Document title:

Above Ground Piping Installations

REVISION STATUS
Issue
No.

Date

Reason of revision

Issued by

Approved by

IS
This copy

CONTROLLED and the NUMBER is

IS NOT

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REVISION STATUS INDEX

SUMMARY OF CHANGES

Initial Review

Section

REVISIONS

Number

General

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CONTENTS
1.0

INTRODUCTION

2.0

SCOPE

3.0

SAFETY

4.0

RESPONSIBILITIES

5.0

CONSTRUCTION PROCEDURE
5.1

Preparatory Works

5.2

Fabrication and Erection

5.3

Welding

5.4

Radiographic Examination

6.0

PRESSURE TESTING

7.0

IDENTIFICATION RECORDS

8.0

EQUIPMENT
APPENDICES
1. Daily Tally Sheet (for A/G Piping Installation)

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1.0

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INTRODUCTION
The purpose of this procedure is to define the methods of erection and welding
for the above ground piping at Zawiya Terminal Facilities. The procedure target is
to help the site personnel to execute the job in a planned, controlled manner and
in accordance with the relevant codes and contract requirements.

2.0

SCOPE
The Scope of Work covered by this procedure includes all aboveground carbon
steel pipes and tanks interconnecting pipework at Zawiya Terminal Facilities.
In support of the Works, reference shall be made to the following:
CODES AND STANDARDS
ANSI B 31.3 Chemical Plant and Petroleum Refinery Piping
ANSI B 31.4 Liquid Transmission and Distribution Piping Systems
ASME

Boiler and Pressure Vessel Code :

Section VIII, Unfired Pressure Vessels parts applicable to Piping

System
Section IX, Welding Qualification
Section V, Non Destructive Examination
AWS A5.18 Specification for Carbon Steel Filler Materials for Shielding Arc
Welding
ANSI B 16.5 Pipe Flanges and Flanged Fittings
ANSI B 16.25

Butt Welding Ends

MANUFACTURERS STANDARD SPECIFICATIONS (MSS)

MSS-SP-44 Steel Pipeline Flanges
REPSOL OIL OPERATIONS DOCUMENTS
02/54/008
Valve Specification
02/54/039
Fabricated Piping and Inspection Specification
02/54/046
Pipeline Flanges and Fittings Specification
02/54/084
Pipe Support Specification

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J&P (O) LTD DOCUMENTS

9601004/DO/C/901

Project Quality Plan

9601004/DO/M/103-ZW

Welding Procedure Specifications

Procedure Qualification Records (attached to WPS)

Approved Construction Drawings

9601004/DO/M/106-ZW

Radiographic Examination Procedure

9601004/DO/M/107-ZW

Magnetic Particle Examination Procedure

9601004/DO/M/113-ZW

Dye Penetrant Examination Procedure

9601004/DO/H/122-ZW

Hydro testing Procedure of fluid service carbon

steel above ground piping.

9601004/DO/M/104-ZW
3.0
SAFETY

This procedure

Safety precautions shall be of paramount importance to prevent any possible

danger to the public and site personnel. All pipe work activities shall be closely
monitored by the Project Safety Officer.
Site personnel shall adhere to the site safety policies at all times with emphasis
on the following precaution measures:
-

Safety Clothing
Safety Shoes
Hard Helmets
Safety Belts
Welders Gloves and Helmets
Safety Goggles
Dust Masks
Tidy Work Area
Warning Signs (for radiographic activities)

4.0

RESPONSIBILITIES

SITE MANAGER
Responsible to the Project Manager for:

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Planning and acquisition of labour resources.

Ensuring the smooth and on time execution of the fabrication works, according to
schedule.

Liasing with the Operators Construction Manager regarding the progress of

works.

Originating the weekly or biweekly reports.

MECHANICAL ENGINEER
Responsible to the Construction Manager for :

Co-ordination of all pipe work activities in progress.

Determining the plant and equipment to be used during the above operations.

Ensuring plant and equipment is in suitable, safe working condition.

Supervising the Piping Foreman(en) for proper execution of the work.

Reviewing site daily generated documentation and recording all as-built

information.

Liasing with the Operators Mechanical Engineer to resolve any related

problems.

Preparing all the necessary shop construction sketches related to pipes, spools
etc. according to the approved drawings and handing over the same for
execution on site.

PIPING FOREMAN
Responsible to the Mechanical Engineer for:

Supervision of the pipe work activities on site and control of all stages of the
work, i.e. fitting, welding and installation throughout the Project.

Assignment of Gang Loaders and tradesmen to perform the pipework in situ.

Ensuring that all related works are carried out in good workmanship and
according to the approved drawings and procedures.

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Ensuring that each individual operation is carried out safely under the proper
conditions.

Preparing all the necessary plant, equipment, tools, consumables etc, required
for the execution of the job.

Monitoring all A/G pipe work installation activities and tests (e.g. welding, hydro
testing etc) being performed and notifying / informing the Mechanical Engineer
accordingly on a daily basis.
MATERIALS CONTROLLER
Responsible to the Construction Manager and Mechanical Engineer for :

Receiving, handling and storing at site of all the pipe work materials.

Releasing all the necessary pipes and appurtenances needed for erection.

