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PIPING FABRICATION & Doc. No.
INSTALLATION PROCEDURE REV. 0 Page 2 of 15
PROJECT : DATE. 03-March.-14
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REVISION SUMMARY
PIPING FABRICATION & Doc. No.
INSTALLATION PROCEDURE REV. 0 Page 3 of 15
PROJECT : DATE. 03-March.-14
TABLE OF CONTENTS
1. SCOPE
2. REFERENCE
3. REQUIREMENT FOR WORKS
4. SAFETY
5. EXECUTION OF WORKS
6. SHOP FABRICATION WORK
7. FIELD INSTALLATION WORK
8. QUALITY CONTROL FOR WELDING
9. INSPECTION AND TESTING FOR PIPING
10. GENERAL CLEANING
11. COLOR CODING AND LINE NUMBERING
1. SCOPE
PIPING FABRICATION & Doc. No.
INSTALLATION PROCEDURE REV. 0 Page 5 of 15
PROJECT : DATE. 03-March.-14
This document covers the work procedure for Piping Work (i.e. shop fabrication, field installation,
inspection, internal cleaning and testing of piping system) at Rawa Modification LTRO Project. All
piping shall be fabricated in accordance with the applicable Piping Code, Standard, Engineering
Drawing, and Project Specification.
2. REFERENCE
All piping shall conform to the requirements of the latest edition of the following applicable codes,
standards, and testing specifications, including its addendum.
The intent of this procedure is not to supersede those codes, standards, and Company
specification, but to supplement them as necessary and to stress their important points by reciting
their major requirements.
Codes and Standards
ASME B31.3 Process Piping
ASME Section IX Welding & Brazing Qualifications
ASME Section V Non-destructive Examination
ASME B16.25 Butt Welding Ends
ASME B20.1 Pipe Threads, General Purpose (Inch)
P.F.I. ES-3 Fabricating Tolerances
Project Specification
ID-N-BU-LL2-STS-GN-00-0001 Rev.2 Standard Specification Welding
3. REQUIREMENT FOR WORKS
a. Material
All Piping materials shall be in accordance with Project Specification, if any of material to be
supplied by Contractor, it shall be clearly stated in the requisition and in accordance with Project
Specification as well.
b. Testing and Inspection of Materials
Contractor shall use materials which passed the test and inspection based on Project
Specification
c. Documents to be submitted
As a rule Contractor shall submit the records of any test (Pressure Test, Radiography Inspection
or PWHT if any) and reporting period of the work execution in daily report, weekly report, monthly
report and/or any other report.
4. SAFETY
Full care and precaution shall be given for the safety of the personnel in the site/project to prevent
from incidents/accidents during the work execution, and mandatory safety induction will be
introduced to each personnel that newly arrived at site.
5. EXECUTION OF WORKS
5.1. Welding
5.1.1. Welding shall be performed as per the Project Specification and Procedure.
5.1.2. Welding Procedure Specification (WPS) shall be prepared and submitted to Company
for approval together with Procedure Qualification Test Record (PQR).
5.1.3. Contractor in the presence of Company shall perform welder qualification tests. All
materials and equipments shall be supplied by Subcontractor, including welding rods, gases and
steel pipes that required for the above test.
5.1.4. All the welders to be engaged in this works must pass the examination as specified in
the procedures. For those who failed, re-examination will be allowed only once.
5.1.5. A specific dry method and drying condition of welding electrode shall be selected as
per manufacturer instruction.
5.1.6. Rule and procedure of welding shall be as follows, unless otherwise specified
in the drawings.
a. Prior to welding, beveled surface and all welding area shall be cleanly, free from rust, oil,
paint, moisture and other foreign matters, which are detrimental to welding. Especially for
austenitic Stainless Steels and Duplex any adhering zinc-rich paint shall be completely removed.
b. End of piping to be welded shall be well aligned for avoiding improper butting which may
result in developing residual stress in piping components.
c. Grounding wire cable shall be firmly fastened by screw or clamp to the material to be welded,
at the position as near as possible to the welded part.
d. All welding areas shall be adequately protected against inclement weather conditions such as
rain, wind, dust, and the like.
PIPING FABRICATION & Doc. No.
INSTALLATION PROCEDURE REV. 0 Page 6 of 15
PROJECT : DATE. 03-March.-14
e. Welding shall be performed in flat position in principle. When the flat position is impossible,
welding shall be done in a position as close as to flat position if possible.
f. Electrodes size for tack welding shall be selected corresponding to the root opening.
g. Material of wire brush shall be properly selected for working on stainless steel.
5.1.7. Butt joint welding of pipes shall be performed as follows:
a. Circumferential butt-welding joint shall be performed without using backing ring in principle.
b. Before welding of first layer, both ends of tack weld bead shall be sharpened with grinder in
order to allow complete fusion.
