PROCEDURE Code: DO-TEC-130Eng

HHHH
Revision : 02
PIPING PREFABRICATION Edition: 12/15

PIPING PREFABRICATION

STATUT DE DOCUMENT :

Signature

02 23/12/2015 Update

01 19/10/2015 Update

0 07/09/2015 Creation

Rev. Date Description Issued by Verified by Approved by Client Validation

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Summary

1. Definitions: ......................................................................................... Error! Bookmark not defined.

2. Reference documents :................................................................................................................. 3

3. General : ........................................................................................................................................ 3
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1. Reference documents :
 NDT procedures
 Tunisian Laws and regulations:
 Décret N°62-129 du 18 avril 1962,
 Law n° 2009-11 dated 2 March 2009, promulgating the code of security and prevention of the
hazards of fire, explosion and panic in the buildings
 loi n° 66 27 du 30/04/1966 modifié par la loin n ° 94 29 du 21/02/1994 et la loi n° 96 62 du
15/07/1996 :(1) ART 152
 Loi n° 94-9 du 31 janvier 1994, relative à la responsabilité et au contrôle technique dans le
domaine de la construction
American National Standards Institute (ANSI) American
Society of Mechanical Engineers (ASME)
 ANSI/ASME B16.11 Forged Fittings, Socket-Welding and Threaded
 ANSI/ASME B16.20 Metallic Gaskets for Pipe Flanges - Ring joint, Spiral Wounds and
Jacketed
 ANSI/ASME B16.21 Non-metallic Flat Gaskets for Pipe Flanges
 ANSI/ASME B16.25 Buttwelding Ends
 ASME Boiler and Pressure Vessel Code
Section V Non-destructive Examination
Section VIII Boiler and Pressure Vessels - Divisions 1 & 2
Section IX Welding and Brazing Qualifications
 ASME B31.3 Chemical Plant and Petroleum Refinery Piping
 ASME B31.1 Power Piping
American Petroleum Institute
 API 601 Metallic Gaskets for Refinery Piping (Double Jacketed Corrugated and
Spiral Wound)
 AFC Drawings
 Approved WPS

2. General :
The purpose of this method statement is to ensure that the methods and procedures shall be carried
out for the fabrication of piping as per the technical/control specification.
This Standard covers the minimum requirements and acceptance criteria for:
 Fabrication of piping (both in site and/or at Workshops as assemblies/sub-assemblies).
 Certification and records keeping.
It is to be used together with ASME B31.3 Chemical Plant and Petroleum Refinery Piping Code, all
government statutory requirements and referenced standards.

A- GENERAL:
 Ensure that key personnel involved in piping fabrication understand fully the requirement
mentioned in this procedure.
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 All storage, traceability, identification, tolerances, welding, inspection and testing shall be
carried out as stipulated within the specifications, procedures and codes.
 The Engineering drawings and documents received shall be clearly understood to find out the
service, material specification, size, thickness, NDT requirements, pipe routings quantity etc.
line wise and area wise
 Ensure that the documents received bear the stamp “Issued for Construction” and are of latest
revision.
 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
 Piping General Arrangement drawings will be provided showing equipment location and piping
configuration. These drawings shall be adhered to for the erection and installation of pipe
spools.
 Fabrication of pipe spools shall be in accordance with the Piping Isometric drawings which will
be provided for all lines size DN 50 and above.
 Small bore piping DN 40 and below shall be field run in accordance with the General
Arrangement drawings.
 Pipe support location plans may be provided for complex piping systems but generally
pipe supports will be located on General Arrangement drawings and Isometric drawings.
 Where pipe supports need to be manufactured detail drawings will be provided.
 Only qualified welders that have been approved by Company shall be used for any piping
welding.
 The electrodes or wire to be utilized for piping welding will be as stipulated in each W.P.S as
approved by Company.
 The scope of this method statement is limited to Pre-fabrication for Carbon Steel, low
temperature carbon steel and Stainless Steel piping.

