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PROCEDURE FOR UG PIPING FABRICATION & ERECTION

PROCEDURE NO. L&T/ KKRO / MECH / WP 06

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UG PIPING FABRICATION & ERECTION DESCRIPTION

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Procedure no L&T/ KKRO / MECH / WP 06 REV-00

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WORK PROCEDURE FOR UG PIPING FABRICATION & ERECTION

CONTENTS: 1. PURPOSE 2. SCOPE 3. CONTROLLING SPECIFICATIONS 4. PROCEDURE 5. SURFACE PREPARATION, PRIMING, AND TAPE COATING 6. DOCUMENTATION

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Procedure no L&T/ KKRO / MECH / WP 06 REV-00

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1.0

PURPOSE: The purpose of this procedure is to provide guidelines to carry out the piping fabrication and erection at site and to ensure that proper quality control and documentation are maintained at site. SCOPE: This procedure covers execution, inspection, testing, and method of record keeping for fabrication & erection of all under ground piping systems other than GI and CI piping at site. CONTROLLING SPECIFICATIONS: Process and instrument diagram. Piping materials specification. Piping support standards. Line list. Job specification of non-destructive testing of piping Job specification of welding Job specification for pressure testing of erected piping system Welding specification for fabrication of piping Procedure for positive material identification of materials Job specification for fabrication & erection of piping Job specification for shop & field painting Job specification for earthwork for u/g piping Corrosion protection tapecoating of u/g steel pipelines Specification for inspection, flushing & testing of piping systems (4644-6-44-0013)

2.0

3.0

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Procedure no L&T/ KKRO / MECH / WP 06 REV-00

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4.0 4.1 4.1.1

ASME B 31.3 process piping, ASME Sec.VIII, IBR, NACE MR-01-75. UG piping spec. No.4644-6-65-1030-R0 PROCEDURE: FABRICATION/ERECTION: The complete piping work shall be carried out as per Approved for Construction drawings and sketches. For piping falling under IBR, necessary approval of boiler inspector on the drawings shall be obtained prior to start of fabrication and all works shall be carried out as per the requirement of IBR.

4.1.2 4.1.3

Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system shall be strictly as per the PMS for the pipe class specified for the system. After receipt of approved drawings, detailed fabrication schedule shall be worked out by Planning Engineer / Piping Engineer based on availability of drawings and material. The approved ISO drgs. shall be marked with all the welded joints (shop & field) prior to fabrication from following flow direction or left to right with a number to identify each weld in sequence,VIZ1,2,3. and each line shall have the joint nos. in sequence, no joint nos. shall be repeated in same line no. The marked up copy of the isometric will be made available for planning/fabrication personnel & QC dept. for co-ordination. Any addition joint in between two joints if arises due to modifications of line, this joint will bear next continuation joint number of the previous joints. For example a line is having join nos from 1 to 12 and one additional joint came in between joint no 2 and 3,then that additional joint shall have joint no will be J 2.01. Sequence of fabrication of piping spools shall be decided by the Planning Engineer / piping engineer based on availability of erection front. Any change from the sequence can be made by discussions and approval from Planning Engineer. Only accepted material will be issued for fabrication, however, in case of urgency material with positive identification shall be issued for fabrication in absence of MTC. MTC shall be subsequently reviewed and accepted.

4.1.4

4.1.5

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4.1.6

Material will be marked as per requirement of sizes and transfer the control no.On each piece. Field welds shall be provided during piping fabrication and an extra length may be left on one side of the pipe at each field weld. Field welding of weld joint near the pumps shall be done only after pump and connected piping have been truly aligned. Pipe material like C.S., Low Alloy steels (containing upto 5% Cr) shall cut to size by gas cutting or grinding machines and High alloy steels (>05%) & stainless steel shall be cut by grinding or plasma arc cutting machine. The grinding wheel used for SS works shall be identified separately. Finished flame cut edges shall be smooth with no cutting oxides, slag or other cutting marks such as drag grooves. Root, face landings on flame cut bevel joints shall be ground axially square to the axis of the pipe.

