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    158 views22 pages

    Piping Pre - Fabrication Procedure

    Uploaded by

    sbmmla

    Copyright:

    © All Rights Reserved
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    of 22
    ‘Transmittal No. Date To: FROM: ContactName Projet Te: ConractNo.s Location: ‘Saud Aramco Approval Status Code Approved “correct & Resubmit "For Information “Other as Noted *Rpproved with Comments *Not Approved * No Comments For Action PSAL Reference No. Document No | Rev ‘Subject statu [ Qty | Remarks ‘2 | PIPING PRE FABRICATION PROCEDURE FAB” | APPROVED | 1 SHOP}. REVO Reviewed and Aocepted™ Me Transmitted bys Received ‘Received Date: PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) ‘TABLE OF CONTENTS. Description Page No. scope 2 Punrose 2 erinmions 2 REFERENCES 2 RESPONSIBILTIES 3 [MATERIALS HANDLING 5 [MATERIALINSPECTION 5 [MATERIAL STORAGE & PRESERVATION. ‘ FABRICATION PROCEDURE 7 FABRICATION OF PIPE SUPPORTS 2 BUTTERING OF WELD JONT ry 22 FABRICATED PIPE AND ASSEMBLIES B 13 WyoROTEST 3 24 INSPECTION & TEST PLAN 3 15 TOLERANCES “ 36 BLASTING AND PAINTING 5 17 SPOOL FINALINSPECTION & RELEASE 8 38 DOCUMENTATION as 19 ATTACHMENTS 6 Page 1 of 16 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) 10 score “his procedure defins the various stages of ppl spools prefabrication and inspection of piping for Fadl Sula Recovery Unit “This quality procedure describes the minimum qualty requirement to ensure that piping Prefabrication actives are performed in accordance with applicable Saudi Aramco specifications and international codes. ‘30. DEFINITIONS coMPANY Save Aramco Rovecr Fadhil Gas Plan Sulfur Recovery Unt-3 ‘CONTRACTOR = Petrofac Sal Arabia International Limited (PSAL) SUB-CONTRACTOR Nasser Al Haj Corporation (NSH) snes, Saud Aramco Engineering Standard sass, Saul Aramco Material System Speciation ‘40 REFERENCES saes.1136 Pipe, Flange and Fitting Material Requirements SAESH200 Storage, Handling an installation of Externally coated pipe SAES L105, Pring Line lasses snesu10 Limitations of Piping Joints and Components SAES-350, Construction of Pant Piping SRESA-50 Construction of On Land & Near-Share Pipelines SnES.0.206 Positive Material entiation sAESWoll Welding Requirements for On- Plot Piping SAES.W-016 Welding of Special Corrosion Resistance Materials SsAEs-109, =Selacton of Flanges, Stud Bots and Gaskets oxsamss-o10 Fabricated stel Piping SAEP.216 Performance qualification of Coating Personnel saep-1160 “Tracking and Reporting of Welding, NOT and Pressure Testing for Capital Projects Page 2o0f 16, PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) saep-a10 Piping and Ppeine Repair aA. 599196 Pipe marking & color coding aa A. 585265 Piping Material specication pliable Inspection and Test plan Schedule "a" Quality Requirements ASME SEC Part A Ferrous material specication ASME SEC Pat Nonferrous material specication sme 031.3 Proce Piping sme SEC = Nondestructive xamination ‘SMe SECIK Welding and Brazing Quolifiations PrLes43 Standard for protection of Austenitic Stainless Stee & Nickel ‘Alloy Matera [NSHLPSAL-SRU-PRO P0003: Welder and WPS qualifeation and contol procedure RESPONSIONITIES ‘5. Project Manager shall be Responsible for the overall implementation of company safety & qual plan and ensure effiient execution of wrk in accordance with project, specification. 5.2 QC Manager sal oversee all activites, and ensure that all are executed 8s per the project quality aanand specifications 53. Construction Manager shall be the Responsible for all Mechanical and Piping Fabrication actities pertaining to this project. [5.4 Shop in-charge wll pan the daly work schedule; te ob to concerned Supervisors and controling piping works inthe shop. 5 Piping Fabrication Supervisors shal be Respite Lo ensure the safe and efficient working envircament to monitor plant and equipment requirements and to ensure that productivty and quality are maintained by thelr subordinates. They are also responsible for ensuring that the proper material is being used in addition to the correct welding consumable and the corect welding procedure Page 3 0f 16 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) 5.6. Planning Engineer wil receive all he drawings from document controller and same wil, bbe kept updating a per the latest visions, Preparation of weekly, monthly and overall schedule wil be compiled and the same wil be monitored on daily basis. The Planner wilissue the 7.2. ta PSAL any engineering constralnsare reported. 