Doc Ref: QCP-03

QUALITY CONTROL
Date: 1
st
January 2009
Kencana Infrastructure
PROCEDURE
Revision No : 0
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Cover Page
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PIPING FABRICATION
PROCEDURE
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Doc Ref : QCP-03
Date : 1
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January 2009
Revision No : 0


PIPING FABRICATION
PROCEDURE
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TABLE OF CONTENTS


SECTION DESCRIPTION PAGE

1.0 PURPOSE 2

2.0 SCOPE 2

3.0 REFERENCE 2

4.0 DIFINITION 2

5.0 PROCEDURE

5.1 GENERAL 2-3
5.2 FIT-UP 3-4
5.3 PREHEATING REQUIREMENTS 4
5.4 N.D.T 4
5.5 POST WEALD HEAT TREATMENT (PWHT) 5
5.6 PAINTING OF PIPE SPOOLS 5

5.7 THREADED PIPE, FITTING AND SOCKET
WELDS
5
5.8 PIPE SUPPORTS 6
5.9 FLANGE ALIGNMENT CHECKS 6-8
5.10 FLANGE ALIGNMENT TOLERANCES 8-9
5.11 SHAFT ALIGNMENT DISPLACEMENT LIMITS 9
5.12 HYDROSTATIC TEST 9
5.13 REINSTATEMENT 10
5.14 PIPING MAKE-UP CONDITION 10

6.0 SPECIAL REQUIREMENT 10

7.0 RECORDS 10













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January 2009
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PROCEDURE
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1.0 PURPOSE

This procedure serves as a guideline in carrying-out Piping Fabrication to
ensure systematic approach of work and the requirements are followed.


2.0 SCOPE

This procedure covers the processes associated for the Piping Fabrication,
such as mark , cutting, Fit-up, Weld-up, Testing, Painting etc.


3.0 REFERENCE

ASME B31.3 Chemical Plant and Petroleum Refinery Piping

ASME 1X Boiler & Pressure Vessel Code (Welding and Brazing
Qualification)

4.0 DEFINITION

WPS - Welding Procedure Specification
SMAW - Shielded Metal Arc Welding.
NDT - Non-Destructive Testing
DPI - Dye-Penetrant Inspection
MPI - Magnetic Particle Inspection
RT - Radiographic Test.
UT - Ultrasonic Test.
PWHT - Post Weld Heat Treatment
NPS - Nominal Pipe Size
API - American Petroleum Institute,
TFE - Poly-tetra-fluoroethylene


5.0 PROCEDURE

5.1 General

5.1.1 It is the responsibility of the Production Superintendent to
ensure that key personnel involved in piping Fabrication
understand fully the requirement mentioned in this
procedure.

5.1.2 All storage, traceability, identification, tolerances, welding,
Inspection and testing shall be carried out as stipulated
within the specifications, procedures and codes.


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5.1.3 All materials shall have end caps inserts or plug fitted on
pipes, valves, fitting etc. during or after blasting and painting
activities.

5.1.4 Only qualified welders that have been approved by Client
shall be used for any piping welding.

5.1.5 The electrodes or wire to be utilized for piping welding will
be as stipulated in each W.P.S as approved by Client

5.1.6 All welding information for each specific operation shall be
displayed at the working area. Welding consumable control,
shall be as stipulated in QCP-06

5.1.7 The Quality Control Section shall develop and maintain a
record of each welders performance. This record shall
show the defect rate of each welder, based on linear weld
length.

5.1.8 Prior to any fit-up or welding, all material i.e. pipe, fitting,
valve etc. shall be recorded and documented as stipulated
in Material Control Procedure


5.2 FIT-UP

Pipe spool fit-up shall be carried out in a professional manner
adhering to isometric drawings and tolerances.

5.2.1 Small bore pipe can be fit-up with the use of angle bar.
Large bore pipe shall be fit-up with the use interior or
exterior line up clamps HI-LO shall be kept within tolerances
as stipulated in ASME B31.3i.e.,1.6 mm.