4.1.7 4.1.8

4.1.9 4.1.10

4.1.11 The cutting tolerance is based on the Out of Roundness. The tolerance in internal can be adjusted. 4.1.12 Pipe joints type shall be as per approved drawing/piping material specifications. 4.1.13 Fit up shall be done as per approved WPS/drg. For pipes of wall thickness 05mm and above couplers, yokes or C clamps shall be used to maintain perfect alignment. For pipes of wall thickness below 05mm edge tacking shall be done by a qualified welder because the tack welds become part of the final weldment and shall be free from defects. 4.1.14 All piping spools shall be marked/stamped for proper identification like as line no., joint no., welder no., spool no. 4.1.15 Bending of pipe shall be done as per ASME B31.3. Cold bend for lines 1 and below, with a bend radius of 5 times the nominal diameter shall be used as required in place of elbows wherever allowed by piping specifications. 4.1.16 Mitre bends and fabricated reducers shall be governed by the piping material specifications. Generally all 90 mitres shall be 4-piece 3-weld types and 45 mitres shall be 3-piece 2-weld types unless otherwise specified.
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4.1.17 Surface preparation, primer painting, and tape coating (except weld joints) will be done before hydro testing. Weld joints will be cleaned mechanically and Primed /tape coated after hydro test. 4.1.18 The erection of piping will be planned in such a way that the Minimum No. Of field welds are encountered. 4.1.19 4.1.20 4.1.21 4.1.22 Slopes specified for various lines in the drawings/P&ID shall be maintained during erection of piping spools. Check the documents of the piping spools and identify the spools ready for erection by suitable identification marks (isometric no, spool no to be painted and punched on the spool). After erecting/placing of piping spools in position, it will be aligned to meet the requirements and its orientation, levels, slopes, will be checked. The trench shall be excavated so as to provide and average cover of 1000mm or equal to the diameter of the largest pipe to be laid in the trench, which ever is greater or as shown in the drawing. The average cover will be reckoned from top of the pipe of the largest diameter to be laid in the trench, to finished grade level. The width of the trench shall be sufficient to give free working space on each side of the pipe and it shall no be less than 150mm on either side or 1/3rd dia of pipe whichever is greater. If the trench is excavated below the required level indicated in the drawing, the extra depth shall be filled with concrete or approved equivalent material. In muddy slushy ground, the bed shall be provided with a layer of a sand or lean concrete. The trench shall follow the gradient of pipeline as specified in the drawing. Coated pipes shall not be placed in trench until cave in plugs; hard clods, stones, skids, welding rods etchave been removed there from. Coated pipes shall not be dragged along the ground or otherwise handle in a manner that will be detrimental to the coating.

4.1.23 4.1.24 4.1.25 4.1.26 4.1.27

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4.1.28

The pipe shall be lowered in the trench by a method that cannot cause any damage to the coated pipe. The ends of the pipeline shall be kept closed to prevent entry of any foreign material after lowering in to the trench. After testing and inspection of the pipeline the trench shall be back filled with the excavated material. The back fill material shall be free from stone pieces.

4.1.29

4.2 4.2.1 4.2.2

PREHEATING: Minimum preheat temperature shall be 10 C. Preheat will be applied with minimum as specified in welding chart or in 330.1.1 of ANSI B 31.3 CHEMICAL & PETROLEUM REFINERY PIPING or as per established welding procedure. Higher pre-heat temperature can be used for particular fabrication procedures. These temperatures will be depending on the carbon equivalent of the joint, welding process and consideration for the control of distortion. Preheating will be applied to weldments by hand held gas heating torch (for low thk) or electrical resistance, heating coils or straps. All welding consumable such as electrodes, filler wires, flux and gas shall be stored, handled and use in accordance with the manufacturers instructions. FILLER MATERIALS: The welding electrodes and filler wires used shall be as per approved WPS/ welding specification chart and B.T.C. of electrode / filler wire shall be submitted to QAQC for approval. Electrodes will be baked in a master oven at manufacturers recommended temperature. Electrodes issued for fabrication should be transferred to portable heating ovens in the working areas. After a maximum working period of 4 hours welders shall return all unused electrodes from working areas into the main baking oven. Each welder will be provided with one portable oven.
UG PIPING FABRICATION & ERECTION

4.2.3

4.2.4 4.3 4.3.1

4.3.2

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4.3.3

All welding filler wires issued to welding operators shall be handled in strict accordance with the manufacturers recommendations. Particular attention should be made to wire used in working areas, welding filler wires shall be kept covered at all times while in the fabrication shop to avoid contamination by oil and grease or allow moisture to form rust on the wire. All filler wires shall be identified by a colour coding system at both ends to avoid mixing of wires at the time of welding. SHIELDING & PURGING GAS: Welding gases shall be supplied with analysis ( at random) sheets showing the purity of the gas and manufacturer shall certify it. Purging shall be maintained during the root pass and for the first filling pass to minimise oxidation on the inner side of the pipe, unless otherwise specified in welding specification chart. Initial purging shall be maintained for sufficient period of time so that at least 4-5 times the volume between the dams is displaced in order to completely remove the entrapped air.

