Doc. No.

WSM-PSFP-01
PIPING SPOOL FABRICATION Rev. 0 11/03/19
  PROCEDURE Page 1 of 14 

PT. WISESA MANDIRI

PIPING SPOOL FABRICATION

PROCEDURE

WSM-PSFP-01

11/03/19 0 Issued for Approval MKY MKY AA

Date Revision Revision Description Prepared Checked Approved

 Doc. No. WSM-PSFP-01
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Revision Summary

Date Revision Revision Description Prepared Checked Approved

11/03/19 0 Issued for Approval MKY MKY AA

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INDEX

1 SCOPE AND PURPOSE................................................................................................................5

2 REFERENCE DOCUMMENT........................................................................................................5
3 DEFINITION AND ABBREVIATIONS............................................................................................5
4 RESPONSIBILITIES......................................................................................................................5
4.1 Production Engineering...........................................................................................................5
4.2 Supervisor................................................................................................................................5
4.3 Quality Control.........................................................................................................................5
5 PIPING SPOOL FABRICATION PROCEDURE................................................................................6
5.1 General.....................................................................................................................................6
5.2 Material Preparation...............................................................................................................6
5.3 Cutting and Marking.................................................................................................................6
5.4 Machining (Bevelling, Threading and Drilling).........................................................................6
5.5 Fit Up/Assembly.......................................................................................................................7
5.6 Dimensional Control/Fit Up Inspection....................................................................................7
5.7 Welding....................................................................................................................................8
5.8 Visual Weld Control.................................................................................................................8
5.9 Non Destructive Testing/X-Ray (If Required)...........................................................................8
5.10 Hydrostatic Test.....................................................................................................................9
5.11 Painting (If Required).............................................................................................................9
5.12 Other Treatment (If Required)...............................................................................................9

5.13 Storage of Fabricated Spool.................................................................................................10

5.14 Handling of Pipes Spool.......................................................................................................10
6 EXOTIC PIPES MATERIAL PRECAUTIONS..................................................................................10
6.1 General...................................................................................................................................10
6.2 Worksop Preparation, Storage and Handling.........................................................................10
6.3 Cutting, Marking, Machining and Assembly...........................................................................11
6.4 Dimensional Control, Welding, Visual Weld Control..............................................................11
6.5 Non Destructive Testing (X-Ray)............................................................................................11
6.6 Hydrostatic Test.....................................................................................................................11
6.7 Passivation.............................................................................................................................12
6.8 Preservation...........................................................................................................................12
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7 ATTACHMENT..........................................................................................................................13
7.1 Flow Chart of Piping fabrication process (Carbon Steel)........................................................13
7.2 Flow Chart of Piping fabrication process (Exotic Materials)..................................................14
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1  SCOPE AND PURPOSE

This procedure covers the basis for material traceability and fabrication work for pipes
spool pre-fabricated in the workshop provided with spool drawing. The procedure purpose is
to provide guidelines on general working procedure and operative method for conducting
piping fabrication work.

2  REFERENCE DOCUMMENT
Piping Fabrication shall be in accordance with latest edition of the following international
codes and standards.

ASME B16.5 Pipes Flange and Flanged Fittings

ASME B16.9 Factory-Made Wrought Buttwelding Fittings
ASME B31.3 ASME Code for Process Piping

WSM Internal Procedure and Documents

WSM-WP-01 Visual Inspection

WSM-WP-02 Repair Procedure
WSM-WP-03 Tack Welding Procedure
WSM-DP-01 Dimensional Control Procedure
WSM-PP-01 Painting Procedure

3  DEFINITION AND ABBREVIATIONS 

Contractor PT. WISESA MANDIRI
NDE/NDT Non Destructive Examination/ Non Destructive Testing
Spool Drawing A drawing used for pipes fabrication, detailed with all information
necessary for all fabrication work.
WPS Welding Procedure Specification

4  RESPONSIBILITIES
4.1   Production Engineering
Production Engineering is responsible to verify the completeness and correctness of the
piping isometric drawings and the spool drawing which should be used as a reference for the
fabrication operation. Production Engineering also responsible to issue out material take off for
material preparation purpose.

