of temporary
supports to the turbocompressor building
1.1.1.14. Joint between 045-air-1022-SP-02 and header to be adjusted and assembled as
follow:
1.1.1.14.1. The joint to be cleaned and ready for assembly
1.1.1.14.2. Pipes to be assembled together by means of tackweld (according to the
WPS)
1.1.1.14.3. The joint to be ispected by QC representative in order to released for
welding
1.1.1.14.4. Welding to be done (according to the WPS)
1.1.1.14.5. Welding to be inspected by QC representative

Figure 20

1.1.1.15. The following supports to be installed see figure 21:

1.1.1.15.1. 05.65.SP-102
1.1.1.15.2. 05.65.SPT-103
1.1.1.16. Spool 045-air-1022-SP-03, 04,05 and 06 to be assembled together in worksop and
to be transported to site
1.1.1.17. Pipes to be cleaned
1.1.1.18. As one pipe to be lifted on position rested on its supports
1.1.1.19. The joint between this pipe assembly and 045-air-1022-SP-02 to be assembled and
adjusted as follow see figure 22:
1.1.1.19.1. The joint to be cleaned and ready for assembly

Figure 21

1.1.1.19.2. Pipes to be assembled together by means of tackweld (according to the

WPS)
1.1.1.19.3. The joint to be ispected by QC representative in order to released for
welding
1.1.1.19.4. Welding to be done (according to the WPS)
1.1.1.19.5. Welding to be inspected by QC representative

Figure 22
 1.1.1.20. Pipes to be cleaned
1.1.1.21. 045-air-1022-SP-07 to be lifted and fixed to support 05.65.SPT103 from one side
and to a temporay supprt to the building roof from the other side

Figure 23

1.1.1.22. The joint to be assembled, adjusted and welding as follow see figure 24:
1.1.1.22.1. The joint to be cleaned and ready for assembly
1.1.1.22.2. Pipes to be assembled together by means of tackweld (according to the
WPS)
1.1.1.22.3. The joint to be ispected by QC representative in order to released for
welding
1.1.1.22.4. Welding to be done (according to the WPS)
1.1.1.22.5. Welding to be inspected by QC representative
1.1.1.23. 045-air-1022-SP-08 to be lifted and fixed to two temporary supports one to be
installed on turbo compressor building roof nad the other to be installed on the
biological top wall as shown in figure 25
1.1.1.24. The joint to be assembled, adjusted and welding as follow see figure 24:
1.1.1.24.1. The joint to be cleaned and ready for assembly
1.1.1.24.2. Pipes to be assembled together by means of tackweld (according to the
WPS)
1.1.1.24.3. The joint to be ispected by QC representative in order to released for
welding
1.1.1.24.4. Welding to be done (according to the WPS)
 1.1.1.24.5. Welding to be inspected by QC representative

Figure 24

Figure 25
1.1.1.25. The following supports to be installed on the top wall of biological reactor
building as shown in figure 26:
1.1.1.25.1. 05.10.SPT-125
1.1.1.25.2. 05.10SPT-126

1.1.1.26. 045-air-1022-SP-09 to be assembled to 045-air-1022-SP-10 as follow:

1.1.1.26.1. The joint to be cleaned and ready for assembly
1.1.1.26.2. Pipes to be assembled together by means of tackweld
(according to the WPS)
1.1.1.26.3. The joint to be ispected by QC representative in order to
released for welding
1.1.1.26.4. Welding to be done (according to the WPS)
1.1.1.26.5. Welding to be inspected by QC representative
1.1.1.27. The assembled spools to be lifted and fixed to the installed supports
1.1.1.28. The joint to be adjusted, assembled and welded as follow:
1.1.1.28.1. The joint to be cleaned and ready for assembly
1.1.1.28.2. Pipes to be assembled together by means of tackweld (according
to the WPS)
1.1.1.28.3. The joint to be ispected by QC representative in order to released
for welding
1.1.1.28.4. Welding to be done (according to the WPS)
1.1.1.28.5. Welding to be inspected by QC representative
 1.1.1.29. Expansion joints inside turbocompressor building to be installed stress
free as follow:
1.1.1.29.1. Spacers to be removed
1.1.1.29.2. Check the pipe cleaness
1.1.1.29.3. Space for the expanion joint to be check and adjusted
1.1.1.29.4. Expansion joint to be installed