4.4 4.4.1 4.4.2

4.4.3

4.5 WELDING: 4.5.1 4.5.2 4.5.3 4.5.4 All welding shall be carried out by qualified welders as per approved WPS, welding specification chart and approved drgs. Welding technique / process (es) followed during welding shall be as per approved WPS. All root pass must be completed by one or more welders as a continuous operation. Each layer of deposited weld shall be thoroughly cleaned before further deposits of weld metal are commenced. When necessary the deposited metal shall be ground free of profile irregularities. Particular attention shall be given to the toe of each layer of welding at the junction to the fusion face of the joint to avoid slag traps or lack of fusion in subsequent welding deposits. All weld joints are defined as full penetration welds with a minimum of two passes.

4.5.5

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4.5.6 4.5.7

A minimum of two passes shall be made in multi layer joints before welding stopped for any reason. Fillet joints shall be welded with a proper weld profile as per codes & Standards.

4.6 VISUAL INSPECTION OF WELDS: 4.6.1 During final examination, all temporary bridge attachments and welds located on the parent metal shall be removed. Oxy-acetylene cutting and grinding can remove temporary attachments. Any damage to parent material shall be repaired by welding and grinding. All piping spools shall be checked for proper identification/ stamping like as line no., joint no., welder no., spool no. Visual inspection of weldments shall include location and distance between all welds. Finished weld joints must not have any surface porosity, spatters, under cuts etc Finished weld joints must have proper reinforcement, if fillet proper leg length and throat and thickness shall be maintained.

4.6.2 4.6.3 4.6.4 4.6.5

4.7 HEAT TREATMENT OF WELD JOINTS: 4.7.1 4.7.2 4.7.3 PWHT, wherever required for weld joints shall be carried out as per the welding specification chart/ codes. PWHT procedure shall be submitted to QAQC for approval before starting of job. No welding / hot work shall be permitted after Post Weld Heat treatment.

4.8 INSPECTION, TESTING AND REPAIR OF WELD: 4.8.1 4.8.2 All NDT works like as RT, DPT, MPT, UT shall be carried out by experienced/qualified personnel as per approved job procedures. The application of above NDT for welding shall be as per inspection class mentioned in contract document.
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4.8.3 4.8.4

For spot or random Non Destructive examination, the selection of joints shall be by QAQC department if required. All repair work shall be carried out as per established welding procedure followed during actual welding. Repair area of the weld can be removed by grinding according to the size, depth, and location of the weldment. The complete repair will have a specified appearance, which will meet the established welding procedure specification and code inspection standards. Welding repairs are unavoidable made on PWHT, and then complete PWHT cycle must be repeated with a second heat chart. After PWHT the hardness value on the weld, HAZ and parent metal shall be measured either using Poldi type or portable hardness instrument wherever PWHT is applicable and hardness requirement shall be as per welding specification chart. Hydro/Pneumatic test will be carried out, as per approved procedure No: LT/PREP/MS/F&TP/014, after fulfilling the requirement of mechanical completion, and NDT completion. The Hydro-testing of the loop shall be carried out as per the Contract specification class of piping. The test pressure and holding time will be as specified in Isometrics/line schedule. After Hydro-testing is complete the water will be drained off safely and pipelines will be demarcated by painting HYDRO TESTED on the pipelines. SURFACE PREPARATION, PRIMING AND TAPE COATING Surface preparation, priming, and tape coating of pipeline shall be carried out by approved procedure.

4.8.5 4.8.6 4.8.7

4.8.8

4.8.9

5.0

6.0

INSPECTION The stage wise inspection shall be carried out as per approved ITP.

7.0

DOCUMENTATION:

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Reports and documentation shall be maintained as per approved ITP & in the approved format only. 9. HEALTH, SAFETY & ENVIRONMENT (HSE) 1> All necessary PPEs shall be available with all workmen. 2> Only trained & experienced workmen shall be deployed for this job. 3> Provide sufficient safety protection (like warning signs, barricading etc) around the working zone. 4> Sufficient width of working platform & hand railing should be provided as per safety plan when working at height

Note:

Any conflict between the job procedure & contract documents, the later shall be followed.

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