5.1.8. As a rule, edge preparation of butt-welding shall be beveled in accordance
with ASME B16.25 figure 2a for thickness 22 mm and smaller as figure 3a for greater than 22 mm
5.1.9. In the case of butt-welding of pipes having unequal wall thickness of which
the difference is more than 3 mm in outer surface and/ or 1.5 mm in inner surface. The end of
pipes shall be trimmed by grinding. The gradient of this trimming shall be less than 30 0 between
worked and un-worked parts .The deposit welding will be required if wall thickness after trimming
becomes less than the design thickness.
5.1.10. Branch connections shall be made refer to COPI standard A-84523-DY-LL0-SPC-GN-
00-0001 Pipe, Valves and Fitting.
5.1.11. When the seam pipe is used in horizontal line, the pipe shall be laid so that
the longitudinal weld seam is located at side of the pipe.
5.1.12. Reinforcement of weld bead shall be in accordance with vendor Engineering
Specification. Insufficient reinforcement (less than the thickness of parent metal) is not permitted.
The bead shall not be finished mechanically. Last layer itself shall be neatly laid.
5.1.13. Seal weld shall be applied for the leakage threaded joint and it required if thread
circumferential is covered.
5.2. Preparation for Welding
5.2.1. End Preparation
Preparation of pipe ends shall preferably be done by any combination of sawing, milling, turning
and grinding.
a. Grooves for butt weld ends shall be suitable for the welding process to be used, and the
contour shall permit complete fusion throughout the joint. In principle, the grooves shall be in
accordance with the Welding Procedure Specification (WPS), however, when not specified, the
grooves shall be in accordance with the requirements of Fig. 1.
b. Piping having a nominal thickness less than 3 mm for stainless steel or duplex and 4 mm for
carbon and low alloy steel may have a slight chamfer.
c. The ends of piping components to be joined shall be aligned as accurately as practicable
within existing commercial tolerances on diameters, wall thickness and out of roundness.
5.2.2. Cleaning
Surface for welding shall be cleaned and shall be free from paint, oil, rust, scale/ other material,
which is detrimental to welding 50 mm min. back from weld.
For the cleaning of stainless steel and duplex, only stainless steel brushes and tools shall be
used. These brushes and tools shall not be contaminated by use on carbon or low alloy steels.
Grinding disc containing sulphur shall not be used on stainless steel, duplex or non-ferrous
materials.
5.2.3. Alignment
The end of piping components to be joined shall be aligned as accurately as is practicable within
existing commercial tolerances on diameters, wall thickness and out-of-roundness.
Radial misalignment at any location shall be limited to 3.2 mm total or 1.6 mm each side.
Minimum thickness must be kept taper trimming shall be done.
5.2.4. Backing Ring
Permanent installed backing rings or strips shall not be used without prior written approval.
5.2.5. Minimum Distance Between Weld
a. The distance between edges of adjacent circumferential butt welds and circumferential butt
weld to fillet in pipe shall be not less than 4 times of wall thickness or 25 mm (1 inch) which ever
is greater. When weld joints over lap such as branch welds, weld-o-lets, sock-o-let as required by
the Engineering drawing
b. Longitudinal seams in adjoining lengths of welded pipe shall not be located as to clear
openings and external attachments. Clearance shall not be less than 4 times the pipe wall
PIPING FABRICATION & Doc. No.
INSTALLATION PROCEDURE REV. 0 Page 7 of 15
PROJECT : DATE. 03-March.-14
thickness or 25 mm, whichever is greater and distance between longitudinal seams measured on
the circumferential weld is at least 5 times the wall thickness of pipe.
The Subcontractor shall check the finish dimension of pipe rack, others structures against the
Piping Arrangement Drawings and make sure that is available support before mounting the piping
where the piping to be connected to or from equipment.
7.3 Threading
7.3.1 Thread to be used for pipe shall be taper pipe threads stipulated in vendor
specification. Taper pipe threads shall be in accordance with ANSI B.2.1 Pipe Treads, General
Purpose, Inch.
7.3.2 Threaded end connection shall be seals as follows :
a. 260 OC (500 OF) and below: with Teflon tape or Teflon threading compound.
b. Above 260 OC: seal welding of joints.
7.3.3 The threaded joints for the following shall not be welded :
a. Thermo-wells
b. Screwed ends of control valves and bronze valves
c. Screwed connection at instruments
d. Caps on drain and vent connections
7.3.4 In threaded joint between pipe and flange, the length of thread on the pipe shall be
prepared in such manner that the end of the pipe comes shorten to reach the gasket surface on
the flange by 1.5 to 3.0 mm when screwed-in. Otherwise reduce the length of thread by cutting-
off.
7.4 Installation of Instruments
7.4.1 Fabricate all the tapping points for instruments connection and install instruments in
position as shown in the Pipe Drawing (isometric or piping plan).