Figure 26
2. Biological Reactors Piping
 2.1.Work shop activities:
2.1.1. Main Header:

2.1.1.1.Stainless steel Pipe DN1800 (see figure 27)

Figure 27

2.1.1.1.1. FlangeDN1800 to be welded to the pipe DN1800 as follow:

2.1.1.1.1.1. The joint to be cleaned and ready for assembly
2.1.1.1.1.2. Pipes to be assembled together by means of tackweld (according to
the WPS)
 2.1.1.1.1.3. The joint to be ispected by QC representative in order to released
for welding
2.1.1.1.1.4. Welding to be done (according to the WPS)
2.1.1.1.1.5. Welding to be inspected by QC representative
2.1.1.1.2.Pipe to be cut according to the drwaing as follow:
2.1.1.1.2.1.Measure the pie and mark the mensioned length in drawing
2.1.1.1.2.2. Cut the piping using grinder with stainless steel cutting disk
2.1.1.1.2.3. Cleane the cut using stainless steel grinding disk
2.1.1.1.3.Reducer DN1800/DN1600 to be welded to anoter pipe DN1800 as
follow:
2.1.1.1.3.1. The joint to be cleaned and ready for assembly
2.1.1.1.3.2.Pipes to be assembled together by means of tackweld (according to
the WPS)
2.1.1.1.3.3.The joint to be ispected by QC representative in order to released
for welding
2.1.1.1.3.4. Welding to be done (according to the WPS)
2.1.1.1.3.5. Welding to be inspected by QC representative
2.1.1.1.3.6. Pipe DN900 to be welded to the DN1800 pipe as follow:
2.1.1.1.3.6.1. Mark the required opening from drawings
2.1.1.1.3.6.2. Cut the opening
2.1.1.1.3.6.3. Cut the pipe DN900
2.1.1.1.3.6.4. The joint to be cleaned and ready for assembly
2.1.1.1.3.6.5. Pipes to be assembled together by means of tackweld
(according to the WPS)
2.1.1.1.3.6.6. The joint to be ispected by QC representative in order to
released for welding
2.1.1.1.3.6.7. Welding to be done (according to the WPS)
2.1.1.1.3.6.8. Welding to be inspected by QC representative
2.1.1.1.3.7. The two pipes DN1800 to be assembled and welded together as
follow:
2.1.1.1.3.7.1.The joint to be cleaned and ready for assembly
2.1.1.1.3.7.2. Pipes to be assembled together by means of tackweld
(according to the WPS)
2.1.1.1.3.7.3. The joint to be ispected by QC representative in order to
released for welding
2.1.1.1.3.7.4. Welding to be done (according to the WPS)
2.1.1.1.3.7.5. Welding to be inspected by QC representative
2.1.1.1.3.7.6.
2.1.1.2. Stainless steel Pipe DN1600 (see figure 28)
Figure 28

2.1.1.2.1.Pipe DN900 to be welded to the pipe DN1600 as follow:

2.1.1.2.1.1.1. Mark the required opening from drawings
2.1.1.2.1.1.2.Cut the opening
2.1.1.2.1.1.3.Cut the pipe DN900
2.1.1.2.1.1.4.The joint to be cleaned and ready for assembly
2.1.1.2.1.1.5.Pipes to be assembled together by means of tackweld
(according to the WPS)
2.1.1.2.1.1.6. The joint to be ispected by QC representative in order to
released for welding
2.1.1.2.1.1.7.Welding to be done (according to the WPS)
2.1.1.2.1.1.8. Welding to be inspected by QC representative
2.1.1.2.1.2. Reducer DN1600/DN1400 to be welded to pipe DN1600 as
follow:
2.1.1.2.1.2.1.The joint to be cleaned and ready for assembly
2.1.1.2.1.2.2. Pipes to be assembled together by means of tackweld
(according to the WPS)
2.1.1.2.1.2.3. The joint to be ispected by QC representative in order to
released for welding
2.1.1.2.1.2.4. Welding to be done (according to the WPS)
2.1.1.2.1.2.5. Welding to be inspected by QC representative
 2.1.1.3. Stainless steel Pipe DN1600 (see figure 29)

