Field Installation Work Procedure - Piping

PIPING WORK MANUAL DOC.NO.
: 기계기술-M-P-01
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II. FIELD INSTALLATION WORK 0 1 of 76
II. FIELD INSTALLATION

PIPING WORK MANUAL DOC.NO. : 기계기술-M-P-01
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CONTENTS.
1. OVERALL WORK FLOW
2. OVERALL WORKRESPONSIBILITY
3. PLANNING & PREPARATION
4. MATERIAL HANDLING
5. INSTALLATION FOR SPOOL & VALVE
6. FIT-UP & WELDING
7. HANGER & SUPPORT
8. NDE
9. PWHT & HARDNESS TEST
10. CRITICAL CHECK POINTS
11. REFERENCE
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1. Overall Work Flow
1) Die-Stamp & Staincil

2) Material Code
3) Material certification
Material Warehouse Painting Shop Color Code
Pipe Shop Identification

Mark
Field Piping
1) Pipe spool Erection &

2) Valve & Gasket Installation Preheating
(If Required)
1) Pipe Spool Welding 1) Cutting & Beveling

2) Support 2) Alignment & Fit-up
3) Hanger 3) Welding
Daily Welding Preheating

Inspection Report (If Required)
1) Visual Examination NDE 4) Ultrasonic Examination

2) Liquid Penetrant 5) Radiographic
Examination Examination
3) Magnetic Examination
1) PWHT PWHT
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2) Hardness Test
Pressure-Test
2. Overall Work Responsibility
Sl- Work Flow Item Description Responsibility

no
Lead Assist
1. Planning & Preparation 1.1 Reference Documents - -
- -
1) Code & Standard
FP -
2) Specification & AFC Dwg QC FP
3) Procedure - -
- -
1.2 Planning for Field Piping FP -
Installation FP -
1) Labor, Equip’t Mob Sch. & Sch/Cost FP
2) Tool, Consumable Summary
1.3 Daelim Soft Ware Status
2. Material Handling 2.1 Requisition of Spool & Material FP -
FP -
2.2 Receiving Inspection Spool &
Raw Material FP -
2.3 Transfer Spool to Site FP -
2.4 Storing Spool on Site
3. Spool & Valve 3.1 Spool & Valve Installation FP -
Installation
4. Welding 4.1 Cutting & Beveling FP -
4.2 Alignment/Fit-up FP -
4.3 Tack-Welding FP -
4.4 Welding FP -
4.5 Inspection & Acceptance QC FP
5. Hanger & Support 5.1 Pipe Whip Restraint FP -
5.2 Supplementary Support FP -
5.3 Non-Catalog Support FP -
6. NDE 6.1 Visual Examination QC FP
6.2 Liquid Penetrant Examination QC FP
6.3 Magnetic Particle Examination QC FP
6.4 Ultrasonic Examination QC FP
6.5 Radiographic Examination QC FP
7. PWHT & Hardness Test 7.1 Heating Element QC FP
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7.2 Holding & Cooling QC FP

7.3 Hardness test QC FP
7.4 Reference Format QC FP
8. Reference Data 8.1 Highlight for Piping work FP -
FP -
8.2 GPP Project (Malaysia)
8.3 Olefins-III (Saudi Arabia)
Note; FP= Field Piping, PS= Pipe Shop, QC= Quality Control,
3. Planning & Preparation
1) Work Sequence
Reference Document Planning Field Piping Project Management

Installation System (Soft ware)
Planing &
Preparation
Sl-no Item Description Detailed Activities
3.1 Reference Document 1) Code & Standard

a)ASME/ANSI Code
2) Specification & AFC Dwg
a)Technical Spec.
b) DIC Standard Spec
c)Approved Dwg
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3) Procedure
a)DIC QA Standard Procedure
b) DIC QC Standard Procedure
3.2 Planning Field Piping Installation 1) GPP Project (Malaysia)

2) Olefins-III (Saudi Arabia)
3.3 Project Management System(Soft ware) 1) Material Control system