15.7 Material Controllers responsible fr all material receiving & Issuing of the material to fabrication shop 2s per the material request, as well as the transportation of completed {abricated spods to site for eectlon, Records shall be made fr shifting and an updated status of mateale stock and transfer to site wl etal to be maintained daly bash 58 Spool Controle is responsible forthe shifting and transporting the fabricated spools from fabrication shop to laydown yard He wil stiely implement te tg system ofthe stool. He wil closely coordinate with fabrcatlon in-charge, painting supervisor and [NDT controler for spool eleasing and prepare the spools shiping release report. 53.9 QC Supervisor shall arrange and supervises al OC activities ensuring that ll inspectons ‘are performed in timely manner and documented, Before starting new activity tol box stall be conducted, ‘5.20 Piping inspector shall be responsible to inspect the entire piping materials dimension ‘check & orientation prior to fabrication He inspects the beveled ends alignment and ‘ving cearancs fr Fit-up. He is also check the heat umber and material grade, et. Before starting activity too! box shall be conducted 5.11 Welding Foren shall be responsible for aronging and checking all welding related tanks and equipment for welder and welding activity He shal give the practical raining to elders whenever required. He shall be responsible for welder passport updati '5.12 Welding Inspector shall inspect the jont after fitup and gives dearance fr Welding He wl do the visual inspection and non-destructive inspection wil be carried out as required by the project speciation. The Welding report shall be prepared by Welding Inspector and submitted to PSAL and Saud Aramco Inspector. Before starting activity teol box shall 2e conducted, He shall monitor welder rejection rate, welder passport, and progressive examination week. 5.13 NDT Coordinator sal co-ordinate with welding inspectors and NOT service providers for executing the NDT. He shall correctly identi and very the NDT selected weld Joints before oferng to NDT serie provide. He shal be identified joins with warning tapes as per the atachment3 RT offer fr Reshat joints shall be done by same NDT service provide. He shall prepare weelly welding rejection rate, welder rejection rate Page 40f 16 60 70 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) ‘ete as per the SAEP.1260, NOT Coordinator shall ensure that, spot/percentage radiography joints are selected by PSAL Inspector. 5.14 PWT Inspectr shal be responsible for coordinating with welding inspectors, PWHT technician and NOT Coordinator for executing PWHT. He shall enti the Joints and tag shall be put a& per the attachment 3. He shall monitor before, during, and after PWT Joints He hal be responsible for al calibation of PWT machines. (MATERIALS HANDUM 64 Responsible personnel for the transportation and handling of all ind of pling ‘materials (pe fitting, valve, flange, support material & instruments ae assigned to censure ts safety and quality ae assured to & from the worksite. {62_All materials stall be handled with care during fabrieston and instalation to prevent ‘damage in acordance with O1-SAMSS-010 and material contol procedure NSH-PSAL- FsRU-PRO-GE-013), 6:3. Stainless too! & high alloy soe, fitings and valves shall be handled and segregated separately in accordance with PFFES-83. 64 Nylon straps stl be use at tes for handling & moving stainles ste! and high lly steel These Nyon tapes shall not have been used in carbon stool materials. 