4.2   Supervisor
Supervisor is responsible ton ensure that all the piping fabrication activity are conducted
as per approved procedure, achieve desired quality as per required by spec/ client
expectation. Prepared and execute detailed schedule and manpower planning to achieve
master schedule by Planner.

4.3   Quality Control

QC inspector is responsible to check correctness of the assembled pipes spool against the
spool drawing dimensionally, to ensure the end result of weld joint is within acceptance range
of the specification, to arrange for Client inspection (if required) and arranging NDT work.

QC also responsible to arrange any kind of test/examination as per required by spec/code

such as PMI (Positive Material Identification), Ferrite Content and etc.
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5  PIPING SPOOL FABRICATION PROCEDURE

5.1   General
The spool fabrication drawing may be used to record all QC requirement (material
traceability, heat number, welder/fitter identification etc) and accompany the pipes spool
along the entire fabrication process.

Method for workshop progress tracking and material traceability other than above can be
used, such as using a work progress sheet and/or welding follow up sheet. Final record of
workshop progress reporting has to be compiled.

5.2   Material Preparation

All pipe fitting should be prepared according to material take off as shown on spool
drawing. Exact quantity to be released from material storage. Material specification shall
follow approved spool drawing. Below are the standard check list for pipe and fitting.

1.   Check the sizes, obtain nominal diameter and schedule number (pipe, elbow,
tee, etc).
2.   Check the bend radius (elbow).
3.   Check the pressure rating and flange facing
(flange). 4.  Record down the heat number (pipe)
5.  Check for any defect: pitting, corrosion, buckling, flattening, ovality, etc.

5.3   Cutting and Marking

Cutting process may be performed by cutting manually oxy cutting for carbon steel and
plasma cutting for exotic. The work flow will be:

1.   Pipe fitter choose correct pipes as per spool drawing.

2.   Cut pipes using manual cutting as per spool drawing’s required cut length.
3.  Dimensional control on the cut pipes
4.   After cutting, the pipe should receive masking tape label marking (name plate)
with the ISO number, Spool number, position, Heat number. Marking format as
follow:
ISO (Isometric Drawing number)
SPL (Spool Drawing Number)
POS (Position) if any

H N (H e a t N u m b e r )
Material m a n sh ou l d b e ta k e care the marking from
any damage and replaced it if is unreadable.
5.   To maintain material traceability, heat number of each material should be
written in the spool drawing for each pipes and fitting.
6.   Bring cut pipe to worktables on machining/bevelling area.
7.   The spool drawing should follow these materials to the next step of fabrication.
8.  Pipe fitters fill the workshop progress sheet.

5.4   Machining (Bevelling, Threading and Drilling)

Machining and/or bevelling of pipe and fitting will be done in area near the manual
cutting area. On this bevelling area will be placed worktables for bevelling operation. Bevelling
process should be use a portable machine or equivalent. Other type of machining such as
treading, drilling, etc will be done as per required.
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Work flow for bevelling activity will be:

1.   Pipe fitter done the cutting work should do the bevelling work, in any case where
the pipe fitter doing both work is different persons, the pipe fitter doing
bevelling work shall verify the name plate to obtain correct spool pieces
information.
2.   If original material identification marking is to be cut or material divided into two
or more pieces, the heat no, and pipe item code no, shall be transferred to each
of the pieces prior to cutting.
3.   Pipe fitter shall collect other fittings related to the cut pipe (elbow, tee, red, etc)
as per drawing necessary. These fitting should be placed on the same worktables
for the same pipes spool/spool drawing.
4.   Do bevelling work with the help of machine vices. Use grinder (disc and straight)
if necessary. Bevel parameters should be followed and as per required by the
WPS for correct root and edge facing. For carbon steel pipes end result should
be bright metal finish.
5.   Bevelled pipes and fitting should be moved to assembly/fit up box.
6.   Pipe fitters fill the workshop progress sheet.

