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Doc. No.

: FCC-CPP-001
FABRICATION AND ERECTION
PROCEDURE FOR Job No.: 130075
PROCESS PIPING Rev. B Page 2 of 23

REVISION LOG

Rev. No. Rev. Date Revised Page Revision Description

B 09-DEC-13 All Revised as per Company comments


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TABLE OF CONTENTS

1.0 PURPOSE Page 4

2.0 SCOPE Page 4

3.0 CODES, STANDARD AND REFERENCES Page 4

4.0 MATERIALS Page 6

5.0 WELDING Page 7

6.0 FABRICATION WORK Page 9

7.0 ERECTION WORK Page 14

8.0 HANDLING Page 21

9.0 CLEANING Page 21

10.0 FIELD PRESSURE TEST Page 21

11.0 INSPECTION AND EXAMINATION Page 22


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1.0 PURPOSE

The purpose of this procedure is to ensure that all the piping fabrication and erection
works were carried out in accordance with the relevant drawings / specifications,
standard & codes and meet requirements of Chapter E5, Exhibit E of the contract
document.

2.0 SCOPE

This procedure is provided to cover the fabrication and erection of all carbon steel, alloy
steel, stainless steel pipes except cement lined pipes and reinforced plastic pipes at this
project.

The procedure for cement lined pipes and reinforced plastic pipes shall be provided
separately.

3.0 CODES, STANDARD AND REFERENCES

The latest issue of the following Codes and Standard shall be a part of this procedure.

KNPC Engineering Standard 50B15 Steam and Utility Piping

KNPC Engineering Standard 52C1 Shop and Field Fabricated Piping

KNPC Engineering Standard 52C2 Piping Reinforcement

KNPC Engineering Standard 52C3 Piece Marking Fabricated Pipe

KNPC Engineering Standard 54C1 Marking for Piping Materials

KNPC Engineering Standard 53C1 Piping Erection

KNPC Engineering Standard 50D11 Pipe Welding - General

KNPC Engineering Standard 50D12 Piping Welding - Carbon Steel

KNPC Engineering Standard 50D13 Piping Welding - Chrome Alloy Steel

KNPC Engineering Standard 50D14 Piping Welding - Stainless Steel

KNPC Engineering Standard 41A10 Installation of Under Ground Piping


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KNPC Engineering Standard 83A4 Coating & Wrapping for Underground

Steel Pipe - Cold Application

KNPC Engineering Standard 83A1 Painting Specification

ASME B31.3 2008 edition Process Piping

ASME B1.20.1 1983(R1992) Pipe threads, General Purpose (Inch)

ASME B16.25 2003 edition Butt welding Ends

API5L 44th Edition Specification for Line Pipe

ASTM-A333 2010 Edition Seamless and Welded Steel Pipe for

Low-Temperature Service

PFI ES-3 2009 edition Fabricating Tolerances

PFI ES-5 2006 edition Cleaning of Fabricated Piping

PFI ES-24 2008 edition Pipe Bending Methods, Tolerances,

Process and Material Requirements

Shell DEP 31.38.01.31 Shop and Field Fabrication of Piping


Shell DEP 31.40.40.38 Hydrostatic Pressure Testing of New
Pipelines
FCC-CGP-011 Site Material and Procurement Control

Procedure

FCC-CGP-015 Procedure For Piping Flushing,

Hydrotesting and Reinstatement

FCC-CGP-016 Pneumatic and Service Tests Procedure

FCC-CGP-050 Welding Procedure Qualification

FCC-CGP-051 General welding procedure

FCC-CGP-052 Weld consumable control procedure

FCC-CGP-053 Welder and Welding Operator Qualification

Control

FCC-CGP-058 Field PMI procedure


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FCC-CGP-059 Welding Repair Procedure

FCC-CXP-001 Coating & Painting Procedure

FCC-CGP-054-57 NDE Procedure (RT, UT, PT, MT)

4.0 MATERIALS

4.1 Materials Supply and Inspection

Materials controller shall controls materials and delivered materials will be checked
through the delivery note, and actual inspection as per specification, quality, quantity,
and damage that will be reported for further action. Damaged or non-confirming
item/material, if any, upon receiving inspection shall be cordoned to avoid mix up with
other material.