2) Progress Schedule
3) Daily Work Control system
4) Pipe Welding Control system
5) Construction Management System
3.1 Reference Document
1) Code and Standard
a) ASME B31.1. Power Piping

b) ASME B31.3. Petroleum Refinery Piping
c) ASME Sec. V Nondestructive Examination
d) ASME Sec. IX Welding & Brazing Qualification
e) ASME Sec II Part C Specifications for Welding Rods,Electrods,and Filler Metals
f) API 5L. American Petroleum Institute Specification for Line Pipe
g) API 6D Specification for Pipeline Valves
h) MSS SP-25. Standard Marking System for Valves, Fittings, Flanges and Unions.
i) ASME B16 Series. American National Standard Institute (B16 Series)
j) ANSI MC-96.1 Temperature Measurements-Thermocouple
k) ASTM. American Society for Testing and Materials.
l) API 1104 Standard for welding pipe lines & related facilities.
2) Specification & AFC Dwg
a) Client Technical Specification

b) Daelim Standard Specification
-SSP-3P-001 Welder Qualification Test
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-SSP-3P-002 Construction Work for Piping

-SSP-3P-003 Piping Fabrication and Erection
-SSP-3P-004 Inspection & Testing of Piping Construction Work
-SSP-3P-006 Cleaning for Pipe Lines
-SSP-3P-007 Welding Procedure For Piping
-SSP-3P-008 Shop Fabrication of Piping
-SSP-3P-009 General Piping Construction
-SSP-3P-011 Shut-Down Tie-in Work
-SSP-3P-012 Hot Tapping Tie-in Work
-SSP-3P-017 Coating & Wrapping(Coal-tar & Asphalt)
-SSP-3P-019 External Polyethylene Coating for Pipes
-SSP-3P-024 Piping Hanger & Support
-SSP-3P-025 Steam Tracing and Winterizing for Piping
-SSP-3P-026 Marking for Piping Materials
-SSP-3P-029 Inspection & Test of Piping Materials
-SSP-3P-034 Steam Jacketing for Piping
c) Approved Piping Plan Dwg

Approved P & ID Plan Dwg
Approved Vender Dwg
ISO Dwg
3) Procedure
a) Daelim QA Standard Procedure

-QAP-C-001 Rev.5 QA Manual Control Procedure
-QAP-C-002 Rev.2 Document Numbering Procedure
-QAP-C-003 Rev.5 Document Control Procedure
-QAP-C-004 Rev.4 Correct Action Procedure
-QAP-C-005 Rev.2 QA Records Control Procedure
-QAP-C-006 Rev.2 Source Verification Procedure
-QAP-C-007 Rev.4 Supplier Survey Procedure
-QAP-C-008 Rev.3 Procurement Execution Procedure
-QAP-C-009 Rev.1 Nonconformance control Procedure
-QAP-C-010 Rev.3 Audit Procedure
-QAP-C-011 Rev.2 Customer Order Control Procedure
-QAP-C-012 Rev.1 NDE Personnel Qualification and Certification Procedure
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-QAP-C-013 Rev.3 Indoctrination and Training Procedure

-QAP-C-014 Rev.1 Inspection and Test Personnel Qualification Procedure
-QAP-C-015 Rev.1 Audit Personnel Qualification Procedure
b) Daelim QC Standard Procedure

-QCP-710-10 Piping Fabrication and Installation
-QCP-710-11 Pressure Leak Test
-QCP-710-12 Coating and wrapping
-QCP-710-20 Welding (General)
-QCP-710-21 Welding Material Control
-QCP-710-22 Qualification Program for Welding Procedure
-QCP-710-23 Welder & Welding Operator Qualification & Control Procedure
-QCP-015-10 NDE Procedure
-QCP-710-24 Post Weld Heat Treatment Procedure
3.2 Planning for Field Installation (See Attached Reference Data)
1) GPP Project (Malaysia)

a) Staff & Labor Manpower Mob. Status
b) Organization Chart
c) Equipment Mob. Status
d) Tool & Consumable List
2) Olenfins-III Project (Saudi Arabia)

a) Staff & Labor Manpower Mob. Status
b) Equipment Mob. Status
c) Welding Material Storage Plan
d) Welding Rod Status
e) Tool & Consumable List
3.3 Daelim Soft Ware Status

1) FMCS-1 Material Control System(EPC Project)
FMCS-2 Material Control System(Construction Only)
2) PMCS Progress Management Control System
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3) DWRS Daily Work Report System

4) PWCS Piping Welding Control System
5) CMCS Construction Management Control System
4. Material Handling
1) Work Sequence
Warehouse Pipe Shop Non-Painted Identification