B- SAFETY:
 SITE HSE INDUCTION
1) Activities on site area have to comply with Client Permit to Work Procedure and HSE procedures
2) Task Risk Assessment to be carried out in accordance to Task Risk Assessment Procedure.
All active site workers shall wear appropriate safety equipment and clothing to prevent electrocution and
burns.
3) When welding, flammable materials shall be removed from work area to avoid ignition and possibly
fire outbreak.
4) Only qualified welders, fitters and fitter mates shall be allowed to carry out welding, cutting and
grinding activities on site.
5) Welding and electrical cables shall be properly arranged to avoid damage and possible current
leakage.
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 LIFTING / RIGGING WORKS

1) Mechanical / manual lifting shall be applied in the lifting operation using qualified and experience
riggers.
2) All lifting operations including movement of steel pipes and fittings, valve, etc shall be carried out by
experienced riggers.
3) All lifting equipment including slings, shackles, lifting beam etc, shall be pre mobbed / inspected and
color coded prior to being used.

 MATERIAL WASTE MANAGEMENT

All waste material generated by piping prefabrication works shall be controlled as per the applicable site
procedures, and preserved in the dedicated areas.

 WORK SITE CONDITION

1) Work Shop shall be prepared to maintain adequate control of all items on site.
2) Housekeeping shall be conducted on a regular basis to maintain an orderly, clean, healthy and safe
workplace. All waste material shall be preserved and appropriate on the appropriate area.
3) All safety precaution shall be performed in accordance with the attached job hazard analysis and pipe
spool fabrication and painting works.

 Equipment and tools

 Portable cranes, column cranes (all lifting equipments and tools shall be third party certified),
 Scaffolding,
 Small items (lifting jacks, slings, chain block, D-shackles, etc.)
 Oxygen Acetylene Cutting, Portable Power Tools, and Welding units.
 Argon bottles, (gas cylinders shall be certified by supplier)
All lifting equipments and tools shall be inspected and color coded prior to being used.
 Safety measures
 Flame-resistant coveralls,
 Welding masks and/or goggles
 Face shields,
 Gloves :
 Arc welding gloves made from various grades of leather to provide both heat, spark
and abrasion protection.
 MIG/TIG welding gloves have no padded liner for heat, but focus on giving the worker
excellent dexterity while welding

C- MATERIAL RECEIVING AND STORAGE:

 CERI piping supervisor in cooperation with CERI material manager prepare a material request and
submitted to CLIENT piping representative (Piping supervisor / filed technical office manager) and
CLIENT warehouse manager for approval.
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The specific isometric to be attached to this material request.

 Handling and transportation of piping materials shall be done with utmost care to avoid any damage.
 Separate area shall be assigned for the storage of Carbon Steel and Stainless Steel piping materials.
Pipes shall be stored in open area resting on wooden sleepers and small pipe fittings, bolts, nuts, and
gaskets shall be stored in shelved containers.
 Documents shall be maintained by the material controller till the end of the project.
 All material shall be fully inspected upon receipt to be ensured that the correct grade of material has
been supplied and that identification, dimensions, material quality and preparation are in accordance
with the requisite standards and specifications.
 Material found to be defective or incorrectly marked shall be immediately placed in a quarantine area
separate from accepted material with sufficient safeguards to preclude it being used.
 All flange faces including gasket grooves in ring joint flanges shall be protected by plastic cap, plywood
or equivalent method before fabrication stage or relocating. After completion of weld, flange face shall
be protected again by plastic caps or plywood.
 Scratches on gasket faces are not allowed.
 Any re-facing that reduces the flange thickness to less than the minimum thickness allowed by the
relevant code or standard is rejected. Edge thickness of flange will be checked after re-facing. any re-
facing will be done only after CLIENT/Company approval.
D- PRE – FABRICATION:
 Cutting and Beveling
1) Before starting the activities of cutting pipe, a safe scrap area should be designed for the
scrub of cut piping; those scrubs should be handled or moved by safe procedure.
2) Select the proper cut method. Do not use flame cut for stainless steel piping.
3) Pre-fabrication of Carbon Steel and Stainless Steel Pipes shall be done in separate
fabrication areas. The 2 areas shall be physically segregated and separated.
4) For stainless steel fabrication, equipment and tools which are identified with color coding
and compatible for stainless steel shall be used. No carbon steel contamination is permitted on
SS, DSS and SDSS materials.
5) Prior to cutting of piping materials, the heat number, material grade/specification, spool
number and all other necessary identification shall be transferred on cutting material with
permanent marker.
6) Proceed with cutting of pipes, edge preparation, joint alignment, and fit-ups as per the WPS.
7) The edge cleaning and beveling shall be done using grinding disc/ beveling machines,
dedicated discs to be used for carbon steel and stainless steel material.
8) Line Number, Spool Numbers, heat number, Joint Numbers and date of welds are to be
clearly identified and marked on the spool.
Pipes to be cutted shall be marked for each spool with material grade and heat
number.
Heat number is reported in two ways: daily welding report and welding summary list.
9) Low chloride content level markers shall be used for marking on stainless steel material
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 Fit – Up and Tack Welding