Figure 29

2.1.1.3.1.Pipe DN900 to be welded to the pipe DN1400 as follow:

2.1.1.3.1.1. Mark the required opening from drawings
2.1.1.3.1.2.Cut the opening
2.1.1.3.1.3.Cut the pipe DN900
2.1.1.3.1.4. The joint to be cleaned and ready for assembly
2.1.1.3.1.5.Pipes to be assembled together by means of tackweld (according
to the WPS)
2.1.1.3.1.6. The joint to be ispected by QC representative in order to
released for welding
2.1.1.3.1.7.Welding to be done (according to the WPS)
2.1.1.3.1.8. Welding to be inspected by QC representative
2.1.1.3.2. Reducer DN1400/DN900 to be welded to pipe DN1400 as
follow:
2.1.1.3.2.1.The joint to be cleaned and ready for assembly
2.1.1.3.2.2. Pipes to be assembled together by means of tackweld (according
to the WPS)
2.1.1.3.2.3. The joint to be ispected by QC representative in order to released
for welding
2.1.1.3.2.4. Welding to be done (according to the WPS)
2.1.1.3.2.5. Welding to be inspected by QC representative
2.1.1.4. Stainless steel Pipe DN900 (see figure 30)

Figure 30
 2.1.1.4.1. Flange DN900 to be welded to the pipe DN900 as follow
2.1.1.4.1.1. The joint to be cleaned and ready for assembly
2.1.1.4.1.2. Pipes to be assembled together by means of tackweld (according
to the WPS)
2.1.1.4.1.3. The joint to be ispected by QC representative in order to released
for welding
2.1.1.4.1.4. Welding to be done (according to the WPS)
2.1.1.4.1.5. Welding to be inspected by QC representative
2.1.1.4.2. Pipe DN900 to be cut according to drawing
2.1.1.4.2.1. Mark the pipe DN900 with the length mensioned in the drawing
2.1.1.4.2.2. Using grinder and stainless steel cutting/grinding disk cut and
clean the pipe DN900
2.1.1.4.3. Pipe DN900 to be welded to the pipe DN900 as follow:
2.1.1.4.3.1. Mark the required opening from drawings
2.1.1.4.3.2. Cut the opening
2.1.1.4.3.3. Cut the pipe DN900
2.1.1.4.3.4. The joint to be cleaned and ready for assembly
2.1.1.4.3.5. Pipes to be assembled together by means of tackweld (according
to the WPS)
2.1.1.4.3.6. The joint to be ispected by QC representative in order to
released for welding
2.1.1.4.3.7. Welding to be done (according to the WPS)
2.1.1.4.3.8. Welding to be inspected by QC representative

2.1.2. Reactors’ distribution header:

Figure 31

2.1.2.1. Line 040-AIR-2001

2.1.2.1.1. To be fabricated as the following spools see figure 32:
2.1.2.1.1.1. 040-AIR-2001-SP-01
2.1.2.1.1.2.040-AIR-2001-SP-02
2.1.2.1.1.3.040-AIR-2001-SP-03
2.1.2.1.2. Every joint in each spool to be fabricated as follow:
 2.1.2.1.2.1.Pipe to be cur according to the drawing using stainless steel cutting
disk
2.1.2.1.2.2. The joint to be cleaned and ready for assembly
2.1.2.1.2.3. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.1.2.1.2.4. The joint to be ispected by QC representative in order to
released for welding
2.1.2.1.2.5. Welding to be done (according to the WPS)
2.1.2.1.2.6. Welding to be inspected by QC representative