5.5   Fit Up/Assembly

Assembly work (fit up work) will be done in the assembly area near the bevelling area. This
assembly box may use red plastic as a separator with adjacent boxes. Fit up work may be helped
by pipe jacks as pipe support. Alignment work may use three points pipe fit up clampers.
Work flow for assembly work will be:

1.   Pipe fitter done the bevelling work should do the assembly work, in any case
where the pipe fitter doing both work is different person. The pipe fitter doing
assembly work shall verify the name plate to obtain correct spool pieces
information.
2.   Pace the pipes/fitting in the pipes jack, assemble other pipes/fitting as per spool
drawing.
3.   Align the pipes and fitting using pipe clampers.
4.   Check the alignment result with welding gauge for misalignment, root gap etc.
5.  Tack weld on the pipes if necessary as per applicable tack weld.
6.   Clean the pipes weld joint preparation.
7.   Pipe fitters fill the workshop progress sheet.

5.6   Dimensional Control/Fit Up Inspection

A dimensional control inspector shall be carried out the quality team to ensure the
assembled pipe spools are fabricated as per approved spool drawing.

This step may be done in the same assembly box where the pipe being assembled. In case
any fault/ discrepancies. Comments for repair work shall be directly given to the pipe fitter
team.

Pipe fitters/ piping supervisor need to check below parameters internally before request
for inspection to QC team:

   Check all length.

   Check all directions of the spool.
   Check the materials and the type of flanges.
  Check the square of the flanges.


   Check the axis of the flange holes.

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   Check the gap of welding.

   Check the internal offset.
5.7   Welding
Welding should be done in the same assembly box where the assembly work took place.
The welding work shall be carried out as per approved WPS. Pipe welders has to be a certified
welder. During the welding process. Foreman welder should constantly monitor the welding
process to ensure application of WPS on the welding process.

Work flow for welding:

1.   The welding work will be carried out in the same box where the pipes being
assembled, the pipe fitter should back to the material preparation work/cutting
work for next spool.
2.   Welder need to ensure that weld preparation joint are clean and free of all
extraneous matter such as grease, dirt, scale, rust, water, etc that may affect the
weld quality.
3.   Conduct preheat (when required by WPS).
4.  Conduct welding work as per WPS.
5.  Fill workshop progress sheet.
6.  Fill welding follow up sheet.
 
7. AwAfatietrin wg evlidsuinagl ,t seesnt,t N thDeT painpde h sypdorooltse tsot) s.
torage area (this is only storage area for

5.8   Visual Weld Control

After welding, a visual weld inspector/welding inspector shall be carried out to verify the
quality of weld result. The visual weld examination shall be carried out by QC team.

Work flow for Visual control:

1.   Welding supervisor informs QC team to conduct visual welding inspection by

visual weld control form.
2.   The inspection may be conducted in the welding area (assembly box).
3.  QC inspector performs the visual weld inspection.
4.   If any weld defect found (mark on row VW is failed on welding matrix) , QC
inspector shall mark and inform the welder team or welder supervisor

5.   iPmermfoerdmia tweelyld. repair work (if any).

6.   In case of un-repairable weld defect, welder team shall coordinate with fitter
team to reassembly the defect weld joint.
7.   After successfully inspection, pipe welder should fill workshop progress sheet
and welding follow up sheet.

5.9   Non Destructive Testing/X-Ray (If Required)

The NDT phase 1 should be carried out to ensure that only a good weld joint will continue
through the Post Weld Heat Treatment process. The NDT will be X-Ray/Radiography test unless
stated otherwise by the spec or codes.

Work flow this work:

1.   Bring the pipe spools from Fabrication area (after Visual result) to NDT area.
2.  QC team arranges NDT work.
3.   NDT result obtained.
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4.   When the weld joint are found failed during NDT(mark on row NDT is failed on
welding matrix) bring the pipes to assembly box or fabrication area, welding
supervisor and his team have to directly carried out repair work, fill wielding
follow up sheet and work progress sheet.

5.10   Hydrostatic Test

Hydrostatic test on workshop after fabrication completed is to ensure the welding
integrity from any leak. This hydrotest applicable for pipe spools with flanges joint only, for
others the hydrotest will be carried on erection area.

Work flow hydrotest work:

1.   Bring the pipe spools from NDT area to Hydrotest area (usually the area is same
area).
2.   Layup pipe spools on the hydrotest area.
3.   Prepare the blank flange and other hydrotest equipment.
4.  Conduct hydrotest work as per pressure required.
5.   Obtain the hydrotest result.
6.   When the result is leak during hydrotest (mark on row NDT is failed on welding
matrix) bring the pipes to assembly box or fabrication area. welding supervisor
and his team have to directly carried out repair work.
7.   Depressurize the water and clean the water inside pipes with compressed air
blow.
8.   Collect the pipe spools and sent to storage area(this storage area is means
collection of pipes passed the test and ready to paint or erection).