4.2 Materials Management and Control

Piping materials (Pipes, Fittings, Flanges, Valves, Bolts & Nuts and etc.) be placed in
designated storage yard for shop fabrication and field erection respectively. Storage yard
will be barricaded and isolated from other object to assure safety to avoid damage
before using. Materials will be sorted out and stored and issued before proceeding for
fabrication in accordance with Site Material and Procurement Control Procedure,
FCC-CGP-011. Remaining parts from cut pipe will be marked and segregated to one
place.
Piping materials such as Pipes, Valves, Fittings, Flanges, Gaskets and Bolt/Nuts shall
be color coded for easy identification in the vendor shop and/or in the job site as per
KNPC Engineering Standard 54C1.

4.3 Handling of Coated Piping Material

Internal and External coated pipes shall be handled carefully to safe guard the coated
surface from damages. Special supports and pads shall be provided to hold the pipe in
position to facilitate fabrication. Sufficient length of internal/external coating shall be
removed by mechanical means from edges that to be welded. The subject surfaces shall
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be made free from all type of dirt.

During handling and transporting activities, proper measures such as using of sling belts
shall be taken to prevent unnecessary damages on the coated surface of piping
material.

5.0 WELDING
5.1 General

All welding work shall be governed by General Welding Procedure, FCC-CGP-051 and
detail procedures for each activity shall follow respective procedure.

No welding is allowed when the surface of the parts to be welded are wet from rain,
when rain is falling on such surface, or during periods of high winds unless the welder
and the work are properly shielded.

Electrodes shall be stored in a proper manner to prevent from damp or damage under
the conditions of drying temperature and times as per Welding Material Control
procedure FCC-CGP-052

All surfaces to be welded shall be thoroughly free from scale, oxide, dirt. grease. Paint or
other contaminants.

In order to prevent weld splatter, grinding or possible contamination on the coated pipes
during the work, protective canvas such as tarpaulin should be used on the adjunct
coated area.

Screens shall be provided around grinding & welding locations to prevent injury to
adjacent workers.'

5.2 Welder Qualification

All welders shall be qualified in accordance with ASME Sec. IX and Welder Qualification
Test, FCC-CGP-053. Only qualified welders in compliance with the requirement and
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Welding Procedure Specification (W.P.S.) shall do all welding.

5.3 Welding Performance

Tack Weld shall be performed by qualified welder and as per number and size of tack
welds specified in KNPC Engineering Standard 50D11 and surface defect shall not be
found by visual inspection.

Tack welds at the root of the joint shall be made with filler metal equivalent to that used
for the root pass. Tack welds shall be removed during root pass welding.

In the shop and field weld, it shall not use make-up lengths of pipe less than 150mm (6
inch) long on butt weld pipe spools, as fill pieces, unless otherwise approved. The use of
three or more short lengths of pipe welded together in a line to make a pipe length in 6M
is not permitted. Short length is defined as 1.2M (4 feet) long minimum.

Longitudinal seams in the pipes shall be staggered in such way to clear the openings
and attachments.

Longitudinal welds shall be staggered as away as possible and minimum distance


between longitudinal seams shall be 100mm (4 inches). Any deviation shall be
considered subject to approval by Company.

Butt welds shall be prepared in accordance with requirements shown in table 1 and as
per KNPC Engineering Standard 50D11.4.

Table 1
Groove for Butt Welding
Pipe Wall Thickness (t) Type of Groove

3mm or less (stainless steel)

4mm or less (carbon steel and Square groove or slightly beveled

lower alloy steel)


Over 4mm to 22mm (but over 3mm for
Single V groove as per WPS
stainless steel)
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Over 22 mm Single U groove or as per WPS

Filet welds shall be multi-layered and sufficient strength.

Sealed welding works for fabrication and erection would be done, if applicable. Sealed
welding shall be done with electrodes not exceed 1/8 inch in diameter using an
amperage in the low to minimize distortion of the connection and of the parts being
welded. The finished weld shall not exceed 3/8 inch fillet.

Socket welding fitting or valves are fit-up with the face and shall be spaced
approximately 1/16 inch (1.6 mm) from the root face of the socket and shall not exceed
1/8 inch (3.2 mm). Socket weld should be welded at least 2 passes. PT examination is
required for socket welding joints

In case of the defects in weldments, correction shall be made in accordance with


Welding Repair Procedure, FCC-CGP-059

6.0 FABRICATION WORK

Fabrication and Installation of the piping shall be performed in accordance with the
technical requirements stated in the relevant specification and piping drawings. When a
conflict between requirements shown in the drawings and actual field situation is found,
field change shall be made for the approval of field change notification.

