Piping Spool Fabrication Procedure

PIPING SPOOL FABRICATION PROCEDURE

Doc. No. WSM-PSFP-01 Rev. 0 11/03/19 Page 1 of 14

PT. WISESA MANDIRI

PIPING SPOOL FABRICATION PROCEDURE

WSM-PSFP-01

11/03/19

0

Issued for Approval

MKY

MKY

AA

Date

Revision

Revision Description

Prepared

Checked

Approved

PIPING SPOOL FABRICATION PROCEDURE

Doc. No. WSM-PSFP-01 Rev. 0 11/03/19 Page 2 of 14

Revision Summary Date

Revision

Revision Description

Prepared

Checked

Approved

11/03/19

0

Issued for Approval

MKY

MKY

AA

PIPING SPOOL FABRICATION PROCEDURE

Doc. No. WSM-PSFP-01 Rev. 0 11/03/19 Page 3 of 14

INDEX

1

SCOPE AND PURPOSE ................................................................................................................ 5

2

REFERENCE DOCUMMENT ......................................................................................................... 5

3

DEFINITION AND ABBREVIATIONS ............................................................................................. 5

4

RESPONSIBILITIES ....................................................................................................................... 5

5

6

4.1

Production Engineering...................................................................................................... 5

4.2

Supervisor .......................................................................................................................... 5

4.3

Quality Control ................................................................................................................... 5

PIPING SPOOL FABRICATION PROCEDURE................................................................................. 6 5.1

General ............................................................................................................................... 6

5.2

Material Preparation.......................................................................................................... 6

5.3

Cutting and Marking .......................................................................................................... 6

5.4

Machining (Bevelling, Threading and Drilling) ................................................................... 6

5.5

Fit Up/Assembly ................................................................................................................. 7

5.6

Dimensional Control/Fit Up Inspection ............................................................................. 7

5.7

Welding .............................................................................................................................. 8

5.8

Visual Weld Control ........................................................................................................... 8

5.9

Non Destructive Testing/X-Ray (If Required) ..................................................................... 8

5.10

Hydrostatic Test ................................................................................................................. 9

5.11

Painting (If Required) ......................................................................................................... 9

5.12

Other Treatment (If Required) ........................................................................................... 9

5.13

Storage of Fabricated Spool ............................................................................................. 10

5.14

Handling of Pipes Spool ................................................................................................... 10

EXOTIC PIPES MATERIAL PRECAUTIONS .................................................................................. 10 6.1

General ............................................................................................................................. 10

6.2

Worksop Preparation, Storage and Handling .................................................................. 10

6.3

Cutting, Marking, Machining and Assembly .................................................................... 11

6.4

Dimensional Control, Welding, Visual Weld Control ....................................................... 11

6.5

Non Destructive Testing (X-Ray) ...................................................................................... 11

6.6

Hydrostatic Test ............................................................................................................... 11

6.7

Passivation ....................................................................................................................... 12

6.8

Preservation ..................................................................................................................... 12

PIPING SPOOL FABRICATION PROCEDURE 7

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ATTACHMENT........................................................................................................................... 13 7.1

Flow Chart of Piping fabrication process (Carbon Steel) ................................................. 13

7.2

Flow Chart of Piping fabrication process (Exotic Materials) ............................................ 14

PIPING SPOOL FABRICATION PROCEDURE

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1

SCOPE AND PURPOSE This procedure covers the basis for material traceability and fabrication work for pipes spool pre-fabricated in the workshop provided with spool drawing. The procedure purpose is to provide guidelines on general working procedure and operative method for conducting piping fabrication work.

