Professional Documents
Culture Documents
Doc. Type
Discipline
SA-JER-XXXXXX-XXXXXXXXXX
PRC
CNS
System
JOB No.
3000235453
FABRICATION,
ERECTION AND INSTALLATION
PROCEDURE FOR PIPING
Revision
No.
Remarks
Issued Date
Return Date
00
01
20-APR-2010
13-JUN-2010
20-MAY-2010
02
28-JUN-2010
Prepared By
Checked By
Approved By
21-JUN-2010
Issued By
IMPORTANT:
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by means of
electronic, mechanical, photocopying, recording, or otherwise, without the written permission of Rotary Engineering
Limited.
Revision History
Revision
Revision date
Page
Scope of Revision
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25-MAY-2010
25-MAY-2010
ALL
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25-MAY-2010
01
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25-MAY-2010
25-MAY-2010
25-MAY-2010
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TABLE OF CONTENT
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SCOPE
DEFINITION
REFERENCE.
.
RESPONSIBILITY
.
PROCEDURE
..
PRODUCTS AND
MATERIALS..
PREFABRICATION..
PIPING
ERECTION
1
3
INSTALLATION OF UNDERGROUND
PIPING...
1
5
10
DIMESIONAL
CHECKING
1
6
11
WELDING
.
1
6
12
1
9
13
2
0
14
2
0
15
PRESSURE
TESTING...
2
2
16
FLUSHING...
...
2
3
17
REINSTATEMENT .
...
2
3
18
EQUIPMENT AND
RESOURCES...
2
4
19
2
4
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2
6
21
3
2
22
3
3
23
3
4
24
3
5
1. SCOPE
This document covers the sequence of activities for Fabrication, Erection and Installation
procedure for Metallic Piping (Carbon Steels, Alloy Steels, Stainless Steels, Nickel Alloys)
systems and to ensure the compliance to the above activities with the contractual applications
and HSE requirements in PORT TANK FARM PACKAGE 9 Project.
2. DEFINITIONS
2.1 COMPANY
2.2 CONTRACTOR
2.3 DDDD
2.4 DDDD
2.5 D
2.6 D
2.7 D
2.8 D
2.9 D
2.10
2.11
DD
3. REFERENCE
The following documents shall form a part of this specification in the manner extend indicated
herein.
DOCUMENT No.
TITLE
XXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXX
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XXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXX
JERES-L-105
JERES-L-350
JERES-L-460
JERES-L-450
JERES-L-150
JERES-A-004
JERES-H-001
Coating
Selection
&
Application
Requirements
for
JERES-B-064
JERMS-L-1010
JERMS-L-350
JERMS-L-1010
JERMS-L-1017
ASME B31.1
ASME B31.3
Process Piping
ASME B31.4
ASME B31.8
ASME PCC-1
ASME SEC IX
ASME B16.1
ASME B16.3
ASME B16.5
ASME B16.21
ASME B16.22
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Steel Valves
API 5L
ASTM A53
ASTM A105
ASTM A106
ASTM A126
ASTM A312
ASTM A335
MSS SP-83
Steel
Pipe
Unions,
Socket-Welding
and
Threaded
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Shall be responsible for inspection on production of pipes ,fittings and spools to ensure
the procedures are being followed in order to ensure that quality standards being
achieved as per Project procedures, requirements and specifications.
4.7.2 Shall be responsible for maintenance of NDT records & Project documentation.
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All lifting tools, equipments and ropes used for erection shall be inspected and certified
by HSE regulations. Activities shall be done according to the proper method statement
for lifting and handling.
8.1.2
Pre-fabricated spools shall be shifted to site carefully; care shall be taken while handling
and stacking of spools to prevent any possible damage.
8.1.3
The Pre-Fabricated spools shall be identified by spool and line numbers before erection.
8.1.4
Before erection of spools ensure for inside cleaning of the spools and their items.
8.1.5
The pre-fabricated supports shall be installed as per drawings, the pipe supports details
shall be followed in the piping layout drawings and Isometric drawing for location and
supports detail drawing.