1) Fit-up assembly shall be carried out by using locally prepared couplers. All the required
pipe holding work benches, assembling brackets, ‘U’ bolts etc. would be made in house to suit
the pipe sizes.
2) For butt welds a uniform root opening as specified on the specific WPS shall be followed.
3) Internal misalignment to be conform to as the Welding procedure specification WPS, and in
accordance with ” American National Standard Code for Pressure Piping – Chemical Plant and
Petroleum Refinery Piping, ASME B31.3”
4) The pipes shall be tack welded in three equidistant positions. Tack Weld shall be done as
per approved WPS by a qualified welder. Dedicated discs for carbon steel and stainless steel
to be used. No mixing will be done.

 Branch Connections:
1) Branch connection requirements shall be in accordance with Project Specifications.
2) The lateral offset of branches and connections from the centerline of run shall not exceed±
1.6mm.
3) All welded branch connection and other joints shall be full strength reinforced as indicated
on the drawings. Reinforcement material shall be made from the same pipe material as
specified by the relevant piping class and subject to the same specification requirements as
the piping to which it is attached.
4) All cuts shall be carefully beveled and accurately matched to form a suitable preparation
for welding and to permit full penetration of welds between the branch and the run pipe at all
points.
5) Details of reinforcement pad, if any, will be available on drawings provided by Client .

6) The Preheat zone shall extend at least 25mm (1in) beyond each edge of the weld. ASME
B31.3.

 Flange Connections
1) Unless otherwise indicated on the drawings, the bolt holes of all flanges shall be offset to
vertical and horizontal centre lines. The maximum angular deviation of bolt holes shall not
exceed 1.5mm measured across the bolt pitch circle.
2) The flange faces shall be square to the pipeline in which they are fitted.
3) Shop fabrication of flanged spool pieces for connection to existing pipe work or equipment,
shall have the mating flange tack welded to the spool and an additional allowance of 150mm of
pipe shall also be provided for the correct field fitment.
4) The fit up of pipe ends and weld neck flanges shall be done to obtain uniform root opening.
The criteria given in related WPS shall be followed.

 Cleaning of Spools
1) All pipes shall be internally cleaned by air blowing. In addition, for large diameters pipes
rag cleaning should be conducted if found practical.
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2) All prefabricated pipe spools shall be visually inspected for cleanliness, and shall have
foreign material removed from the inside.
3) The piping ends shall be covered before and after inspection to prevent unauthorized
removal of the end cover prior to making the joint to the succeeding section of piping.

 Welding
1) Welding procedures and welders shall be qualified as per Project Specifications and
relevant codes, prior to start of the welding.
2) Welding shall not be made when weather conditions are likely to impair the quality of the
weld metal or joint. In particular, welds shall not be made on surfaces which are wet due to
rain or condensation, etc. Wind shields and shelter shall be used wherever necessary.
3) Fit-up inspection shall be carried out by QC inspector.
4) Ensure that the edges are free from dirt, rust, oil, grease, paint etc.
5) Preheating, inter-pass temperature control requirements shall be followed as given in AFC
WPS.
6) For stainless steel welding back purging shall be done as given in AFC WPS. Prior to set up
all hoses and connections shall be checked for leakages. The weld groove containing the
purging gas in the chamber between the dams must be sealed from outside. All purging
materials shall be removed from pipe after welding.
7) Welding shall be done as per approved WPS for the particular piping. Preheating and
welding consumable shall be checked before starting of welding as indicated on procedure for
welding consumable control
8) Welding procedure shall be displayed at all welding stations.
9) Arc strikes shall be avoided, and if found shall be repaired and examined with either liquid
penetrant test or magneto test.
10) During welding, sections of pipe shall be adequately supported so that joints are relieved
of unnecessary stresses.
11) Each weld layer shall be cleaned before starting to weld next layer. The cleaned area
shall be free from slags.
12) All welds shall be visually examined externally for faults and irregularities. 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 attack points of each weld.
Any possible weld excess layer to be removed by grinding.
13) Appearance of finished weld shall be as even as possible and free from spatter, under
cutting, cracks, excess reinforcement etc.
14) After welding, all flange faces shall be cleaned of weld spatter, arc strike or any other
defects or damage.
15) All welding shall be supervised and records maintained to ensure that each weld can be
subsequently identified with the individual welder concerned, the weld procedure used, and
electrodes used.
16) Welding record shall be maintained with proper identification of joint, welder etc. for all
joints and welding summary register should be updated.
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17) Joint details like line number, joint number, welder ID, date of welding.
18) All welded joints shall be checked visually in daily basis. Only accepted joints shall be
reported on the daily welding report. In case there is any defect, repair shall be done in the
same day.
19) Welding repair shall be performed by qualified Welders and according to an approved
welding repair procedures.