65 Material recehing shall be immediately inspected agalnst the requirements of the Purchase Order to ensure the shipping documentation, certification records and alvery notes ae correct. {66 Ping identfation, color cade, labels and marking shall be cased out a5 per the Piping marking color coding specication (O84-A-RE 589196) MATERIALINSPECTION 114. Al materia sal be inspected on receipt in acordance with procedure no: NSH FSRU-PRO-GE-0013, The responsile QC Inspector shall check and very the dentition tags on materials f the materials are not confocming to the relevant drawing oF specification it shall be separated from undamaged materials and tagged ‘th REJECTED mark so those material can easly identified Page 5 of 16 80 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) 72 Damaged mateal shall be documented, photographed and report shall ndcate the ‘r8ason forthe condition ofthe materials. The receiving inspector shal record condition ‘of material onthe material receiving so that the materials personal can take necessary corretve measures [MATERIAL STORAGE & PRESERVATION 181 Pipe shal not be stored directly on the ground. Pipe shal be placed on wooden or sleepers '82._ Stacking of pipe shal be made n'a manner to avoid damage to pipes or coatings. £83. Fitings and vaNes shall be stored in shipping crates or on racks. Stiles Steel pipe a ting mus be separate from carbon steel to avoid contamination 84 All materials stall be handled with care during fabrication and installation to prevent damage. 185. End protectors on pines, flanges, weld bevel, threads, ad socket ends shall be fly attached, £6 Pipe shall nat te rolled or dropped off trucks. 18:7. End bevel protectors shall remain on pipes and fitings wl in storage, protectors shall not damage internal or exterral coating. 88 Flange face and threads shall be protected from rust by applying sultable rust preventive 189 After completion of pretabviaton, the spoo! shall be cleaned and fre from weld pater, arstikes and foreign materials on outside and inside of pipes. 8.10 Lined and costed pines and fitings shall be lifted with wide fabric or rubber-covered slings and pacing shall be used to prevent damage to lining or coating, Wire rope slngs shall ot bese 8.11 Stainless steel materials shall be covered and protected from seawater splash and ‘other contamination during storage. £8.12 Staines steel spools, components and other materi shal keep cover during storage Inlaydown an staging areas. Page 6of 16 90 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) FABRICATION PROCEDURE 92. NSH wild the prefabricatin activity s pr the attached plan (Attachment) 9.2 Alwalding machines and instruments to be used for Inspection shal be calibrated and ‘maintain calivation log sheet updated to be checked by NSH QC and verted by PSAL ac 93S, NACE CS, $5 & Nonfercous spools fabricated In segregated and protected fabrication shop shall be separated as per the attached layout of fabrication shop (astaehment1) 94 Fabrication crew will transport the materials to the cutting area as per the requirement. ‘95 Al fabrication shall be carted out only In according to the approved latest revision isometric drawing; the Piping Inspector shall confirm the same prot to cutting. ind the atache flow chart of ometric drawing Attachment-2) 96 Cutting shall ecarred out as follows ‘Carbon stee pipes Bygas cutting & grinding + Alloy Steel pes By lammablecuting & ringing + stainless tee! By grinding & Plasma cutting ‘Nonferrous materials By grinding BPlasma cutting 9.7. Thermal eut or gouged surfaces fo all mate Is Including carbon steel, shal be power brushed or ground prior to welding 98 Before cuting the pipe heat number will be transferred to the cut pleces by low stress ‘ye stamping cr permanent marker for above 6mm thickness and Paint marking or ‘wing for bolew 6mm thickness. Heat number should be written at both end of the cut pipe plece located at 100 mm from the pipe end, 99. End preparation and fi-up shall be done at shop as per the approved WPS and IFC drawing 9.10 Ragged and regular edges shall be ground or machined to bright metal hoes eut for Seton nonies, bosses, or branch connections shall be ground smooth and the Page 70F 16 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) ameter ofthe ole shal be £1.6mm ofthe inside lameter ofthe seton member, I setonis permite. {9,11 For nozzles with reinforcing pads, the nore attachment weld shall be completed and Inspected prior nstaling the relofoccing pad, 9:12 Internal misalignment of butt jints shall not exceed 1.5mm. Internal tapering in accordance with ASME 831.3 by machining, back welding, ora combination may be sed to corractthe misalignment. 