Figure 32

2.1.2.2. Line 040-AIR-2011

2.1.2.2.1. To be fabricated as the following spools see figures 33 and
34:
2.1.2.2.1.1.040-AIR-2011-SP-01
2.1.2.2.1.2. 040-AIR-2011-SP-02
2.1.2.2.1.3. 040-AIR-2011-SP-03
2.1.2.2.1.4. 040-AIR-2011-SP-04
2.1.2.2.1.5. 040-AIR-2011-SP-05
2.1.2.2.1.6. 040-AIR-2011-SP-06
2.1.2.2.1.7. 040-AIR-2011-SP-07
2.1.2.2.1.8. 040-AIR-2011-SP-08
2.1.2.2.1.9. 040-AIR-2011-SP-09
2.1.2.2.1.10. 040-AIR-2011-SP-10
2.1.2.2.1.11. 040-AIR-2011-SP-11
Figure 33

2.1.2.2.2. Every joint in each spool to be fabricated as follow:

2.1.2.2.2.1. Pipe to be cur according to the drawing using stainless steel
cutting disk
2.1.2.2.2.2. The joint to be cleaned and ready for assembly
2.1.2.2.2.3. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.1.2.2.2.4. The joint to be ispected by QC representative in order to
released for welding
2.1.2.2.2.5. Welding to be done (according to the WPS)
2.1.2.2.2.6. Welding to be inspected by QC representative
Figure 34

2.1.2.2.3. Welding to be inspected by QC representative

2.1.2.3. Line 040-AIR-2101
2.1.2.3.1. This line to be fabricated as one piece in workshop see figure 35
2.1.2.3.2. Avery joint to be assembled, adjusted and welded as follw:
2.1.2.3.2.1. Pipe to be cur according to the drawing using stainless steel
cutting disk
2.1.2.3.2.2. The joint to be cleaned and ready for assembly
2.1.2.3.2.3. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.1.2.3.2.4. The joint to be ispected by QC representative in order to
released for welding
2.1.2.3.2.5. Welding to be done (according to the WPS)
2.1.2.3.2.6. Welding to be inspected by QC representative
Figure 35
2.1.2.4. Line 040-AIR-2114
2.1.2.4.1. This line to be fabricated as one piece in workshop see figure 36
2.1.2.4.2. Avery joint to be assembled, adjusted and welded as follw:
2.1.2.4.2.1. Pipe to be cur according to the drawing using stainless steel cutting disk
2.1.2.4.2.2. The joint to be cleaned and ready for assembly
2.1.2.4.2.3. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.1.2.4.2.4. The joint to be ispected by QC representative in order to released for
welding
2.1.2.4.2.5. Welding to be done (according to the WPS)
2.1.2.4.2.6. Welding to be inspected by QC representative

Figure 36
2.1.2.5. Line 040-AIR-2118
2.1.2.5.1. This line to be fabricated as one piece in workshop see figure 37
2.1.2.5.2. Every joint to be assembled, adjusted and welded as follw:
2.1.2.5.2.1. Pipe to be cut according to the drawing using stainless steel cutting disk
2.1.2.5.2.2. The joint to be cleaned and ready for assembly
2.1.2.5.2.3. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.1.2.5.2.4. The joint to be ispected by QC representative in order to released for
welding
2.1.2.5.2.5. Welding to be done (according to the WPS)
2.1.2.5.2.6. Welding to be inspected by QC representative

Figure 37
2.2. Site installation activities:
2.2.1. As all the biological pipe routing is supported on top of wall so this area is
to be arranged for safe work as follow:
2.2.1.1. Several access to be arranged up/down the wall
2.2.1.2. Side walk way to be arranged somewhere if required see figure 39
2.2.1.3. Barriers to avoid falling to be arranged both sides of top of walls see
figure 38

Figure 38

Figure 39
2.2.2. Mixed Liquor Recirculation
2.2.2.1. The following supports to be installed on biological internal wall:
2.2.2.1.1. 05.10.SPT-201 (SEVERAL)