Completed pipe spools shall be internally cleaned prior to installing temporary end caps
to prevent ingress of foreign objects at the fabrication facility.

6.1 Standard Pipe Spooling

Shop fabrication consist of all piping 2 inches and larger, field fabrication consist of
piping up to and including 1-1/2 inches in size. The shop spool fabrication is to include
all branch connection for the field piping up to the first butt weld, first socket weld, first
screwed connection or first flanged connection, as applicable.
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For each pipe spool, drawing shall be provided and it shall include all the necessary
information to fabricate the spool, pipe spool number and material classification.

6.2 Surface and Pipe End Preparation

Pipe ends shall be beveled. Machining and grinding shall do beveling. All oxides and
surface of previously melted and occasional notches will be removed from edges by
grinding or machining. Cutting will put suitable allowance taken into account for shape of
connections and shrinkage due to cutting and welding.

Cold cutting shall be preferably used wherever possible and on internal coated pipes in
particular. Flame cutting shall be done taking care of protection for external / internal
coating. In case of coated pipes provide sufficient margin to avoid damage to heated
affected zone. Pilot hole of sufficient dia shall be drilled before gas cutting on blind
surfaces. All safety precautions are to be adhered to avoid localized fire.

For carbon and low alloy steel, gas-cutting torch shall be used for cutting, oxide scale
shall be removed by grinding, and for stainless steel pipes plasma cutting or machining
shall be done.

Special materials will use special cutting machine and procedure as per required.
Cutting and beveling of pipes shall be done the methods shown in table 2.
Special care shall be taken to remove the internal burrs and clean for distance 1 inch
(25.4mm) in external and internal surface for equal or less than 2 inch pipe

Table 2
Pipe Cutting
Pipe Material
For Cutting For Beveling
Rough Cutting Grinding
Carbon Steel
Grinding Cutting Machining
Grinding
Stainless Steel Plasma-arc Cutting
Machining
Mechanical Cutting Grinding
Alloy Steel
Plasma-arc Cutting Machining
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All pipes to be cleaned after cutting for fabrication prior to fit-up. Fabrication shop should
be provided proper method such as compressed air-etc.

6.3 Fit - up

Inner and outer surface should be free from foreign materials and unnecessary spots
and groove should be removed to avoid the damage in welding joint. Cleaning shall be
carried out using suitable means Le. air, water, wire brush etc.

Fit-up of pipes shall be conducted with the suitable height support and at proper position
before welding to avoid misalignment.

Fit-up and alignment shall be done with accordance of WPS procedure.

6.4 Alignment

Pipes shall be adequately supported and aligned through the use of jigs, C clamps.
chain blocks and other devices as required or direct tack welding if possible. Pipe shall
be supported as per calculated weight and dimension. Alignment shall be check as per
drawing requirement and standard tolerance.

Where component ends have an internal misalignment over 1.6mm, the thicker
component with the wall extending internally shall be trimmed internally to an angle less
30-degree as per WPS.

Internal/External line up clamps shall be used depending on pipe diameter for fabrication
and alignment. Special pads and supports shall be used for coated / stainless steel
pipes. Clamp shall be retained until root pass is carried out as far as possible for internal
clamps.

Stainless steel materials shall under no circumstances be in contact with Galvanised


material or halides and chlorides

Trimming for joints having misalignment shall be as per clause 4.2 of KNPC engineering
standard 50D11.
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6.5 Branch Connection

Branch connection shall be as per KNPC Engineering Standard 52C2. Branch piping will
be supported while performing the fit-up and welding to assure the proper alignment.
Welded Branch Connection

a) Welded branch connections shall be stub in non-reinforcing pad connection.


b) Welded branch connections shall be stub on reinforcing pad connection.
c) Opening cut of the run wall shall be done in accordance with the cutting and beveling
methods specified in this specification. The branched in parent pipe weld seams is
not permitted and shall follow the specification with regards to weld separation.
d) Opening cut in the weld seam of run shall be prohibited.
e) In order to avoid the wrap of the welded part due to heat of welding of the branch,
reinforcing members may be preferably attached for temporary. Branch re-enforcing
pads shall be subject to air test
f) The reinforcing pad for fabricated tees. where indicated on the fabrication drawings,
shall be provided.