8.1.6
All pipe openings shall be sealed before, during and after erection to prevent the ingress
of moisture and foreign matter. Threaded ends shall be plugged and sealed by
waterproof grease tape or purpose made plastic caps or plugs. End cap or cover shall
be placed on the open valve ends.
8.1.7
Erection of spools shall be carried out area by area as per piping layout drawings and
Isometric drawings.
8.1.8
Approved and safe scaffolding and temporary platforms shall be arranged to carry out
erection, fit up and welding of field joints at elevated positions.
8.1.9
Erect the spools in position using crane or other lifting devices as per the drawings.
8.1.10 Shifting of pipe spool on pipe racks should be done on the roller support if required.
8.1.11 Piping installation on pipe rack shall be from lower level to higher level.
8.1.12 Large bore random length shall be installed, which is followed by small bore field run
pipe. The sequence of composite spool will be same as of random length.
8.1.13 Joints shall be aligned and complete the fit-up / welding as per applicable WPS,
Isometric drawing and Project specifications
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Fabrication and installation of all pipe supports, hangers, guides and other support
attachments shall be done in accordance with the details in the IFC drawings.
8.2.2
Welding preparations for the pipe to pipe supports and structural steel welding for pipe
supports shall be in accordance with corresponding WPS
8.2.3
All pipe support shall be individually indentified by number and this number shall be
marked on the piping layout plans.
8.2.4
A 6 mm weep hole shall be drilled for dummy supports and shall be located near the
base plate for all vertical dummy supports, and near the run pipe at 6 oclock position for
all horizontal dummy supports.
All flanged connections shall be made using fully threaded stud bolts and nuts. A
minimum of one complete thread shall protrude from the nut after completion of
tightening.
8.3.2
The alignment of flanges to rotating and static equipments, the requirement shall be in
accordance to JERES-L-350 and JERES-L-351.
8.3.3
All temporary gaskets shall be identified by color coding on their handles exposed.
8.3.4
All bolt heads shall be assembled from the same side. A logical sequence of Bolt
tightening shall be followed.
8.3.5
Special attention shall be given to ensure that in line items such as orifice flanges,
spectacle blinds, valves, strainers etc. are installed and oriented correctly as indicated
on isometrics and drawings.
8.3.6
Flange bolt holes shall be oriented as follows, unless otherwise indicated on the
construction drawings:
The tilt of a flange- Periphery across any diameter shall not exceed 1.6 mm from the
square position.
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For piping over 3-inch NPS and connected to machinery/equipment, flange alignment
shall be within the following limits or within the manufacturer's limits for the
machinery/equipment nozzle:
Before starting the works, it must be sure that there are no buried pipelines or cables which
are not included in the drawings.
9.2
Prior to lowering the pipe line, supervisor and surveyor shall ensure the trench excavation is
as per approved drawing, trench bottom shall be firm and give inform support for the pipe
and that all foreign material, debris sharp object that will be harmful to pipeline coating shall
be removed.
9.3
9.4
During the execution of excavation works it is necessary to minimize the time between
cutting and filling of trenches, in order to avoid disintegration of the boundary wall surfaces
and their slow widening.
9.5
The piping arrangement, fit-up, welding shall be done in accordance with the relevant
drawings and specifications.
9.6
During the execution of excavation works it is necessary to minimize the time between
cutting and filling of trenches, in order to avoid disintegration of the boundary wall surfaces
and their slow widening.
9.7
During excavation, should any cables, wires or other installations not belonging to the works
covered by this specification appear, shall report them to the Project Engineer.
9.8
Internal pressure tests as specified for each type of installation, in the respective standards
and specifications, are required and the installations shall not be accepted without them.
9.9
All tests shall be made in the presence of the Project Engineer/ QA/QC Inspector and
before any painting, covering or protection of joints and fittings.
9.10 After the execution of tests, cleaning, protection, inspection and eventual repairs, the piping
network shall be covered up.
9.11 Excavation shall be backfilled only after the permanent works therein have been approved,
with a suitable material in layers, each layer being thoroughly watered and compacted in
accordance with the specification.