 Passivation
All stainless steel joints to be treated by passivation.

 Temporary Attachments
Piping fabrication shall be achieved by use of clamps, jigs, fixtures, without welding to the pipe
or fitting.
Initial fitting up can be achieved using temporary bridge tacks across the groove

 Threaded and Socket Welds

1) Threads shall be concentric with outside of pipe, per ANSI B 31.3. tapped and cleaned out.
2) All surfaces of threaded joints shall be checked before connection, and any dust, oxide and
grease shall be removed.
3) When socket weld fittings are used, pipe shall be spaced approximately 1/15 inch (1.5 ㎜)
away from the “bottom “of the socket. (ASME B31.3)
4) A sealant for threaded piping can’t use Teflon tape except for hydraulics where fluid thread
sealing material shall be utilized.
5) Screwed connections subject to seal welding shall be made without the use of sealing
compound.
6) Seal welding of threaded connections shall be done by a qualified welder and seal welds
shall cover all exposed thread.
7) The joint shall be cleaned of all cutting oil and other foreign material and made up dry to full
thread engagement, before seal welding.

 Non Destructive Examination

1) All welded joints shall be visually inspected by welding inspector before any NDT.
2) The extent of NDT will be in accordance with Project General Specification for different
piping systems. The acceptance criteria shall be in accordance with ASME B 31.3 Table
341.3.2.
3) If PWHT is applicable for any piping system, NDT shall be carried out after completion of
PWHT.
4) NDT shall be carried out as per approved procedure and the results shall be recorded
properly.
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 Heat Treatment
Pipe Heat Treatment shall be performed in accordance with the approved procedure for post
welding heat treatment

 Protection and storage of pipe spools in pipe stock yard.

1) Upon delivery of pipe, checks will be made to ensure that all end covers are in place to
prevent ingress of dirt and moisture.
2) After final completion of carbon spool fabrication, carbon spools will be transferred to the
painting area. Before transfer to painting area, spools should be blown thru or internally to
remove contaminants.
3) After completion of painting, the spools shall be stored on wooden support. For
preservation, all flanges and gasket surfaces shall be adequately protected e.g by plywood,
plastic caps or equivalent methods before moving the pipe spools.
4) All threaded nipples and bosses should be protected using waterproof tape or equivalent
material to prevent damage to the threads.
 Painting
Painting for piping shall be performed in accordance with the approved work method statement
for piping painting application and repair
Before transferring to painting yard all pipe spools shall be identified as follow:
 Using metallic plates attached to the spools with wire,
 Or Sticky label inside the spool,

E- Inspection and quality record

Inspection will be done in accordance with the Company specification and the approved quality
control plan for piping pre-fabrication

Daily welding reports to be prepared after performing a visual inspection for the joints weld
done. This report include details of isometric number, joint weld number and sizes, welders
stamp, material heat number and base material. Visual inspection report and NDT reports to
be issued on daily basis for CLIENT and Company review and approval.

Welding summary register to be shared with CLIENT , on weekly basis, for review
and to be registered into Aconex on weekly basis.
Weekly Inspection Plan to be shared to CLIENT on weekly basis. For Visual and RT
inspections, notification to be provided on weekly basis.

Welder performance shall be monitored for RT repairs, RT Progress and welder performance
on weekly basis and information shall be shared with CLIENT.
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Penalty shots for RT repairs shall be taken within a week. A separate tracking register shall be
maintained for welds RT repairs and penalty for the entire project.