5.2.2 Snaking and distortion in pipe spools shall be limits 1.5 mm
per meter length.

5.2.3 After marking the pipes as per the isometric drawing. The
pipe shall be checked by QC Inspector.
5.2.4 After mark-up has been checked by the piping Supervisor
and the pipe should be cut as per mark-up.

5.2.5 Fit-up tack welds are allowable and if in the root shall be as
per WPS electrode requirement and bridge tacks are also
allowable using SMAW. All tacks using SMAW electrodes
shall be removed during the welding of the joint.


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5.2.6 The fit-up spool at this stage shall be submitted to QC
Inspector for their approval and fit-up to be signed prior to
any welding on the spool.

5.2.7 All pipe prior to fit-up, shall be internally and externally
cleaned to a minimum of 5mm from the edge preparation
and shall be free of rust and surface contamination.

5.2.8 The spool fit-up can now be welded as per the relevant
WPS and preheating requirements as specified in the WPS
and section 5.3 of this procedure.

5.2.9 The completely welded pipe spool shall be visual and the
dimension inspected by the QC Inspector prior to NDT.

5.2.10 Welding Supervisor shall ensure that there is adequate
ventilation at the work place prior to any purging of pipe
works.


5.3 PRE-HEATING REQUIREMENTS

5.3.1 Pre- heating shall be accordance with Client specification,
applicable codes, standards and administered in accordance
with combined thickness and WPS pre-heating requirements.
Pre-heating shall be carried out by electrical resistance or
induction equipment or with gas acetylene /propane/butane
burners and monitored by the used of tempilsticks. The pre-
heating temperature shall be established over an area 75mm
on each side of the joint configuration. Each welder shall be
provided with a set of tempilstick to monitor the preheating
requirement for the joint to be welded.


5.4 NDT

5.4.1 All non-destructive Testing (RT, MPI, DPI, and UT) shall be
carried out after the spool has been visually accepted by the
QC Inspector and documented. NDT requirement will be
performed as per isometric drawing and NDT Procedure. All
NDT results shall be documented.

5.4.2 Weld repairs shall be carried out as per the relevant WPS and
in accordance to Client specification and welding repairs
procedure.



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5.5 POST WELD HEAT TREATMENT (PWHT)

Post Weld Heat Treatment (PWHT) shall be carried out as per QCP-7.


5.6 PAINTING OF PIPE SPOOL

5.6.1 Following satisfactory NDT and PWHT results, pipe spools can
be released for painting.

5.6.2 Pipe spools shall be blasted to SA 2.5 or Clients requirement
and primed as per the requirements of the painting procedure.
All pipe spools intended for insulation and heat tracing shall be
blasted and primed only.

5.6.3 Where possible all pipe spools will have its final coat
completed prior to erection fit-up. Pipe spools with field welds
will be spot blasted and primed and final coated in-situ.


5.7 THREADED PIPE, FITTINGS AND SOCKET WELDS

5.7.1 All treaded pipe and pipe fitting, shall be installed with the use
an anaerobic pipe thread sealant with T.F.E. on the following
which do not required seal welding.
a) Plugs and cap for drain and vent valves.
b) Thermowell
c) Union ring threads and union bonnets of valves.
d) Instrument tubing fittings.
e) Union nut rings.
5.7.2 For service employing hydrocarbon, acid and toxic materials,
threaded connection shall be seal welded. The threads are to
be made up using no sealant and two threads maximum
exposed followed by back welding.

5.7.3 Seal welding shall be done with electrode not to exceed 3.2mm
in diameter using amperage in low range.

5.7.4 Prior to assembly, all cutting oil shall be removed.

5.7.5 All small bore fitting shall be arranged and storage at the rack
between type threaded and non-threaded.






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5.8 PIPE SUPPORTS

5.8.1 Ensure that pipe guide, anchor, sliding shoes, stoppers are
Installed correctly where specified according to the IFC
drawings

5.8.2 Field Engineer Inspect the spring hanger/ supports to ensure
that the type (suspension, compression variable load of fixed
load types) and capacity are correct and that the actual loading
is within designed capacity.

5.8.3 For insulated piping, ensure that the load is transmitted directly
from the piping to the supporting structure through the pipe
support, and not through the insulation.