6.6 Thread Connection

Check the threaded pipe and fittings to be joined. Carry out external threading (NPT) to
the standard length at the ends of the pipe. Threaded ends of pipe shall be clean cut
without burrs or stripping of threads. Apply company-approved sealant or propriety
anaerobic sealing compound (eg: SWAK pipe thread sealant, John crane plastic
lubricant (PSL No.2) or equivalent) all around the threads and screw the fitting with the
help of pipe wrench and tighten fully.
The threaded pipe sealant shall be selected to meet the required pipe design
temperature and process fluid. Sealant tape is not permitted
Check for minimum three threads expose after joining. Remove excess sealant if any
inside the pipe and clean thoroughly

6.7 Flange Connection

Flanges shall be positioned in accordance with the specification.


Flange faces shall be protected at all times to prevent mechanical or environmental
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damage
Flange bolt holes shall be distributed to straddle the established centerlines (horizontal,
vertical, or layout centerlines) of pipe or shall match the orientation of bolt holes of
flanges on equipment. For angled pipe spools, flange bolt holes shall straddle
north-south centerlines unless otherwise indicated.
All flanged connections to equipment, pumps compressors, exchangers shall be
installed with a T handled bling plate as a temporary measure to ensure construction
debris does not enter the Equipment. Blind plates will also serve as positive isolation to
assist with Permitted confined space entry.
Gaskets and bolts shall follow piping specification. Gaskets and bolts of different grades
shall be clearly identified. ( i.e., perimeter colour coding on gaskets)

Flange connection to equipment shall be adequately supported to ensure that excessive


forces are not placed on equipment nozzles, particularly pumps and compressors

6.8 Bolting Procedure

Bolts will be tightened, torqued, tensioned in accordance with the Project Specification.

All flanges shall be fitted-up so that the gasket contact faces of flanges may meet
uniform with gasket, and then bolts shall be tightened to build uniform bolt stress. During
bolt tightening, care shall be taken to ensure smooth rotation and then tighten the bolts
diagonally until parts are fully engaged.

Bolted flange connections can in general be tightened by means of spanners, impact


tools or torque wrenches. Hydraulic bolt-tensioning equipment shall be applied for the
tightening of bolted flange connections which are exposed to severe operating
conditions or where a proper stress distribution in the bolts is required for other reasons.

In bolting flanges joints, bolt shall be tightened in a proper manner to obtain suitable
gasket stress for each type of gasket used.

Cast iron flange joints shall be assembled with great care to prevent damage of the cast
iron flange.
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All bolts shall be extended completely through their nuts at least two (2) full threads.

In bolting joints with spiral wound gaskets, the gasket shall be compressed until the
raised faces of the flanges contact the compression gauge ring uniformly.

After bolting of nozzle flanges of rotating machinery such as pumps, compressors,


blowers, clearance between flange face shall be measured to check uniform
compression of gaskets. For flanges with solid metal gaskets such ring type, the above
measuring is also required.

Gaskets and bolts shall follow piping specification. Gaskets and bolts of different grades
shall be clearly identified. ( i.e., perimeter colour coding on gaskets)

Flange connection to equipment shall be adequately supported to ensure that excessive


forces are not placed on equipment nozzles, particularly pumps and compressors

6.9 Painting on Weld Joints

All welds shall be left bare of insulation and unpainted. Painting / Insulation shall be
carried out after successful completion of pressure test.

6.10 Identification of Fabricated Pipe

Pipe spool marking for identification shall be in line with KNPC Engineering Standard
52C3, In order to enable at shop and field to fabricate/install the correct material,
numbering system shall be applied and maintained at each pipe spool and loose piping
materials such as random pipe, valves, flanges, fittings, gaskets, etc. until completion of
erection strictly.

7.0 ERECTION WORK

7.1 Above ground pipe

When fitting random pipe, pipe spools or other combination of piping item one another or
to equipment, if alignment does not meet the tolerance it must not be twisted or heated
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to make up the piping. In fit-up, if there is a gap between two adjacent pipe ends, the
erector shall not install a pipe piece less than 150mm (6 inches) in length instead one
end, or if necessary, both ends of the piping should be cut to meet the requirement.