9.13 Fitings that ave re-cut or re-beveled shall have the cut surface examined for laminations before welding. The NOT method to be used shall be determined by Saudi Aramco inspector. 9.14 The wind velocty inthe area for GTAW, GMAW, or gas sled FCAW shall not exceed ‘igh (2.2m). Necessary shielding. and wind protection shall be installed if wind velocity exceeds kph 9.15 Welding sal at be done when surfaces area wet or damp or exposed to rain or snow ‘or when the welders are exposed to inclement conditions. ‘9.46 Contamination from the environment, suchas wind-blown sand shall be prevented by use of adequate shielding. 9.17 Ol, moisture, rust, scale, sand, paint (except weldable primers for approved applications) metalic coatingleg ine) or other foreign matter shal be removed from ‘the weld surface and at least 25mm of adjacent base metal prior to welding ncuding any such coatig on temporary attachments or supports. 19.18 Allflnge connected to equipment sll be tack welded ony 9.19 Welding wil not carried out before clearance from NSH QC & PSAL QC. Welders shall have the qualfications stipulated in ASME SEC 1X to cover the type of materials concerned inthe piping works, and the welder qualification test in accordance with “WELDER AND WPS QUALIFICATION AND CONTROL PROCEDURENSH-PSAL-ESRU-PRO: 0003 19.20 All welding shal be caried only by qualified welders with Jo Clearance Card (CC) and as per approved Welding Procedure Spectfiation (WPS). Page 8of 16 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) 9:21 All WPSs, PAR, nd Weld and line description table shal be avalabe atthe work ite for verifiation at any time forthe authorized Saudi Aramco Inspector. 9.22 Alltack welds stall be made by qualified welders Al tacks or temporary welds shall be performed with the same care, materials, electrodes, minimum preheat, and procedure that are used for permanent wal 9:23 Tac welds shal be suffllent size to maintain Joint alignment. The recommended ack thickness is 32-48 mm and length is 12.5 - 25.4 mm. The minimum number of tack welds are + Pipe dameter of101.6mmorless three equally spaced tacks + Pipe diameter above 101.6mm ‘minimum of four equaly spaced tacks “Te designated inspector should determine if more tacks ae needed, 19.28 Bridge tacks (located above the root ara) are acceptable but such tacks must be completely removed prior to completion f the wel, 9.25 Arc strikes, gouges, and other indications of careless workmanship (such as surface porosity uneven weld profiles, and undercut} sal be removed by grinding and tested by m/e. 9.26 Any temporar/ welded attachments or temporary tacks shall be ground of "Atachments may be cut of no closer than 3mm tothe base metal surface, prior to the required groan. 9.27 any grinding reduces the base metal thickness to ess than the design minimum, the round area shal bere welded and ground flush with the original base metal surface or ‘the component shal be replaced. Re-weldng shall be done only with the prir approval ‘of Saud Aramen nspectr. 9.28 For all materi, inspection by MPT/PT methods of area shall be performed where temporary weds have been removed or weld repsir to ground areas of the base materia have been made or ac strikes after repair by srinaig, 9.29 Except for ASME P. No, 1 through P. No, SA/SB/SC base materials, all manual GTAW shall use a high frequency start and post purge gas flow forthe torch, Page 90F 16 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) 9.30 For P. No, 5 and high materials, back purging shall be maintained until atleast 2 ‘minimum 10mm ofthe weld deposit thickness has been completed, Back purging shall bbe done as per Purging procedure {NSH-PSAL-FSRU-PRO-PLO017). 9.31 All Welding Consumable storage and handling shall be accordance withthe "Welding ‘consumable handling and storage procedure (NSH-PSALFSRU-PRO-P:.0006). A 1932 Each weld pass shall be thoroughly cleaned and slag or other foreign matter removed before the next pass Is deposited. Adjacent beads of weld shal be staggered and not started inthe same location. 9:33 All slag, flux and spatter shall be removed from the completed weld and surrounding 9.34 Stainless steel and nonferrous materials shall be cleaned with grinding wheels or stainless steal bushes not previously used on other materials 9.35 The heat input) ofeach production weld must be ealeulated, and ensure that heat Input shall not exceed the heat input limits lsted in the welding. procedure specifiation. 