2.2.2.2.Using crane, the DN1200 pipes to be lifted inside the biological reactor
2.2.2.3.By means of transporting carriage the pipes DN1200 to be transported underneath its
position
2.2.2.4.On the top of the wall a beam with reinforcements to the wall top platform to be welded as
shown (TO BE CALLED LIFTING MECHANISM)
2.2.2.5.10 lifting mechanisms to be assembled
2.2.2.6. 2 Lifting lugs to be welded to every lifting mechanism on each side.
2.2.2.7.Pipes to be cleaned
2.2.2.8. Using chain blocks hanged to the lifting lugs pipes DN1200 to be lifted on top of
supports
2.2.2.9. Joints to be assembled, adjusted and welding as follow:
2.2.2.9.1. The joint to be cleaned and ready for assembly
2.2.2.9.2. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.2.2.9.3. The joint to be ispected by QC representative in order to released for
welding
2.2.2.9.4. Welding to be done (according to the WPS)
2.2.2.9.5. Welding to be inspected by QC representative
2.2.2.10. The Elbow 45 to be welded to the last pipe by the same manner

2.2.2.11. Supports to be adjusted and finalized after the complete welding of joints
2.2.2.12. Pressure test
2.2.2.12.1. Line to be plugged both sides with blinds containing test connections
2.2.2.12.2. Test pressure is 1.5 Bar
2.2.2.12.3. Test medium is air
 2.2.3. Line 040-AIR-2001
2.2.3.1. The following supports to be installed on the top of the biological
wall:
2.2.3.1.1. 05.10.SPT-120 (SEVERAL)
2.2.3.1.2. 05.10.SPT-119

Figure 40

1.1.1.1. Pipes spools to be cleaned before installation using air

1.1.1.2. 040-air-2001-sp-01 to be lifted and fixed on the support
05.10.SPT-120 one side and on a temporay support the other side
1.1.1.3. 040-air-2001-sp-02 to be lifted and fixed to two temporay
suppots both sides
1.1.1.4. The joint between 040-air-2001-sp-01 and 040-air-2001-sp-02
to be adjusted and welded as follow:
1.1.1.4.1.1. The joint to be cleaned and ready for assembly
1.1.1.4.1.2. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
1.1.1.4.1.3.The joint to be ispected by QC representative in order to released
for welding
1.1.1.4.1.4.Welding to be done (according to the WPS)
1.1.1.4.1.5.Welding to be inspected by QC representative
1.1.1.4.2. 040-air-2001-sp-03 to be lifted and fixed to temporay
supports
1.1.1.4.3. The joint between 040-air-2001-sp-02 and 040-air-2001-
sp-03 to be adjusted and welded as follow:
1.1.1.4.3.1.The joint to be cleaned and ready for assembly
 1.1.1.4.3.2. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
1.1.1.4.3.3. The joint to be ispected by QC representative in order to
released for welding
1.1.1.4.3.4. Welding to be done (according to the WPS)
1.1.1.4.3.5. Welding to be inspected by QC representative
1.1.1.4.4. Spacer to be put and fixed in the position of the
electric control butterfly valve
2.2.4. Line 040-AIR-2011
2.2.4.1. The following supports to be installed on the top of the biological
wall see figure 41:
2.2.4.1.1. 05.10.SPT-109 (SEVERAL)
2.2.4.1.2. 05.10.SPT-110 (SEVERAL)
2.2.4.1.3. 05.10.SPT-111 (SEVERAL)
2.2.4.1.4. 05.10.SPT-112 (SEVERAL)
2.2.4.1.5. 05.10.SPT-113 (SEVERAL)
2.2.4.1.6. 05.10.SPT-114 (SEVERAL)
2.2.4.1.7. 05.10.SPT-115 (SEVERAL)
2.2.4.1.8. 05.10.SPT-116 (SEVERAL)
2.2.4.1.9. 05.10.SPT-117 (SEVERAL)
2.2.4.1.10. 05.10.SPT-118 (SEVERAL)