2

REFERENCE DOCUMMENT Piping Fabrication shall be in accordance with latest edition of the following international codes and standards. ASME B16.5 ASME B16.9 ASME B31.3

Pipes Flange and Flanged Fittings Factory-Made Wrought Buttwelding Fittings ASME Code for Process Piping

WSM Internal Procedure and Documents WSM-WP-01 WSM-WP-02 WSM-WP-03 WSM-DP-01 WSM-PP-01 3

Visual Inspection Repair Procedure Tack Welding Procedure Dimensional Control Procedure Painting Procedure

DEFINITION AND ABBREVIATIONS Contractor PT. WISESA MANDIRI NDE/NDT Non Destructive Examination/ Non Destructive Testing Spool Drawing A drawing used for pipes fabrication, detailed with all information necessary for all fabrication work. WPS Welding Procedure Specification

4 RESPONSIBILITIES 4.1 Production Engineering Production Engineering is responsible to verify the completeness and correctness of the piping isometric drawings and the spool drawing which should be used as a reference for the fabrication operation. Production Engineering also responsible to issue out material take off for material preparation purpose. 4.2

Supervisor Supervisor is responsible ton ensure that all the piping fabrication activity are conducted as per approved procedure, achieve desired quality as per required by spec/ client expectation. Prepared and execute detailed schedule and manpower planning to achieve master schedule by Planner.

4.3

Quality Control QC inspector is responsible to check correctness of the assembled pipes spool against the spool drawing dimensionally, to ensure the end result of weld joint is within acceptance range of the specification, to arrange for Client inspection (if required) and arranging NDT work. QC also responsible to arrange any kind of test/examination as per required by spec/code such as PMI (Positive Material Identification), Ferrite Content and etc.

PIPING SPOOL FABRICATION PROCEDURE

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5 PIPING SPOOL FABRICATION PROCEDURE 5.1 General The spool fabrication drawing may be used to record all QC requirement (material traceability, heat number, welder/fitter identification etc) and accompany the pipes spool along the entire fabrication process. Method for workshop progress tracking and material traceability other than above can be used, such as using a work progress sheet and/or welding follow up sheet. Final record of workshop progress reporting has to be compiled. 5.2

Material Preparation All pipe fitting should be prepared according to material take off as shown on spool drawing. Exact quantity to be released from material storage. Material specification shall follow approved spool drawing. Below are the standard check list for pipe and fitting. 1. 2. 3. 4. 5.

5.3

Cutting and Marking Cutting process may be performed by cutting manually oxy cutting for carbon steel and plasma cutting for exotic. The work flow will be: 1. 2. 3. 4.

5. 6. 7. 8. 5.4

Check the sizes, obtain nominal diameter and schedule number (pipe, elbow, tee, etc). Check the bend radius (elbow). Check the pressure rating and flange facing (flange). Record down the heat number (pipe) Check for any defect: pitting, corrosion, buckling, flattening, ovality, etc.

Pipe fitter choose correct pipes as per spool drawing. Cut pipes using manual cutting as per spool drawing’s required cut length. Dimensional control on the cut pipes After cutting, the pipe should receive masking tape label marking (name plate) with the ISO number, Spool number, position, Heat number. Marking format as follow: ISO (Isometric Drawing number) SPL (Spool Drawing Number) POS (Position) if any HN (Heat Number) Material man should be take care the marking from any damage and replaced it if is unreadable. To maintain material traceability, heat number of each material should be written in the spool drawing for each pipes and fitting. Bring cut pipe to worktables on machining/bevelling area. The spool drawing should follow these materials to the next step of fabrication. Pipe fitters fill the workshop progress sheet.

Machining (Bevelling, Threading and Drilling) Machining and/or bevelling of pipe and fitting will be done in area near the manual cutting area. On this bevelling area will be placed worktables for bevelling operation. Bevelling process should be use a portable machine or equivalent. Other type of machining such as treading, drilling, etc will be done as per required.

PIPING SPOOL FABRICATION PROCEDURE

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Work flow for bevelling activity will be: 1. 2. 3. 4.

5. 6. 5.5

Pipe fitter done the cutting work should do the bevelling work, in any case where the pipe fitter doing both work is different persons, the pipe fitter doing bevelling work shall verify the name plate to obtain correct spool pieces information. If original material identification marking is to be cut or material divided into two or more pieces, the heat no, and pipe item code no, shall be transferred to each of the pieces prior to cutting. Pipe fitter shall collect other fittings related to the cut pipe (elbow, tee, red, etc) as per drawing necessary. These fitting should be placed on the same worktables for the same pipes spool/spool drawing. Do bevelling work with the help of machine vices. Use grinder (disc and straight) if necessary. Bevel parameters should be followed and as per required by the WPS for correct root and edge facing. For carbon steel pipes end result should be bright metal finish. Bevelled pipes and fitting should be moved to assembly/fit up box. Pipe fitters fill the workshop progress sheet.