7.4.2 When mounting instrument apparatus, orientation and direction of valves stem shall
be in accordance with Piping Arrangement Drawings. However, if there is any inconvenience, the
work shall be done in accordance with instruction of Contractor personnel in charge.
7.5 Erection Works
7.5.1 Special precautions shall be taken during carbon steel piping erection that in adjacent
to stainless steel piping. Direct contact between carbon steel / alloy and stainless steel is not
permitted. Stainless steel piping shall be protected when carbon steel piping is being welded or
worked on in such a manner so that the grinding or welding particles cannot contact with the
stainless steel, or it shall not become contaminated.
7.5.2 Valves shall be installed in closed position after cleaning and it shall not be opened
during erection. Care shall be taken when installing control valves, globe valves, blow-down
valves and pressure relief valves so that the direction of the valves meet the flow direction of the
lines.
7.5.3 Pipe spool erection shall be installed properly by checking horizontal / vertical
directions and the distances between parallel lines, using leveler, transit, plummet, etc.
7.5.4 Adequate measurement including pipe sleeves or collar shall be provided against the
hole of floor and platform through which piping is penetrated.
7.5.5 When the works are executed in adjacent to piping made of, or lined with special
materials such as plastics, rubber, glass, etc., care shall be taken so as not to damage them.
7.5.6 Lines connected to rotating machinery shall be aligned so as meet the following
requirements :
a. Piping around pump and compressor nozzles shall be installed up to a break point between
the nearest pipe support and the equipment. The remaining piping shall be properly fitted in order
to avoid any external loading on the equipment that would cause misalignment or overstressing.
b. Flange faces, which connect piping to rotating machinery, shall be properly/strictly fitted with
the clearance between them equal to the thickness of the gasket.
c. Center of bolt-holes shall be in lined between nozzle and flange so the bolts can pass
smoothly through the bolt-holes.
d. Erect piping on permanent supports/hangers to minimize the adjustment after erection, and
testing. Adjust spring supports/hangers where necessary (spring supports/hanger must remain in
the locked position).
e. The bolting up and tensioning of the flanges, it shall not effect the coupling alignment between
the driver and driven equipment.
7.5.7 Where insulating flange kits are to be installed, care shall be taken not to damage the
bolt sleeve and washer. The completed joint shall be tested with a high frequency insulation
resistance meter or similar device to assure electrical isolation.
PIPING FABRICATION & Doc. No.
INSTALLATION PROCEDURE REV. 0 Page 10 of 15
PROJECT : DATE. 03-March.-14
9.3.1 General
a. Prior to initial operation, installed piping shall be pressure tested to assure the strength and
tightness of all welded joints, threaded of flanged under witness of Contractor QC and Company
QC inspector.
b. Prior to pressure testing, piping joints (including flanged, threaded or welded) will be painted
and left un-insulated. Underground joints shall be exposed.
c. If a pressure test is to be maintained for a period of time and the test liquid in the system is
subject to thermal expansion precautions shall be taken to avoid excessive pressure.
d. Water used for pressure test shall be fresh water for carbon steel and water not contain more
than 30 ppm chloride for pressure test stainless steel and duplex.
10.2.2 Cleaning shall be continuously perform until the water becomes free from foreign
matter, scale, etc. This shall be decided by observing turbidity of water taken out (into bearer or
cup).
10.2.3 The primary cleaning shall be performed for each assembled piping. And secondary
cleaning shall be performed for whole of piping system.
10.2.4 To remove all burning mark after heat treatment, crayon, oil, etc. from stainless steel
and duplex material will be done using chemical cleaning (pickling). Chemical cleaning will apply
with plastic brush and rinse by water.
11.3 Application
11.3.1 After cleaning each spool piece, the line number to be painted in white capital letters
at least one near one end, or near both ends.
11.3.2 Line number to be marked may be replaced with a metal tag stamped with a die
securely, attached to the pipe with metal straps or wires if it difficult to mark the number on a spool
piece of small size or short length.
PIPING FABRICATION & Doc. No.
INSTALLATION PROCEDURE REV. 0 Page 14 of 15
PROJECT : DATE. 03-March.-14
FIG 1
BEVELS FOR BUTT WELDING
37.5o2.5o 20o2.5o
5R
1.60.8 mm 1.60.8 mm
T T
DC0.25 mm
o
14 ~18o 14o~18o
DC0.25 mm
T < 22 mm
10o10o
20o10o
5R 1.60.8 mm
T 25
DC0.25 mm
14o~18o
T > 22 mm
PIPING FABRICATION & Doc. No.
INSTALLATION PROCEDURE REV. 0 Page 15 of 15
PROJECT : DATE. 03-March.-14
FIG 2
DIMENSIONAL TOLERANCES FOR FABRICATED PIPING