Beruflich Dokumente
Kultur Dokumente
&
ERECTION PROCEDURE FOR
PIPING
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FABRICATIONINSTALLATION &
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PROCEDURE FOR
PIPING
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TABLE OF CONTENTS
1. SCOPE
2. DEFINITION
3. REFERENCE
4. RESPOSIBILITY
5. PROCEDURE
6. PRODUCTS AND MATERIALS
7. PRE-FABRICATION
8. PIPING ERECTION
9. INSTALLATION OF UNDERGROUND PIPING
10.
DIMENSIONAL CHECKING
11.
WELDING
12.
GALVANIZING PAINTING AND COATING
13.
IDENTIFICATION AND MARKING
14.
QUALITY ASSURANCE AND QUALITY CONTROL
15.
PRESSURE TESTING
16.
FLUSHING
17.
REINSTATEMENT
18.
EQUIPMENT AND RESOURCES
19.
HEALTH SAFETY AND ENVIRONMENT
20.
ATTACHMENT 1 (JOB SAFETY ANALYSIS)
21.
ATTACHMENT 2 (WORK FLOW-PIPING PRE-FABRICATION)
22.
ATTACHMENT 3 (WORK FLOW-PIPING ERECTION)
23.
ATTACHMENT 4 (TYPICAL LIFTING INSTALLATION PLAN)
24.
ATTACHMENT 5 (INSPECTION FORMS)
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1. SCOPE
This Document covers the sequence of activities for Fabrication,
Erection and Installation procedure for Metallic Piping (Carbon
Steels, Stainless Steels, Nickel Alloys) systems and to ensure the
compliance to the above activities with the contractual
applications and HSE requirements.
2. DEFINITIONS
2.1 COMPANY
2.2 CONTRACTOR
3. REFERENCE
The following documents shall form a part of this specification in
the manner extend indicated here in.
DOCUMENT No:
ASME B 31.1
ASME B 31.3
ASME B 16.5
TITLE
Power Plant Piping
Process Piping
Pipe Flanges and Flanged Fittings.
4. RESPONSIBILITY
4.1 CONSTRUCTION MANAGER
4.1.1 Responsible for overall site management,
dissemination or execution of quality procedures that
meets project requirements.
4.1.2 Establishment of construction organization, monitor
job quality,
Schedule control and overall project management.
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FABRICATION-INSTALLATION &
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4.5.2
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5. PROCEDURE
5.1 Ensure that the document received bear the stamp Issued
for
Construction and are of latest version.
5.2 The documents submitted/referred with this method
statement shall be considered as an integral part of this
method statement and shall be read in conjunction with the
same.
5.3 The engineering drawings and documents received shall be
clearly understood to find out the services, material
specification, size, thickness, QA/QC requirements, pipe
routing quantity etc. line wise and area wise.
5.4 Make sure that all the Quality Control and Pre-Construction
formalities, approvals, and preparations are done
sufficiently in advance to start the construction activity as
per the schedule.
5.5 A checklist of all requirements shall be made internally to
avoid any omission of them.
6. PRODUCTS AND MATERIALS
6.1 GENERAL REQUIREMENTS
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
FABRICATION-INSTALLATION &
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PIPING
(including size, wall thickness, rating, material code,
heat no,
quantity).(Ref: Procedure for Quality Control Of
Material).
6.2 MATERIAL RECEIVING, STORING AND DELIVERY
The following procedure shall be followed for receiving,
storing and delivery of all the materials.
6.2.1 Store Superintendent shall be responsible for
delivering all materials and documentation to the job
site in good condition. All materials and
documentation will be inspected immediately upon
receipt by Client QC Inspector to determine that all
items included in the Bill of Materials have been
supplied, to assure that all documentation has been
received and to check for any damage.
6.2.2 All materials shall be requested or received as per prefabrication or erection sequence or site requirements
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
FABRICATION-INSTALLATION &
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6.2.9 Ensure the material is secured properly so that it does
not fall, roll or move from its storage position. Pipes
will be
supported at bottom with kegs/wooden
blocks at least at three points and choked with
wedges.
6.2.10 Materials stored in open areas will be barricaded and
indicate the type of material and the hazard it poses,
if any.
6.2.11 Coated pipe shall be handled at all times in a manner
that prevents damage to the pipe walls (shall not be
rolled or dragged on the ground), bevelled ends and to
the coating and open end should be covered with
polyethylene sheeting.
6.3.7
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7. PRE-FABRICATION
7.1 Checklist for Pre-Fabrication of Piping.
7.1.1 Approval of Method Statement, Quality Plan and ITP.
7.1.2 Approval of WPS covering all the material
specifications.
7.1.3 Welder qualification list review and approval.
7.1.4 All the required Engineering drawings(approved) and
documents are received in time.
7.1.5 All personnel and procedures for NDT, PWHT are
approved.
7.1.6 Spool drawings marking field and shop weld joints
shall be prepared, numbered and reviewed.
7.1.7 All tools, equipment and temporary items like pipe
stands, pipe clamps etc., are ready in sufficient
quantities.
7.1.8 Consumables shall arrange in sufficient quantities as
per the WPS.