After installations of random piping, pipe spool, valves or other items where open ends
will not be closed immediately, plywood or proper canvas cover shall be installed at the
opening to prevent foreign materials or liquid to enter into the system.

Lifting of spool or pipes shall be check as well as the lifting tools before lifting to avoid
the misconnection of pipes and to protect the materials that can make damage while
lifting.

Crane locations and capacity to be reviewed, by responsible lifting/ rigging supervisor,


prior to lifting of pipe and components. Crane checklist to be completed prior to lifting
components.

Use of correctly rated chain blocks shall be used.

Prior to pipe installation, pipe support shall be erected by the use of shims and wedges
and shall beveled and plumbed so that pipe details can easily be brought into proper
position and easy alignments.

When unavailable circumstances have arisen not to allow the erection of permanent
supports before piping installation work, rigid temporary structural steel frames or other
proper devices may be employed. Such structural steel frames shall be rigid enough so
as not to misalign piping system.

Details regarding welding of orifice flanges shall be included as per clause 6.5.3 of
KNPC engineering standard. 52C1.

Supports permitting pipe move shall be assembled to allow the necessary movement of
pipes as caused by thermal expansion and contraction.

Spring hanger shall be installed exactly as shown on the support drawings. Lock pin of
spring hangers, which are provided for shipping, shall not be removed until the
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completion of the construction work, and shall be removed before the preparation for
initial start-up operation. When the pins of spring hangers are removed, each spring
indicator shall show the right position.

After completion of piping category A punch clear, pressure test will be carried out in
comply with the requirement of KNPC Engineering Standard 93A2 and detail pressure
test diagram and procedure shall be provided to KNPC and approved prior to
commencing the test.

7.2 Underground Pipe

A. Wrapping and Coating

Wrapping and coating will be carried out in comply with the requirement of KNPC
Engineering Standard 83A4

The pipe including valves and fittings shall be free from loose mill scale, rust, dirt,
grease, moisture or other foreign material. Pipe shall be thoroughly cleaned, using
hand or power tools in accordance with SSPC-SP-2 and SSPC-SP-3 respectively.

Pipe shall be thoroughly cleaned to a surface finish SA 2.5 prior to painting.

The primer shall be brushed to cover the entire surface for the pipe and fittings.
The primer dry film thickness should range 35 - 50 micron. No application of coating
material shall take place when the pipe is wet by any form of precipitation or when
excessive sand is blowing or during inclement weather.

Two layers of 50-micron (20 mil) thick spiral wrap to be applied to all size, over the
entire pipe surface including irregularities such as welds, couplings, elbows, etc.

Filler tape with a heavy putty consistency to be applied over all valves, flanges,
sleeve ends, and hard to get to areas. Overlap will be 25mm. The optimum bonding
is achieved if the primer layer, when the indicated tape is applicated, is still tacky to
touch, yet dry.
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For mill wrapped pipe, the cut-back from each end of the coated pipe shall be 75mm
(3 inches) for shipping and the wrapping of the field joints shall extend at least
75mm (3 inches) past the shoulder of the mill wrapping. At the beginning and end of
the spiral wrap, there shall be at least one complete parallel turn.

In case of field wrapped pipe after assembly, the spiral wrap shall be continuous
over the pipe and fittings.

In all cases, the manufacturer's detailed application instruction shall be followed.

Materials : Primer &Putty


Under wrap : Polyethylene 20-25 mil thick
Outer wrap : Polyethylene or PVC 20-25 mil thick

After shop and field wrapping operations have been completed, the contractor shall
conduct an electrical inspection of all wrapped surfaces with an electrical holiday
detector to the extent necessary to assure that the final in place pipe coating is free
of voids, bruises and holydays.

The contractor shall mark any detective areas, recheck for detects and repair as
required and additional holyday detection may be conducted. The repair shall be
made by first removing loose of disbanded material from the area around the
holyday and the exposed area shall then be repaired using the same system of
primer and cold applied tape as the original wrapping while maintaining a minimum
of 50mm of overlap. Holiday tester shall be calibrated regularly per 24 months. The
holiday tester voltage will be in accordance with Nace Standard RP02- 74,
paragraph 3.2 in case of 2 layers of 20 mils thick each, the test voltage should be
set at 10 KV.