Fit Up/Assembly Assembly work (fit up work) will be done in the assembly area near the bevelling area. This assembly box may use red plastic as a separator with adjacent boxes. Fit up work may be helped by pipe jacks as pipe support. Alignment work may use three points pipe fit up clampers. Work flow for assembly work will be: 1. Pipe fitter done the bevelling work should do the assembly work, in any case where the pipe fitter doing both work is different person. The pipe fitter doing assembly work shall verify the name plate to obtain correct spool pieces information. 2. Pace the pipes/fitting in the pipes jack, assemble other pipes/fitting as per spool drawing. 3. Align the pipes and fitting using pipe clampers. 4. Check the alignment result with welding gauge for misalignment, root gap etc. 5. Tack weld on the pipes if necessary as per applicable tack weld. 6. Clean the pipes weld joint preparation. 7. Pipe fitters fill the workshop progress sheet.

5.6

Dimensional Control/Fit Up Inspection A dimensional control inspector shall be carried out the quality team to ensure the assembled pipe spools are fabricated as per approved spool drawing. This step may be done in the same assembly box where the pipe being assembled. In case any fault/ discrepancies. Comments for repair work shall be directly given to the pipe fitter team. Pipe fitters/ piping supervisor need to check below parameters internally before request for inspection to QC team:     

Check all length. Check all directions of the spool. Check the materials and the type of flanges. Check the square of the flanges. Check the axis of the flange holes.

PIPING SPOOL FABRICATION PROCEDURE   5.7

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Check the gap of welding. Check the internal offset.

Welding Welding should be done in the same assembly box where the assembly work took place. The welding work shall be carried out as per approved WPS. Pipe welders has to be a certified welder. During the welding process. Foreman welder should constantly monitor the welding process to ensure application of WPS on the welding process. Work flow for welding: 1. The welding work will be carried out in the same box where the pipes being assembled, the pipe fitter should back to the material preparation work/cutting work for next spool. 2. Welder need to ensure that weld preparation joint are clean and free of all extraneous matter such as grease, dirt, scale, rust, water, etc that may affect the weld quality. 3. Conduct preheat (when required by WPS). 4. Conduct welding work as per WPS. 5. Fill workshop progress sheet. 6. Fill welding follow up sheet. 7. After welding, sent the pipe spools to storage area (this is only storage area for waiting visual test, NDT and hydrotest).

5.8

Visual Weld Control After welding, a visual weld inspector/welding inspector shall be carried out to verify the quality of weld result. The visual weld examination shall be carried out by QC team. Work flow for Visual control: 1. Welding supervisor informs QC team to conduct visual welding inspection by visual weld control form. 2. The inspection may be conducted in the welding area (assembly box). 3. QC inspector performs the visual weld inspection. 4. If any weld defect found (mark on row VW is failed on welding matrix) , QC inspector shall mark and inform the welder team or welder supervisor immediately. 5. Perform weld repair work (if any). 6. In case of un-repairable weld defect, welder team shall coordinate with fitter team to reassembly the defect weld joint. 7. After successfully inspection, pipe welder should fill workshop progress sheet and welding follow up sheet.

5.9

Non Destructive Testing/X-Ray (If Required) The NDT phase 1 should be carried out to ensure that only a good weld joint will continue through the Post Weld Heat Treatment process. The NDT will be X-Ray/Radiography test unless stated otherwise by the spec or codes. Work flow this work: 1. Bring the pipe spools from Fabrication area (after Visual result) to NDT area. 2. QC team arranges NDT work. 3. NDT result obtained.