Liasing with the Operators Materials Controller for a close monitoring of the
materials.

Monitoring all the A/G piping materials delivered for erection.

Ensuring good housekeeping of his store.

Keeping close records with respect to the incoming and outgoing materials.

PROJECT SAFETY ADVISOR

Responsible to the Construction Manager for :

Conducting regular safety inspections during pipe work operations and ensuring
that all necessary safety precautions are being taken.

Implementing site safety policy.

5.0 CONSTRUCTION PROCEDURE

5.1

Preparatory Works
Before starting any erection / installation activity, all piping shall be closely
observed for any defects during prefabrication in the Workshop.

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The pipes shall be cleaned, if required, by means of power brushes.

5.2

Fabrication and Erection

The prefabricated piping shall be installed in situ (pipe sleepers). Crane
will be used for this reason and all the installation works shall be carried
out as per the Contract requirements and ANSI B31.3
The following main points shall be observed:

All flanged joints shall be correctly aligned with the gasket faces in contact
across their full width.

Valves and pipe work mating flanges shall be parallel and concentric. The gaps
between flange faces shall be just sufficient to insert the gasket before tightening
the flange bolts.

Flange bolting shall be tightened in diametrically opposite direction to ensure

uniform gasket loading.

All welded joints in a pipe work section shall be completed before flanged joints
connections to equipment are done.

Piping shall be erected level on its supports and in a stress free condition.
Piping shall not be strained into position by the use of levers, chain blocks or
other means. If the piping does not fit, it shall be removed and readjusted to suit.

Welding of temporary braces or supports to the piping is not allowed.

Threaded joints shall be made up with PTFE thread tape.

The following fittings shall not be seal welded: -

o Soft seated ball or relief valves with screwed connections.

o Pressure gauges, thermowells, level gauges, pressure switches and other
relevant instruments, directly connected to the hydrocarbon piping.
o Orifice flange taps.
o Drain or vent plugs
o Screwed unions

The ends of all piping shall be securely closed at the end of each days
work and shall not be re-opened until piping works are resumed.

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5.3

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Welding
Welding electrodes shall be of the approved type, i.e. ESAB - OK 6010
pipe weld and ESAB - OK 48.00 E 7018.
Only qualified welders shall be employed in the job and they will have
their identification badges with them at all times. The welders will follow
the applicable welding procedures, as specified in the relevant Welding
Procedure Specifications.
More than one welder may be used for all pipe sizes.
Each welder shall mark with an identifying marker each of his welds. Die
stamping is not permitted.
No electrodes shall be left lying around at site. Electrodes so left shall be
scrapped and removed.
The maximum time delay between completion of the root and the start of
the second pass shall be 5 minutes.
External clamps shall be used and shall not be removed until at least 50%
of the root pass is completed.
The pipe shall not be lifted until the welding is 100% completed.
Downhill mode shall not be used, nor will any kind of internal welding.
Only Shielded Metal Arc Welding (S.M.A.W) process shall be used.
Permanent backing rings and copper backing rings are prohibited.
Penning of the weld is prohibited.
Flame gouging, air-arc gouging and chipping shall not be used.
The pipes shall not be hammered or heated to remove the slag.
The root pass shall be ground clean.
No rectification, repair or modification shall be made without the approval
of the Operators Engineer.
Repairs shall be completed after the initial radiography.
A minimum preheat of the pipes at 40C shall be used when the ambient
temperature is below 0C or when the weld surfaces are humid.

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Complete wind protection shall be provided when any kind of welding is

being executed.
Edge preparation shall be done by thermal or cold cutting and bevelling
machine.
All prepared edges shall be inspected prior to any
commencement of welding.
Two adjacent welds shall not be closer than 2 x nominal bore, unless
otherwise approved by the Operators Engineer.
5.4

Radiographic Examination
The erected and field welded piping joints shall by radiographically
examined as per the relevant QA/QC procedure and records shall be kept
accordingly.
In case of a repair, this shall be carried out according to WPSs

6.0

PRESSURE TESTING

Upon completion of the Radiographic Examination, J&P shall notify the

Operators Engineer for the pressure testing of spools, lines or circuits.
For this reason the identification records (see paragraph 7.0 herein) shall be
submitted to the Operator for review and approval.
The pressure test notification to the Operator shall be made 24hrs before starting
the hydro testing process.
7.0

IDENTIFICATION RECORDS

One set of the AFC drawings pertaining to the aboveground piping shall be
maintained as production welding and fabrication records.
Every spool piece shall be cross-referenced with the associated drawing.
On this drawing, the prefabricated joints will be identified by W symbols (see also
Construction Procedure for Piping Prefabrication) and the field joints by FW
symbols. Only the FW symbols shall be filled in during the aboveground piping
installation stage.
Appendix 1 herein depicts the information required to cover this procedure.
The above-mentioned production records will be updated on a daily basis and be
made available to the Operators Engineer upon request. A set of drawings with
these records will be maintained and submitted as part of the As-built
documentation.

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EQUIPMENT

The following major equipment shall be used for the aboveground piping
installation activities :
-

Welding Sets
Air Compressors
Cranes
Trailers Flat Bed with Prime Mover
Generators
Power Tools
NDT Equipment
Hydro testing Pumps (Filling and Pressurizing)