19.36 The minimum dstance between parallel butt welds shall be 20mm or tree times the wall thickness ofthe joint whichever i greater, 19.37 Pressure contaning welds (e. nomles and other attachments) shall be separated from other pressure containing welds by no less than 20mm oF three times the joint thickness, whichever is greater, Radiography ofthe butt welds i required for situations In which the rnimum separation is not archived. For jeints other than butt welds other appropriate Inspection methods shall be wed, depending on the geometry and ‘material The folowing are exemptions 2) Structural components and reinforcing pads b) Hot |} 238 ioe number, nk number, WPS number, welder number, Heat number, Rup it te end welds which eros the pipe longitudinal seam. Inspection clearance, Visual inspection signature and date of welding wil be marked roar to the joint with metal paint marker. Page 10 of 16 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) {9.39 Spool number wil be marked with paint marker and aluminum tag willbe tied to the Spool. The spoe!Wdentfcation and number shall not be less than 25mm height In auton; pool no, shallbe destamped on therm of each fang. £240 Fabrication completed spon wl be shifted for NDT/PWHTT/PMI actives from shop tolaydown are/RT Bunker PWT area 941 Kdentication tag sal be followed as per Warning tape Cblor code for spools & joints {fod atachmert3) ‘9.42 When a cicumferentil weld wth an intersecting longitudinal wel) i examined, at least the adjacent 38 mm (1 1/2} ofeach intersecting weld shal be examined 143 NOT shall be performed as required by SAESW-O11, ASME 631 .3 & Approved isometric drawing. Aer NDT cesrance, spools shal be released or lasting & painting asrequied. ‘9.44 Joint repir willbe done immediately and adtonal penalty shots a stipulated within SAES9.011 and shal be adographed 9.45 Rejected welds shal be repaired in acordance with approved repair procedure (NSH- PSALESRU-PRC-PI-O016) and WS by qualified welders and inspected asa minimum ‘sng the oii test method ofthe joint. 9.46 Pre heating ard PWHT wil be caried ut 3s er the approved WPS and approved PWT procedue, 2.47 Prior to start of wor, NSH shal prepare a table sting eat ointspo0l requiring Heat treatment and shall be submited to contractor & company for review. The table shall, include Joint number/ocation, speck number, drawing number, clameter, wall thickness, material heating rate, cooing ate, soaking temperature, soaking tine et 248 Preheat temperature shal be estabshed over a minimum dstance of 75mm on each side of the wel [A\ 249 temperate coos temecoules or crated contact prone sa be used to measure preheat and interpass temperatures. Temperature indicating crayons shall nat be used for any weld jin that ito be coated or that will have eat shrinksleeve installed on Page 11 of 16 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) 1950 Postive Mater! Mentiication (PM 1, where applicable, shall be performed by trained and approved personne and approved Third party Pl procedure 1951 For stainless steel & high allay materi, oly stainless ste tool wil be used for nding, brushing and clamping nd not previously used on other materials inorder to ‘vod the kon contamination [A\_ 352 when magn perc or pit sed on austenite sess tee & nonferous ‘materi the marking shal be with suitable weather prof markers and materials such as certified low chloride (50 ppm) markers for stainless ste 110.0 FABRICATION OF PIPE SUPPORTS. 103 All supports, anchors, guides and other support attachments shal be fabricated in ‘accordance with details indicated in the pipe support drawing, approved isometric drawings and contract specication requirements et. 10.2 Reinforcing pad material shal be ofthe same pipe material unless otherwise approved in writing by the SAPO. 104 Fitup and welding shall be done at shop as per the approved WPS and approved rowing. 