5.8.4 Ensure that correct type of flexible connections is installed
where specified in the IFC drawing or by the machinery vendor.

5.8.5 Ensure the pipe supports foundations are adequately
reinforced.


5.9 FLANGE ALIGNMENT CHECKS

5.9.1 The out-of parallel alignment check and out-of axial alignment
check shall be performed to all flange connections between the
piping and the machinery.


(A) Out- of Parallel Alignment Check




FIGURE 1
P1

P2

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5.9.2. The out-of parallel alignment shall be performed using a vernier
caliper.

The measurement shall be taken using the outer periphery of
the inner flange face as the datum. Out-of parallel alignment
will be the results of P1 minus P2 as shown in Figure 1.

4 set of measurements. Each 90 apart shall be taken. The
points selected to measure shall be the point with maximum
misalignment.


(B) Out-of Axial Alignment










FIGURE 2

The measurement shall be taken at the intersecting point of the
flange radii and the bolt hole periphery nearest to the flange
centre. (Refer figure 2 for typical point)

In order to eliminate the manufacturing tolerances in the flange
outside diameter, the average of the measurement at two
points directly opposite each other will be considered the actual
out-of axial alignment












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(c) Out-of Radial Alignment (Bolt Hole Alignment)


-Should not exceed 2mm


FIGURE 3


At least two sets of measurement, each 90 apart shall to be
taken. The point selected to measure shall be the point with
the maximum misalignment.

Neither of the readings shall exceed the limits specified in Para
5.10


5.10 FLANGE ALIGNMENT TOLERANCES

All flanges connection between the piping and rotating equipment
shall be aligned to within the following tolerances.

NORMAL SERVICE SPECIAL SERVICE Design
Temp. 454C or Flange,
Rating ANSI CL900

Out-of Parallel
Alignment
3/32 in. per ft. (1:125) of
nominal pipe diameter max.
out of parallel alignment of
flanges measured at any
point on the flange
circumference

1mm maximum, measured
across any diameter
Out-of Axial Alignment 3mm maximum 3mm maximum
Flange Face Separation Space required for gasket
1.5mm
Space required for gasket
1.5mm


Additional Requirement for Piping Over 80mm NPS

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Equipment having pipes over 80mm NPS shall be checked for
displacement of the drive shaft alignment due to the forces imposed
from the pipes to the equipment.

The shaft alignment displacement check shall be performed in the
following sequence:

i) Align the driver and driven equipment drive shafts to vendor
specified tolerances with piping disconnected.

ii) Install and tighten all hold-down/ anchor bolts and/ or dowel.

iii) Recheck drive shafts alignment with the pipes connected and
tightened, to determine the drive shaft displacement due to forces
imposed by the pipes.

All the drive shaft alignment data shall be recorded.


5.11 SHAFT ALIGNMENT DISPLACEMENT LIMITS

a) Alignment for pipes over 80mm NPS connected to rotating
equipments shall be acceptable if the resultant drive shaft
displacement due to the forces imposed by the pipes are within the
vendor specified allowable displacement.

b) In case which vendor specified tolerances are not available, the
following API standard shall be followed:

API STD 610
For centrifugal pump, the maximum drive shaft displacement
measured at the coupling on the installed pump is 127 micrometer
(0.005 inch)in any direction.

API STD 617
For centrifugal compressors, the maximum shaft displacement
measured at the coupling on the installed compressor is 50
micrometers (0.002 inch) in any direction.


5.12 HYDROSTATIC TEST

Hydrostatic Test shall be carried out as per QCP-10




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5.13 REINSTATEMENT

Pipe spool and valves that has been removed for hydrotesting shall be
reinstated. Reinstatement check of flange connection shall be as per
para 5.9 and tolerances as per para 5.10


5.14 PIPING MAKE-UP CONDITION

Prior to make-up of flange, flange faces shall be check for damages
Flange faces shall be aligned to the design plane to within 1mm
measured across any diameter. Flange bolt holes shall be aligned to
within 2mm offset.


6.0 SPECIAL REQUIREMENT.

NIL


7.0 RECORDS

NIL