7.1.9 Welding data base set up prior start of welding
activities.
7.1.10 Procedure for handling and storage of consumables
shall be issued.
7.2 Isometric Mark-Up
7.2.1 All lines shall be clearly marked to easily identify the
flow direction, service, line designation number, size,
class and specification.
7.2.2 The Isometric drawing shall be used as a weld markup format.
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7.2.3
7.2.4
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7.2.5
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7.3.4
7.3.5
7.3.6
7.3.7
7.3.8
7.3.9
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7.5.8
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8. PIPING ERECTION
8.1 General
8.1.1 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 drawings 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, fitup 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.
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8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
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9. DIMENSIONAL CHECK
The fabricated piping shall be checked with IFC Drawing and
Standard specifications for the following parameters.
9.1 Fit-up tolerances for length, depth, orientation and
straightness of
piping members.
9.2 Limits for spacing between pipe and supports.
9.3 Supports base plate elevation and degree of levelness.
9.4 Piping elevation and degree of levelness or slope.
9.5 Alignment of piping weld edges conforms to the WPS and
Specifications.
LONG WEI CONSTRUCTION & ENGINEERING WORKS PTE,. LTD.
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10.
WELDING
10.1 General Requirements
10.1.1 Scope
It specifies the welding, heat treatment,
Nondestructive Testing (NDT), and hardness testing
requirements for welding pipelined and related
equipments to ASME 31.1 and ASME 31.3, API STD
1104 and ASME SEC IX.
10.1.2 Codes and Standards
Specific ASME, AWS, ASTM, API Standards
WPS and PQR welding book for piping
Welding Requirements for Pipelines.
10.2 Procedure
10.2.1 Before starting welding, the assigned people must
wear proper PPE and adequate safety procedure must
be implemented.
10.2.2 All welding electrodes shall be kept in required
condition in both storage and welding.
10.2.3 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.
10.2.4 On completion of each run, craters, welding
irregularities, slag etc., shall be removed by the
grinding and chiselling. Separate grinding wheels and
wire brushes should be used for carbon Steels &
Stainless Steel.
10.2.5 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.
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10.3 Pre-Heating
10.3.1 Preheat for the various grades of materials shall be in
accordance with the specified Welding Procedures and
Specifications.
10.3.2 Temperature-indicating crayons, thermocouples, or
calibrated contact pyrometers shall be used to
measure preheat and interpass temperatures.
10.3.3 The Preheat temperature shall be established over a
minimum distance of 75mm on each side of the weld.
10.4 Post Weld Heat Treatment
10.4.1 If PWHT is applicable for any piping system, PWHT
procedure will be applicable strictly.
10.4.2 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.
10.4.3 All thermocouples and temperature recorders shall be
calibrated and checked periodically.
10.4.4 All machined surfaces shall be protected from
oxidation during the heat treatment by insulated by
suitable coating material.
10.5 Production Weld Hardness Testing
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11.1 General
11.1.1 Painting shall not start before the acceptance of
testing.It must be in accordance with relevant client
specification for painting of piping line.
11.1.2 Appropriate personal protection and protective
equipment is required in certain areas and when
performing particular task.
11.1.3 All paints, coatings and thinners shall be stored in
enclosed storage areas that are well ventilated and
protected from temperature exceeding manufactures
recommendations, open flames, electrical discharge
and direct sunlight.
11.1.4 All electrical, Blast cleaning and spray painting guns
shall be earthed (spark proofing) to prevent up of an
electrostatic charges, especially when the application
is in confined work places.
11.1.5 All welded areas shall be insulated before application
of paint/coating for the ield joint inspection during
hydrostatic testing.
11.1.6 All mechanical operations, such as welding and
drilling, shall be done before painting and galvanizing.
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13.1 General
13.1.1 The criteria of Quality Inspection will be in accordance
with Project General Specification for different piping
systems.
13.1.2 Inspection records shall be properly recorded and
maintained with proper identification for each welded
joint.
13.1.3 Inspection shall be carried out as per approved
procedure and the results shall be recorded properly.
13.1.4 Safety procedures shall be strictly followed in each
inspection procedure, in handling the inspection
equipments and work environment.
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Keeping the vent valves always open. The line shall be dePressurized and drained completely.
14.16
All test blinds shall be removed and the line shall be
reinstated with permanent gaskets.
14.17
Hydrostatic test shall be followed under code:
Hydrostatic test procedure of piping.
15.
FLUSHING
RE-INSTATEMENT
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17.1 Equipments
Lifting Equipments.
Transportation Trucks.
Personal Protective Equipments.
Fire Extinguishers and Fire Blankets.
Cutting Equipments.
Welding Machines.
Electrical Generators.
Compressors.
Heating Oven
17.2 Tools
Measuring and Levelling Tools
Clamping Tools
Hand Fitter Tools-Spanner, Screw driver etc.
Pip Stand.
Power tools-Grinding machine, Drilling Machine etc.
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18.
HEALTH, SAFETY AND ENVIRONMENT
18.1 In workshop
18.1.1 The CONTRACTOR workshop Safety Procedures shall
be strictly followed by all CONTRACTOR personnels.
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