5.11   Painting (If Required)

Pipes spool will be sent to blasting and panting area as required by spec. For carbon steel
pipes material will have painting work, necessary arrangement should be made on the field
weld
 joint for protection using adhesive tape after the blasting process. For Exotic material a
passivation/preservation will be done after hydrotest.

Work flow for painting work:

1.   Bring the pipe spools to blasting/painting area.

2.   Necessary arrangement need to be taken to protect the name plate during
blasting and painting.
3.   Blast the pipe spools.
4.   Put adhesive tape on the field weld joint.
5.  Paint the pipe spools as per paint spec.
6.   Bring the pipe spools to pipes storage area.
7.   Close the open end of pipe spools using plastic or wooden blank.

5.12   Other Treatment (If Required)

Other Treatment mentioned in here is passivation for exotic pipes material and acid
cleaning for carbon steel material. Both activity will only be conducted if required by
design/code/spec.

Methods for passivation are determined later as per project requirement (either acid bath
method or passivation gel method).
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5.13   Storage of Fabricated Spool

Fabricated pipe spools should be storage in good environment to maintain material
quality of pipes. End flanged spools should be blanked using wooden plate with 5mm thickness
or special plastic cap to avoid any dirt/garbage being put inside the pipe spools. The wooden
blank flange cab be tightened either using bolt-nut or using wire rope.

Prevent direct contact between pipe spools with ground or floor by using wood support.
Pipe spools should be storage with grid basis. This grid basis is a storage system that divided
the pipe spools base on installation sequence by pipe material (carbon and Exotic), location of
installation, isometric drawing numbers and spool drawing numbers, and separate storage
area between after fabricated to be inspection test and pipe spools has been passed the test
or painted. Material controller should be prepared Database on spreadsheet for monitoring
flow pipe spools (flow pipe spools is how many fabricated spools, storage area, passed test
spools or not, painted spools and include with spool numbers.)

5.14   Handling of Pipes Spool

Handling of pipe materials and pipe spools should not cause any damage on the materials
itself. Few method to handle the piping materials and pipe spools are:

   Forklift, use for taking out pipe from rack (if any) or storage area, lifting
materials and transfer materials. Specially protection for the fork should be used
for
fabricated pipe spools and exotic materials.

  Mobile crane/overhead crane and lifting equipment should be used nylon
slings,
for exotic materials separate set of slings should be used for each type of
materials.
   Trailers should be used protection floor/crates/support for fabricated pipe
spools and exotic materials.

6  EXOTIC PIPES MATERIAL PRECAUTIONS

6.1   General 
Above procedure are applicable to exotic pipes materials fabrication with following
precautions as stated in this section

6.2   Worksop Preparation, Storage and Handling

Ferrous contamination on exotic pipes material (such as stainless steel and duplex)
should be avoided. The iron subsequently rusts in a moist or humid environment and can initiate
corrosion on the stainless steel surface. Only stainless steel tools, wire brushes, clamp and
grinding wheels should be used on stainless steel pipes.

To minimized ferrous contamination following preparation should be taken for exotic material
pipe shop:

1.   All handling equipment, such as sling of crane, fork of lift truck, hook of chain
block etc should be a non metallic material or protected by clean wood, cloth or
plastic buffer to avoid iron contact with exotic pipes material surface.
2.   All working bench, working tools and working consumables such as machine
vices, pipes clamp, grinding disk etc should be a non iron material or be isolated
with the rubber, wood, a stainless steel plate etc.
3.   Each equipment and tools as described above shall be used for one type of
material only. Storage are of equipment and tools shall be segregated. An
identification code system shall be established for above segregation.
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4.   Each pipe, pipe fittings, assembled pipe spools. Welded pipes spool shall not be
storage directly into the ground. These item should be storage on wooden bar
at least a 150mm from the ground or on a fully surface cover with wood.
5.   Walking, stepping or placing any items above corrosion resistance piping items
strictly prohibited.
6.   A clean room must be established on the exotic materials pipe shop. A ventilation

sbyes teesmta btolis mheadin. tSapine ciinatle prnerasl opnonseitli vaen dp

rheosususerek eteop ainvog iidn sdtursutc tfrionm a oreu trseidqeu ihreads to
maintain cleanliness of the clean room.
7.   Before start working, please inspection materials exotic from carbon
decontamination.