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4. When the weld joint are found failed during NDT(mark on row NDT is failed on welding matrix) bring the pipes to assembly box or fabrication area, welding supervisor and his team have to directly carried out repair work, fill wielding follow up sheet and work progress sheet. 5.10 Hydrostatic Test Hydrostatic test on workshop after fabrication completed is to ensure the welding integrity from any leak. This hydrotest applicable for pipe spools with flanges joint only, for others the hydrotest will be carried on erection area. Work flow hydrotest work: 1. Bring the pipe spools from NDT area to Hydrotest area (usually the area is same area). 2. Layup pipe spools on the hydrotest area. 3. Prepare the blank flange and other hydrotest equipment. 4. Conduct hydrotest work as per pressure required. 5. Obtain the hydrotest result. 6. When the result is leak during hydrotest (mark on row NDT is failed on welding matrix) bring the pipes to assembly box or fabrication area. welding supervisor and his team have to directly carried out repair work. 7. Depressurize the water and clean the water inside pipes with compressed air blow. 8. Collect the pipe spools and sent to storage area(this storage area is means collection of pipes passed the test and ready to paint or erection). 5.11 Painting (If Required) Pipes spool will be sent to blasting and panting area as required by spec. For carbon steel pipes material will have painting work, necessary arrangement should be made on the field weld joint for protection using adhesive tape after the blasting process. For Exotic material a passivation/preservation will be done after hydrotest. Work flow for painting work: 1. Bring the pipe spools to blasting/painting area. 2. Necessary arrangement need to be taken to protect the name plate during blasting and painting. 3. Blast the pipe spools. 4. Put adhesive tape on the field weld joint. 5. Paint the pipe spools as per paint spec. 6. Bring the pipe spools to pipes storage area. 7. Close the open end of pipe spools using plastic or wooden blank. 5.12 Other Treatment (If Required) Other Treatment mentioned in here is passivation for exotic pipes material and acid cleaning for carbon steel material. Both activity will only be conducted if required by design/code/spec. Methods for passivation are determined later as per project requirement (either acid bath method or passivation gel method).

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5.13 Storage of Fabricated Spool Fabricated pipe spools should be storage in good environment to maintain material quality of pipes. End flanged spools should be blanked using wooden plate with 5mm thickness or special plastic cap to avoid any dirt/garbage being put inside the pipe spools. The wooden blank flange cab be tightened either using bolt-nut or using wire rope. Prevent direct contact between pipe spools with ground or floor by using wood support. Pipe spools should be storage with grid basis. This grid basis is a storage system that divided the pipe spools base on installation sequence by pipe material (carbon and Exotic), location of installation, isometric drawing numbers and spool drawing numbers, and separate storage area between after fabricated to be inspection test and pipe spools has been passed the test or painted. Material controller should be prepared Database on spreadsheet for monitoring flow pipe spools (flow pipe spools is how many fabricated spools, storage area, passed test spools or not, painted spools and include with spool numbers.) 5.14 Handling of Pipes Spool Handling of pipe materials and pipe spools should not cause any damage on the materials itself. Few method to handle the piping materials and pipe spools are:   

Forklift, use for taking out pipe from rack (if any) or storage area, lifting materials and transfer materials. Specially protection for the fork should be used for fabricated pipe spools and exotic materials. Mobile crane/overhead crane and lifting equipment should be used nylon slings, for exotic materials separate set of slings should be used for each type of materials. Trailers should be used protection floor/crates/support for fabricated pipe spools and exotic materials.

6 EXOTIC PIPES MATERIAL PRECAUTIONS 6.1 General Above procedure are applicable to exotic pipes materials fabrication with following precautions as stated in this section 6.2

Worksop Preparation, Storage and Handling Ferrous contamination on exotic pipes material (such as stainless steel and duplex) should be avoided. The iron subsequently rusts in a moist or humid environment and can initiate corrosion on the stainless steel surface. Only stainless steel tools, wire brushes, clamp and grinding wheels should be used on stainless steel pipes. To minimized ferrous contamination following preparation should be taken for exotic material pipe shop: 1. All handling equipment, such as sling of crane, fork of lift truck, hook of chain block etc should be a non metallic material or protected by clean wood, cloth or plastic buffer to avoid iron contact with exotic pipes material surface. 2. All working bench, working tools and working consumables such as machine vices, pipes clamp, grinding disk etc should be a non iron material or be isolated with the rubber, wood, a stainless steel plate etc. 3. Each equipment and tools as described above shall be used for one type of material only. Storage are of equipment and tools shall be segregated. An identification code system shall be established for above segregation.