B. Excavation
All excavation shall be as per the requirements laid in Document No. FCC-CCP-002.
Subject to the fulfillment of safety requirement and type of soil.
The extent of excavations shall be kept to the minimum required to install pipe to the
lines and grades indicated on the construction drawings.
If a single pipe is to be laid in a trench, the trench width at the top of the pipe shall
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not be greater than the outside diameter plus 24 inches. When more than one pipe
is to be placed in a trench, excavate the trench only to a sufficient width for
satisfactory joining of the pipes and tamping of the backfill. Trench walls shall be as
near vertical as possible from the bottom of excavation up to the elevation of the top
pipe.
Where the grade and alignment of the pipe is obstructed by existing structures such
as, conduits, ducts, storm drains, foundations and firewater lines, the obstruction
shall be permanently supported, relocated, removed or reconstructed.

C. Bedding
Bedding shall be defined as a leveling material from the bottom of the trench to
supporting the bottom of the pipe.
Bedding material shall be selected such that the same shall not damage the
wrapping of pipes and same shall be approved by company

D. Laying Pipe
The pipe shall be laid in such a manner so as to ensure uniform and complete
support by the bedding material on the bottom segment of the pipe.

Wrapped pipe shall be laid on sand bags adequately spaced to allow sufficient
support to the pipe. This will allow final holiday test inspection to be completed and
allow for visual inspection where slings have been used for installation.

Pipe with exterior and/or interior protective coating shall be handled with sufficient
lining to prevent cracking of the cement lining or wrapping.
Pipes are to be laid as indicated on the construction drawings with the following
acceptable tolerances.
(a) Vertical: Deviation from given level (grade elevation) shall not exceed ..19mm.
In cases of flatter gradients, 0.4%), not greater than 1/20 the given gradient.
(b) Horizontal : Deviation from horizontal alignment shall not exceed 0.1%
(c) Deviation in alignment and grades shall not be cumulative.

E. Joints
Non-lined steel pipe with welded field joints shall be assembled in accordance
with KNPC Engineering Standard 53C1 for Piping Erection.
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Cement-lined steel pipe with welded field joints, shall be assembled in


accordance with KNPC Engineering Standard 52C6 for Cement Lined Piping
Fabrication
Reinforcing plastic pipe field joints, shall be assembled in accordance with
KNPC Engineering Standard 50A8 for Reinforced Plastic Piping

F. Inspection
Pipe shall be carefully inspected in the field before testing. In any cause for rejection
is discovered it shall be rectified.

G. Testing
All joints and connections shall be hydrostatically tested before covering with
protective pipe coating and/or backfilling.(refer to clause 10.0). Holiday detection test
shall be carried out before backfilling.

H. Backfill
Trenches shall be backfilled as soon as possible after pipes have been laid, tested
and accepted. No construction machinery or vehicles shall be allowed to pass over
the trench until the trench is backfilled and compacted sufficiently to prevent damage
to the pipe unless adequate provisions have been made to span the trench to
prevent damage to the trench and pipe.

Backfill Material shall used sand for trench backfill shall be acceptable to and
approved before placement. Zone 1 shall be defined as the top of bedding material
to 300mm above top of pipes and backfill material shall be free from cinders, ashes,
refuse, vegetation or organic matters, boulders and rocks one 25mm or larger in
diameter.

Over zone 1 material, backfill material consisting of not more than 15 percent having
a dimension larger than 50mm and no rocks over 100mm shall be placed in the
trench so that the material shall not damage the wrapping of pipes.

I. Compaction
Flooding or ponding shall not be permitted as a method of backfilling compaction.
Carefully backfill with sandy material with little or no fines around the haunches,
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firmly compacting the material, using hand tamping equipment. Be careful to avoid
both vertical and lateral displacement of the pipe from proper alignment. The backfill
around haunches shall be hand placed in maximum 150mm layers.

Mechanical compaction around the pipe shall not be permitted to ensure that the
wrapping is not damaged.

After material has been compacted around the haunches, the remainder of the Zone
1 material shall be placed along side the pipe in 150mm loose layers and compacted.
The layers shall be brought up equally on both sides of the pipe. Placing or
compacting, which will place an unequal load on one side of the pipe, shall be
avoided.