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11.2 Procedure
11.2.1 Before starting welding, the assigned people must wear proper PPE and adequate
safety procedure must be implemented.
11.2.2 All welding electrodes shall be kept in required condition in both storage and welding.
11.2.3
The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust,
oxides, sand, earth and other foreign matter. The ends shall be completely dry
before the welding.
11.2.4
11.2.5
The welding work piece shall be shielded against high winds and rain.
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The welding face shall be prepared in such a way that, the face must be cut and
grind smoothly and the imperfections (Slots, spatters, surface oxide due to cutting
and rusting) shall be removed from the welding area
11.2.7
For the fabrication & welding of Stainless Steel pipes, only Stainless Steel tools &
consumables (Wire Brush Chipping, Hammer, and Abrasive disc) shall be used.
11.2.8
The pipe line joints shall be aligned as accurately as possible and the pipe must be
supported properly to avoid bending and displacement during welding.
11.2.9
The fit up joint shall be welded after checked by the QC inspector for acceptance
and registered.
11.2.10 All branch connections shall be joined to headers with full penetration welding. The
bore side shall be ground smooth, free from cracks.
11.2.11 Welding shall be done as per approved WPS for the particular piping. Pre heating
and welding consumable shall be checked before starting of welding.
11.2.12 Each weld layer shall be cleaned before starting to weld next layer. The cleaned
area shall be free from slag. Any visual defects like cracks, pores, spatters weld
shall be removed by grinding before the next layer is applied. The ends of weld
layer shall be removed by grinding at take-up points of each weld.
11.2.13 Appearance of finished weld shall be as even as possible and free from spatter,
under cut, cracks, excess reinforcement etc. with reference to ASME B31.3 and
relevant WPS.
11.2.14 All parts that may be affected by the welding operations, such as accessories,
insulation joints and such, shall be adequately protected.
11.2.15 For flange to pipe connections if welding shrinkage can lead misalignment, two
similar flanges shall be joined by inserting a temporary gasket and then welded.
11.2.16 Where internal misalignment exceeds 1.6mm, internal trimming after approval from
the Company shall be done in accordance with ASME B31.3.
11.2.17 In case of threaded pipes, screw threads shall be concentric with axis pipe with no
blur or stripping. The threading dies shall be sharp and properly designed for the
piping material. Proper tape/ sealant for threaded joint shall be used as per project
specification.
11.3 Pre-Heating
11.3.1
Preheat for the various grades of materials shall be in accordance with the
specified Welding Procedures and Specifications
11.3.2
Wet joints shall be dried by burner heating for a distance of 100 mm from the weld
joint and shall be warm to the hand before welding unless a greater pre-heat
temperature is required.
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11.3.4
If PWHT is applicable for any piping system, PWHT procedure will be applicable
strictly.
11.4.2
The PWHT table shall include the following information for each joint or component:
location, drawing number, diameter, wall thickness, material, heating rate, and
cooling rate, soak temperature, and soak time.
11.4.3
11.4.4
Before starting the Heat Treatment, the contractor assigned for the Heat Treatment
shall submit the documents about heating and cooling methods, temperature
measuring and recording methods; for the approval of QA/QC department.
11.4.5
11.4.6
All machined surfaces shall be protected from oxidation during the heat treatment
by insulated by suitable coating material.
11.5.2
The hardness indentations shall be made at or near the middle of the deposited
weld bead and HAZ if specified.
11.5.3
If any reading exceeds the specified limit by no more than 10 BHN, then minimum
of three additional indentations shall be made near the original high reading.
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ventilated
and
protected
from
temperature
exceeding
manufactures
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No.