6.3   Cutting, Marking, Machining and Assembly

Above procedure on section 5 apply for cutting, marking, machining and assembly
operation of exotic pipes material with following precautions:

1.   Use tools as designated, stainless steel cutting disk for stainless steel only,
stainless steel wire brush for stainless steel only so on.
2.   Eliminated contact between ferrous tools with the exotic pipes. For example, use
insulator on the machine vices, stainless steel lining on the hammer head etc.
3.   Worktables have to use wood protection on top of it.
4.   Pipe jack, pipe fit up clamp and other tools in contact directly with the exotic
materials have to be insulated or made by same grade of the materials.

6.4   Dimensional Control, Welding, Visual Weld Control

These job will be done in the assembly box area. Welding shall follow the WPS, additional
consideration to be taken for gas purging during exotic material welding.

Large wood panel should be installed to guarantee welding segregation between different
type of exotic pipe materials.

6.5   Non Destructive Testing (X-Ray)

As per carbon steel material, the NDT (X-Ray) may be done in the NDT area or storage area.

Work flow for the X-Ray Work:

1.   When transport the pipe spools with forklift, the fork has to be protected by
wood crates or similar protection.
2.   Carried out X-Ray as per procedure.
3.   When NDT process has finished, material man shall install back protection cover
to the pipe spools.
4.   Inform the supervisor after successful result, or not mark on row NDT is failed on
welding matrix and bring the pipes to assembly box or fabrication area.

6.6   Hydrostatic Test

Conduct hydrotest as per arrangement mentioned on previous section if hydrotest
required. When the hydrotest is not required, the pipe spools should be sent to passivation
area directly after X-Ray. When conducting hydrotest, pipe spools are not allowed to be laid
down on the ground, use the wooden block or crates for support. All hydrotest equipment and
fluid should be non ferrous contaminant.
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6.7   Passivation
Passivation is a process to enhance the spontaneous formation of the protective passive
film on an anticorrosion material surface. Passivation process for this exotic material normally
consist of following step:

1.   Descaling, removal of heavy, tightly adherent oxide films resulting from hot
forming, heat treatment, welding and other hot work operations. Descaling can
be done either using chemical descaling (acid pickling) or mechanical descaling
(abrasive blasting, power brushing etc)
2.   Cleaning, all operation necessary for the removal of surface contaminates from
metal to ensure maximum corrosion resistance, prevention of product
contamination and achievement of desired appearance. Some of the methods
used to do cleaning area vapor degreasing, water jetting, acid cleaning, steam
cleaning and mechanical cleaning.

Selection of any method for detailed passivation process shall be determined during
project execution.

6.8   Preservation
To maintain the quality of anticorrosion properties of exotic pipes material and to prevent
the deterioration of pipes surface finish, a special care shall be given during pipe spools
storage and handling after fabrication.

1.   All the pipes opening shall be sealed with air tight closures after passivation
process.
2.   End closures shall be durables and securely attached to the pipes such they will
remain intact and in position during transfer, handling and storage.
3.   Flange end connection can be sealed by wooden blank or plastic cap (similar
material), secured using wire or tightened with bolt and nut at least in 4 holes
bolt. Unflagged pipes and connection can be sealed by plastic cap or similar
material and wrapped with protecting tape 50mm around the pipe cap joint.
Threaded and connection, whenever possible, should be sealed by means of
threaded plastic or similar material so that the pipes thread will be protected.
4.   Pipes cannot be directly storage in the ground, wooden support should be used.
5.  When the pipe spools are storage in outdoor a method for covering with
tarpaulin
or similar material should be established.
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7  ATTACHMENT
7.1   Flow Chart of Piping fabrication process (Carbon Steel)
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7.2   Flow Chart of Piping fabrication process (Exotic Materials)