The percentage of compaction shall be as per procedure No.. FCC-CCP-002

J. All inspection shall be carried out as per approved ITP. Before starting back filling, a
clearance notification shall be obtained from the piping QC team showing that the
line is ready for back filling to ensure all required inspections are completed
satisfactorily

K. Others
Details for underground piping work should refer to KNPC Engineering Standard
41A10.

7.3 Equipment and Tools

Equipment machine and tools will be provided as per requirement in installing pipes and
spool. Equipment and tools will do routing check-up for safety purposes. Capacity of
crane will be based on calculated weight, distance and axis.

7.4 Installation of Valves

Valves shall be installed at the closed position, and shall not be opened during the
construction work.
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Butterfly valves shall be installed at the open position prior to tightening the bolts. After
the bolts have been tightened, operation of the valve through a complete open and
closed cycle shall be checked to ensure that the disk will not be jammed during the
installation.

8.0 HANDLING

a) Pipe spool shall be braced, wired, or restrained to prevent unacceptable shifting,


defection and flexure due to impact to shock loads that may occur during
transportation and shipping.
b) All unloading pipes must be supervised to prevent mechanical damage due to
mishandling.
c) Piping shall be thoroughly examined for mechanical damage at time of shipment,
unloading and at time of assembly which may cause for a rejection.
d) Pipes must not be intermix with other alloy pipe during shipment or in field storage.
e) Improper handling such as dropping the pipe must be avoided or shall not be
allowed, dropping the pipe can result permanent damage to the materials.
f) All piping must be securely fastened to the bed of trailer during shipment to
fabrication shop, field storage and installation.
g) Flange faces shall be protected by plywood cover to avoid damage to flange faces
during shipment and handling.
h) Open-end pipe shall be protected by steel bracing bar or retaining cap supplied by
vendor until installation.
i) All piping spools will not leave the fabrication shop/area without have been
inspected for internal cleanliness. Pipe and flanged ends shall be sealed to prevent
the ingress of foreign materials

9.0 CLEANING

Prior to install the pipe spools at field or inserting into the piping module, all pipe spools
shall be cleaned.
Both ends of pipes shall be covered by plastic cap or canvas properly until completion of
field erection to avoid any contaminants from foreign materials, debris and dust and etc.

10.0 FIELD PRESSURE TEST


Doc. No.: FCC-CPP-001
FABRICATION AND ERECTION
PROCEDURE FOR Job No.: 130075
PROCESS PIPING Rev. B Page 22 of 23

After completion of category A punch clear, pressure test will be carried out in comply
with the requirement of KNPC Engineering Standard 93A2 and detail pressure test
diagram and procedure shall be provided to KNPC and approved prior to commencing
the test.

11.0 INSPECTION AND EXAMINATION

All nondestructive tests shall be performed in accordance with N.D.E procedure and
applicable code as below.

FCC-CGP- 054 Radiographic Testing Procedure

FCC-CGP- 055 Ultrasonic Testing Procedure

FCC-CGP- 056 Magnetic Particle Testing Procedure

FCC-CGP- 057 Liquid Penetration Testing Procedure

FCC-CGP-058 Field PMI procedure

Leak test shall be performed in accordance with below procedure

FCC-CGP-015 Procedure For Piping Flushing,

Hydrotesting and Reinstatement

FCC-CGP-016 Pneumatic and Service Tests Procedure

Inspectors representing the Company shall have access to the fabrication shop and
work area.

Completed welds shall be free from all types of visual defects, Le., undercut, overlap,
excessive protrusion, porosity etc. Weld shall be thoroughly cleaned before carrying out
the required NDE.

On daily basis, all weld joints shall be visually inspected by QC inspector and its results
shall be recorded on the isometric drawing and welding inspection report.
Doc. No.: FCC-CPP-001
FABRICATION AND ERECTION
PROCEDURE FOR Job No.: 130075
PROCESS PIPING Rev. B Page 23 of 23

In selecting weld joints for NDE, Contractor's QC engineer shall select the welds among
the daily production weld joints based on requirement of project specification and a list of
selected weld joints shall be submitted to the Company for their review and comment, if
any. However, welds for NDE can be selected by the representative of Company at their
discretion.

Prior to acceptance of piping system, all punch listed items/defective components and
workmanship (if there's any) shall be resolved and cleared by Contractor before the joint
Company/Contractor final inspection will be performed to ensure compliance with the
materials and fabrication requirement of engineering specification and piping drawings
along with the field installation requirement of this specification.