1
ACTIVITY
HAZARD
CONTROL MEASURES
Area
preparation
1.1 Slipping and
tripping hazards
2.1 Potential
pinch, caught-inbetween, and
crush points
All workers
HSE Dept
RESPONSIBLE
Area Supervisor
Area Supervisor /
Area HSE
Supervisor
Material
preparation
2.1. Manual
handling
2.2. Using
crane
Area Supervisor
2.1.2. Potential
pinch, caught-inbetween, and
crush points
All workers
HSE Dept
Area Supervisor /
Area HSE
Supervisor
2.2.1. Defective
crane
Area Supervisor /
Area HSE
Supervisor
2.2.2. Improper
rigging technique
Crane Operator /
Maintenance Dept
2.2.3. Defective
rigging equipment
2.2.4. Incorrect
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Crane Operator
Rigging Supervisor
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2.2.5. Incorrect
identification of
crane lifting
capacity
Rigging Supervisor
2.2.6.
Incompetent/nonqualified operator
Crane Operator/
Rigging Supervisor
2.2.7.
Incompetent/nonqualified rigger
Rigging Supervisor
2.2.8. Congestion
of area / Limited
equipment
movement
Rigging Supervisor
2.2.9. Outrigger
not fully extended
Rigging Supervisor
2.2.12. Bad
weather condition
Riggers/Crane
Operator
Crane Operator /
Area Supervisor
Crane Operator
Area Supervisor /
Area HSE
Supervisor
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Signalman
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Crane Operator
Rigging Supervisor
Crane Operator/
Rigging Supervisor/
Area Supervisor
2.3.1 Damage to
existing and
2.3.1.1 All vehicles shall be of
surrounding
adequate capacity and of a design
facilities during
suitable for work.
heavy/ light vehicle
movement
Area HSE
Supervisor/ Rigging
Supervisor
2.2.13. Overhead
power lines
2.3 Material
transportation
Crane Operator/
Rigging Supervisor
Area HSE
Supervisor
Rigging Supervisor
Area HSE
Supervisor/ Rigging
Supervisor
Area HSE
Supervisor/ Rigging
Supervisor
Area HSE
Supervisor
Piping
Fabrication
3.1 Fabrication
3.1.1.1 Grinding disc should be
(cutting,
3.1.1 Grinding disc
Concerned worker/
visually inspected and suitable
positioning, fit break
Area Supervisor
grinding wheel (rpm) shall be used.
up, welding)
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3.3 Heat
Treatment
Area Supervisor/
Area HSE
Supervisor
Area Supervisor/
Area HSE
Supervisor
Concerned worker/
Area Supervisor
Area Supervisor
Area Supervisor
3.1.5Object falling
from stand
Area Supervisor
3.1.6 Electric
Shock
Area Supervisor
/Area HSE
Supervisor
Area Electrical
Supervisor /Area
HSE Supervisor
3.1.8 Welding
spatters
Area Supervisor
3.2.1Exposure of
radiation
3.2.1.1Radiation monitoring
devices, barricading, signboards
NDT Supervisor
NDT Supervisor
3.3.1Burns
PWHT Supervisor
3.3.2 Electric
shock
PWHT Supervisor
Field Erection
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4.1.1Crane toggle
Rigging Supervisor
4.1.2 Struck by
equipment
Rigging Supervisor/
Area HSE
Supervisor
Rigging Supervisor
4.1.3 Scaffolding
collapse
4.1.4 Objects
/Personnel falling
from temporary
platform
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Scaffolding
Supervisor/ Area
HSE Supervisor
All
Scaffolding
Supervisor/
Inspector
Scaffolding
Supervisor/
Inspector
Scaffolding
Supervisor/
Inspector
Scaffolding
Supervisor/
Inspector
Scaffolding
Supervisor/ Area
Supervisor
Scaffolding
Supervisor/ Area
Supervisor
Scaffolding
Supervisor/ Area
Supervisor
Scaffolding
Supervisor/
Inspector
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Scaffolding
Supervisor/
Inspector
Rigging
Supervisor /Area
HSE Supervisor
Rigging Supervisor/
Area Supervisor
Area Supervisor/
Rigging supervisor
Pressure
Testing
5.1 Spade
breakage
Area Supervisor
5.2Valve, Cap,
Pipe, Failure
Area Supervisor
Area Supervisor
Flushing
/Drying
6.1Hose breakage,
6.1.1 Recheck all hose connection
inhalation of dust
are clipped
particle of exhaust.
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ATTACHMENT 5
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