Figure 41

2.2.4.2. 040-AIR-2011-SP-01 to be lifted and fixed to the spacer of the electric

butterfly valve in line 040-AIR-2001 and to be adjusted by means of
teporay and permenant supports.
 2.2.4.3. 040-AIR-2011-SP-02 to be lifted and fixed by means of temporay
and /or permenant supports.
2.2.4.4. The joint between 040-AIR-2114-SP-01 and 040-AIR-2011-SP-02 to
be adjusted and welded as follow:
2.2.4.4.1. The joint to be cleaned and ready for assembly
2.2.4.4.2. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.2.4.4.3. The joint to be ispected by QC representative in order to
released for welding
2.2.4.4.4. Welding to be done (according to the WPS)
2.2.4.4.5. Welding to be inspected by QC representative
2.2.4.5. This process to be repeated till last spool to be installed and
welded
2.2.4.6. Adjust the complete line and fix all supports
2.2.5. Line 040-AIR-2101
2.2.5.1. The following suppotrs to be install in the biological wall:
2.2.5.1.1. 05.10.SPT-107
2.2.5.1.2. 05.10.SPT-104 (SEVERAL)

Figure 42
 2.2.5.2. The line is fabricated as one piece
2.2.5.3. butterfly valve to be installed in line Line 040-AIR-2011 ends.
2.2.5.4. Pipes to be cleaned before installation
2.2.5.5. Lift the line 040-AIR-2101 and fix it to its supports and adjudt the
connection with the valve.
2.2.6. Line 040-AIR-2114
2.2.6.1. The following suppotrs to be install in the biological wall:
2.2.6.1.1. 05.10.SPT-104 (SEVERAL)
2.2.6.2. The line is fabricated as one piece

Figure 43

2.2.6.3. Butterfly valve to be installed in line Line 040-AIR-2011 ends.

2.2.6.4. Pipes to be cleaned before installation
2.2.6.5. Lift the line 040-AIR-2114 and fix it to its supports and adjudt the
connection with the valve.
2.2.6.6. Repeat the process till last line is installed.
2.2.7. Line 040-AIR-2118

Figure 44
 2.2.7.1. The following suppotrs to be install in the biological wall:
2.2.7.1.1. 05.10.SPT-101 (SEVERAL)
2.2.7.1.2. 05.10.SPT-102 (SEVERAL)
2.2.7.1.3. 05.10.SPT-103 (SEVERAL)
2.2.7.2. The line is fabricated as one piece
2.2.7.3. butterfly valve to be installed in line Line 040-AIR-2011 ends.
2.2.7.4. Pipes to be cleaned before installation
2.2.7.5. Lift the line 040-AIR-2118 and fix it to its supports and adjudt the
connection with the valve.
2.2.7.6. Repeat the process till last line is installed.
2.2.8. Adjust all supports on final position
2.2.9. Prepare the supports that require grouting
2.2.10. Finalize the grouting for that supports
2.2.11. Line 040-AIR-1022
2.2.11.1. Following supports to be installed:
2.2.11.1.1. 05.10.STT-001 (SEVERAL)
2.2.11.1.2. 05.10.STT-002 (SEVERAL)