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4. Each pipe, pipe fittings, assembled pipe spools. Welded pipes spool shall not be storage directly into the ground. These item should be storage on wooden bar at least a 150mm from the ground or on a fully surface cover with wood. 5. Walking, stepping or placing any items above corrosion resistance piping items strictly prohibited. 6. A clean room must be established on the exotic materials pipe shop. A ventilation system to maintain internal positive pressure to avoid dust from outside has to be established. Special personnel and housekeeping instruction are required to maintain cleanliness of the clean room. 7. Before start working, please inspection materials exotic from carbon decontamination. 6.3

Cutting, Marking, Machining and Assembly Above procedure on section 5 apply for cutting, marking, machining and assembly operation of exotic pipes material with following precautions: 1. Use tools as designated, stainless steel cutting disk for stainless steel only, stainless steel wire brush for stainless steel only so on. 2. Eliminated contact between ferrous tools with the exotic pipes. For example, use insulator on the machine vices, stainless steel lining on the hammer head etc. 3. Worktables have to use wood protection on top of it. 4. Pipe jack, pipe fit up clamp and other tools in contact directly with the exotic materials have to be insulated or made by same grade of the materials.

6.4

Dimensional Control, Welding, Visual Weld Control These job will be done in the assembly box area. Welding shall follow the WPS, additional consideration to be taken for gas purging during exotic material welding. Large wood panel should be installed to guarantee welding segregation between different type of exotic pipe materials.

6.5

Non Destructive Testing (X-Ray) As per carbon steel material, the NDT (X-Ray) may be done in the NDT area or storage area. Work flow for the X-Ray Work: 1. When transport the pipe spools with forklift, the fork has to be protected by wood crates or similar protection. 2. Carried out X-Ray as per procedure. 3. When NDT process has finished, material man shall install back protection cover to the pipe spools. 4. Inform the supervisor after successful result, or not mark on row NDT is failed on welding matrix and bring the pipes to assembly box or fabrication area.

6.6

Hydrostatic Test Conduct hydrotest as per arrangement mentioned on previous section if hydrotest required. When the hydrotest is not required, the pipe spools should be sent to passivation area directly after X-Ray. When conducting hydrotest, pipe spools are not allowed to be laid down on the ground, use the wooden block or crates for support. All hydrotest equipment and fluid should be non ferrous contaminant.

PIPING SPOOL FABRICATION PROCEDURE 6.7

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Passivation Passivation is a process to enhance the spontaneous formation of the protective passive film on an anticorrosion material surface. Passivation process for this exotic material normally consist of following step: 1. Descaling, removal of heavy, tightly adherent oxide films resulting from hot forming, heat treatment, welding and other hot work operations. Descaling can be done either using chemical descaling (acid pickling) or mechanical descaling (abrasive blasting, power brushing etc) 2. Cleaning, all operation necessary for the removal of surface contaminates from metal to ensure maximum corrosion resistance, prevention of product contamination and achievement of desired appearance. Some of the methods used to do cleaning area vapor degreasing, water jetting, acid cleaning, steam cleaning and mechanical cleaning. Selection of any method for detailed passivation process shall be determined during project execution.

6.8

Preservation To maintain the quality of anticorrosion properties of exotic pipes material and to prevent the deterioration of pipes surface finish, a special care shall be given during pipe spools storage and handling after fabrication. 1. All the pipes opening shall be sealed with air tight closures after passivation process. 2. End closures shall be durables and securely attached to the pipes such they will remain intact and in position during transfer, handling and storage. 3. Flange end connection can be sealed by wooden blank or plastic cap (similar material), secured using wire or tightened with bolt and nut at least in 4 holes bolt. Unflagged pipes and connection can be sealed by plastic cap or similar material and wrapped with protecting tape 50mm around the pipe cap joint. Threaded and connection, whenever possible, should be sealed by means of threaded plastic or similar material so that the pipes thread will be protected. 4. Pipes cannot be directly storage in the ground, wooden support should be used. 5. When the pipe spools are storage in outdoor a method for covering with tarpaulin or similar material should be established.

PIPING SPOOL FABRICATION PROCEDURE 7 ATTACHMENT 7.1 Flow Chart of Piping fabrication process (Carbon Steel)

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PIPING SPOOL FABRICATION PROCEDURE 7.2

Flow Chart of Piping fabrication process (Exotic Materials)

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