1044 A Gmm weep hole shall be delled forall dummy supports. The weep holes shall be located near the base plate forall vertical dummy supports and near the run pipe at 6." lock postion forall horizontal dummy supports 1055 Separate storage facility shall be made to store fabricated supports in area wise and material wise, 1045 Fabricated CS, 1S, 8S & Nonferous supports shall be placed separately with proper protection & Wentfation like type of support, sequence number, et. with legible 10:7 Ate panting inspection i complete, the support shal be released for erection. Page 12 of 16 PIPING PREFABRIGATION PROCEDURE (FABRICATION SHOP) 11.0 BUTTERING OF WEL JOINT 11,1 Butering or weld buld-up on the prepared surfaces shallot exceed the lesser of 1/3, ‘ofthe base metal thickness or 10mm without the approval af CSO. Ifthe buttering or buld-up exceed thi, then the following requirements shall ppl + Specific apprevals required from PSAL QC. If not approved the spool pipe shall be replaced toa length agree by PSAL.C. + The buteringoperation shallbe witnessed by Saud Aramco Inspection + The buttering shall be inspected by RT, PT or MT after completion of the bulldup but before inal welding ofthe joint. 11.2 Buatering of ots between desimitar metal joints requires prior approval by CSO. 120 FABRICATED PIPE AND ASSEMBLIES 12, Fabricated pipe & spools shall be placed on level timbers or pallets providing good round dearance, Al spools shall be cleaned and fre from weld spatter, are strikes and foreign motels on outside and inside of pipes 4122 Pipe opening stl be protected from entry of rain and foreign matter by end caps ut closure welds re made. 1223 Al fabricated spoofs handling and storage requirements covered in section 6 & 8 of this procedure, 1244 For acceptance purpse, all applicable NDT shal be performed after PWAHT. vDRO TEST 13.1 Hydo test shal be performed in accordance with the above ground hydro test procedure (NSI-PSAL-FSRU-PRO-P-0027) and ITP. 413.2 It shall be ensured that ll NDE including weld repair f any, visual inspection and imensional inspection ave been completed and released for hydro test. 12, It shall be enced that all piping items excluding removable items have been assembled andwelded. 134 Hydro test packages shall be prepared in accordance with above ground hydro tost procedure and submitted to Contractor/Company for review and approval Page 13 of 16 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) 140 INSPECTION & TEST PLAN 1111 No spool should be released from the fabrication shops to lay down yard, painting oF site before being fly inspected and released by the QC department of both NSH & Psa. 142 Saul Aramco representative shall have free acess othe work tal times. 1143 Prior to start, NSH shall ensure that al required Welding Procedure Speciation (WPS) are approved and have evidence of approval in each pages of WPS. 144 Ensure the welder JCC qualified forthe welding proces, thickness range, dameter range and welder shaving a ICC for particular welding. 414.5 Inspection & Test forthe fabrication & Welding shall be carted as por the approved i. 1146 NH shall progressively enter on a database operated bya software Inthe control the ‘up, welang 4 NOT activities as por the SAEP-1360. 1147 If hydeo testis not performed to any wel of a spool, 100% Radiography is to be performed as par se 9.1.3 of O1-SAMSS-01 415.0 TOLERANCES 15.1 Where intemal misalignment exceeds 1.Srim, internal trmming/loping shall be In accordance wity ANSY/ASME 831.3 Fi 328.43 ater agreeing with PSAL AC. 1522 Keep an extra ength of 200mm i required) fr fed Joints to facitate possible fed dimensional adustments 15,3 Flatening of bends, measured asthe ciference between the largest and the smallest ‘outside dlameter at any cross section shall not exceed 5% ofthe nominal diameter of the pipe. Flatening of bends at weld ends shall not exceed 3% ofthe nominal pipe Sarees. 154: Lateral ost of branches and connections from centerline of run shall not exceed 1.6, 1555 Thetit of a lange measured atthe periphery across any ameter shall ot exceed ‘mm from the square postion. Page 14 of 16 PIPING PREFABRICATION PROCEDURE (FABRICATION SHOP) 1546 The tolerance for axisl dimension, facetoface, conterto-ace and location of ‘attachments shallbe #3 mm maxienum, 15,7 Flange bolt holes shal saddle the established centerlines. Rotation of flanges, ‘measured ae the ofeet between elevations of bolt holes on opposite sides of a flange

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