Figure 45

2.2.11.2. Pipes to be cleaned before installation

2.2.11.3. 040-AIR-1022-SP-01 DN1800 to be lifted and fixed to supports
2.2.11.4. Joints to line 040-AIR-2001 to be assembled, adjusted and welded
as follow:
2.2.11.4.1. The joint to be cleaned and ready for assembly
2.2.11.4.2. Pipes and fittings to be assembled together by means of
tackweld (according to the WPS)
 2.2.11.4.3. The joint to be ispected by QC representative in order to
released for welding
2.2.11.4.4. Welding to be done (according to the WPS)
2.2.11.4.5. Welding to be inspected by QC representative
2.2.11.5. 040-AIR-1022-SP-02 DN1600 to be cleaned using air, lifted and
fixed to temporay supports
2.2.11.6. Dimenstions to be check and adjstment for the length to be done
2.2.11.7. Joint to reducer DN1800/DN1600 to be assembled, adjusted and
welded as follow:
2.2.11.7.1. The joint to be cleaned and ready for assembly
2.2.11.7.2. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.2.11.7.3. The joint to be ispected by QC representative in order to
released for welding
2.2.11.7.4. Welding to be done (according to the WPS)
2.2.11.7.5. Welding to be inspected by QC representative
2.2.11.8. First part of DN1400 to becleaned with air, lifted and fixed to
supports
2.2.11.9. Joint to reducer DN1600/DN1400 to be assembled, adjusted and
welded as follow:
2.2.11.9.1. The joint to be cleaned and ready for assembly
2.2.11.9.2. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.2.11.9.3. The joint to be ispected by QC representative in order to
released for welding
2.2.11.9.4. Welding to be done (according to the WPS)
2.2.11.9.5. Welding to be inspected by QC representative
2.2.11.10. Repeat the process to install the fourth part od DN1400
2.2.11.11. Joints to line 040-AIR-2001 (DN900) to be assembled, adjusted
and welded as follow:
2.2.11.11.1. The joint to be cleaned and ready for assembly
2.2.11.11.2. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.2.11.11.3. The joint to be ispected by QC representative in order to
released for welding
2.2.11.11.4. Welding to be done (according to the WPS)
2.2.11.11.5. Welding to be inspected by QC representative
2.2.11.12. pipe DN900 to becleaned with air, lifted and fixed to support
2.2.11.13. dimentional check to be done and the length to be adapted
2.2.11.14. joint to reducer DN1400/DN900 to be done as follow:
2.2.11.14.1. The joint to be cleaned and ready for assembly
2.2.11.14.2. Pipes and fittings to be assembled together by means of tackweld
(according to the WPS)
2.2.11.14.3. The joint to be ispected by QC representative in order to
released for welding
2.2.11.14.4. Welding to be done (according to the WPS)
2.2.11.14.5. Welding to be inspected by QC representative
2.2.11.15. Joint to DN900 branch to be done as follow:
2.2.11.15.1. The joint to be cleaned and ready for assembly
2.2.11.15.2. Pipes and fittings to be assembled together by means of
tackweld (according to the WPS)
2.2.11.15.3. The joint to be ispected by QC representative in order to
released for welding
2.2.11.15.4. Welding to be done (according to the WPS)
2.2.11.15.5. Welding to be inspected by QC representative
2.2.11.16. Blind flange DN900 to be installed
2.3. Pressure test:

Figure 46

2.3.1.1. The piping system will be divided to loops as follow see table 1:
2.3.1.1.1. Loop NO. 1
2.3.1.1.2.Loop NO.2
2.3.1.1.3. Loop NO.3
2.3.1.1.3.1.1.Loop3.1
2.3.1.1.3.1.2. Loop3.2
2.3.1.1.3.1.3. Loop3.3
2.3.1.1.3.1.4. Loop3.4
2.3.1.1.4. Loop NO.4
2.3.1.1.5.Loop NO.5
2.3.1.1.6. Loop NO.6
2.3.1.1.6.1.1. Loop NO.6.1
2.3.1.1.6.1.2. Loop NO.6.2
2.3.1.1.6.1.3. Loop NO.6.3
2.3.1.1.6.1.4. Loop NO.6.4
 Loop #No Loop description Test Pressure Test
(Bar) Fluid
1 From 5 turbos compressors up to 1.5 Air
expansion joint flange in biological 118.1
2 From expansion joint flange in 1.5 Air
biological 118.1 up to electric butterfly
valves DN900 flanges
3 From each electric butterfly valves 1.5 Air
(3.1, 3.2, 3.3 DN900 flange to connecting flange of air
and 3.4) distributer
4 From the other 5 turbos compressors up 1.5 Air
to expansion joint flange in biological
118.2
5 From expansion joint flange in 1.5 Air
biological 118.2 up to electric butterfly
valves DN900 flanges
6 From each electric butterfly valves 1.5 Air
(6.1, 6.2, DN900 flange to connecting flange of air
6.3 and 6.4) distributer

Table 1: the Loops descriptions and each test pressure value with test fluid

2.3.1.2. All expansion joints in each loop to be replaced by pipes with tow
welded flanges
2.3.1.3. All pipe ends to be plugged using blind flanes provided with test
connections
2.3.1.4. Testing of mixed liquor recirculation line has been up menstioed
with istallation.
2.3.1.5. See figure 47 and figure 48 for lopps highlighted in the P&ID
Figure 47
Figure 48