Spool Mark
Painting Shop Painted Spool Color Code
Field Piping Tagged Piping Class

Material Identification
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Protect Flange
Spool End
Transportation
to Site
Storing/Install
at Site
4.1 Requisition of Piping Material 1) Non-Painted Spool

2) Painted Spool
3) Tagged Material
4.2 Receiving Inspection for Spool & Raw Material 1) Color code
2) Identification Mark &
Stamp
3) Protect Flange & Spool
End
4) Temporary attachment
5) QC Inspection Result
4.3 Transfer Spool to Site 1) Access Road
2) Unloading Area
4.4 Storing Spool on Site 1) Protection Materials
2) Inspection and Test Plan
Inspection Items Specification/ Format No. Responsibility

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Code Cont Client Action by

1. Material Certificates Manufacture’s Doc. I D Mat’l
2. Color code marks on Piping SSP-3P-026 I/R - PS
System
Note 1: I= Inspection, R= Reporting results of Inspection, Examination or Test, D= Document Review, (W)=Random or
Partial Witness, W= Witness
Note 2: QC= Quality Control, PS= Pipe Shop, FP= Field Piping
4.1 Requisition of Piping Material
1) Non-Painted Spool, Painted Spool, Bare Material

;To be confirmed as below matters before requisition for Piping Materials
a) Erection Schedule By DKNP & CPAS
b) Status of Fabricated spools By PWCS
c) Status of Painted Spools By PWCS
d) Status of Material Stock in Warehouse By FMCS
e) Status of QC Inspection Result By DWRS
f) Requisition Format
-Fabricated Spools to Pipe Shop
-Painted Spools to Painting Shop or Pipe Shop
-Bare Material to Warehouse
4.2 Receiving Inspection for Spool and Raw Materials

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1) Color Code &

a)Reference Procedure; SSP-3P-026 Marking for Piping Materials
2) Identification Mark & Stamp
a) Identification stamping shall be done only with a roundness or interrupted dot die. Stainless
steel shall not be marked by stamping, but may be marked using a Vibra-Etch tools.
b) Paints or inks may be used for marking of pipe, but those marking materials to be used for
stainless steel pipe shall be certified and conformed to the chemical composition
acceptance criteria indicated in Project Specification or relevant code.
c) Care shall be taken while stamping to assure that the maximum depth of identification does
not infringe on minimum wall thickness of the pipe.
d) For field modification, the material identification shall be maintained for all cut length (except
for Scrap), of stainless and alloy, carbon steel pipe, by the craftsman doing the work and
shall be verified by QC engineer.
e) Material considered to be scrap shall be so designated by writing the word “SCRAP” in large
letter on it and shall be transferred to a segregated area.
3) Protect Flange & Spool End
a) Lifting of material during the transfer, fabrication and installation, Nylon Sling shall be
used for the lifting of stainless steel piping or pipe spools.
b) All of the valve shall be protected with end cap under the storage condition.
c) All openings of pipe and pipe spool shall be protected with temporary cover during
storage and transfer
4) Temporary Attachment
a) Breaking shall not permit removal of the temporary attachments.

b) The affected piping and component surface shall be properly repaired and ground smooth
to meet the contour of the pipe or component.
4.3 Transportation of Material to Site
1) Due care shall be taken in the transportation of materials, equipment and others to be used in
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the field. All obstructions such as, foundation, trenchs, etc. shall be reviewed and sufficient
countermeasures shall be taken against these obstructions to prevent the material &
equipments from damage.
2) All work shall be scheduled in a proper manner, so as to prevent interruption in the work or
damage to other existing facilities. Contractor shall explain his detailed transportation plan,
including arrangement of guy-wire, installation of transporting facilities or materials, to
Client's personnel in charge and obtain the approval.
4.4 Spool Storing on Site
1) Sufficient protecting means shall be taken not to allow sand or other foreign matters go into
inside of pipes and other piping materials.
2) Protection Materials
a) Warning Tape or Fence
b) Wooden Pallet
c) Wooden Timber
d) End Cap
5. Spool & Valve Installation
1) Work Sequence
Progress Schedule U/G Piping Wrapping & Coat

Process Priority
Material Delivery
Spool Fab. Status
Other Dep’t Progress
Client Requirement
Sleeper Double Joint
Main Pipe Rack

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Sub-Pipe Rack
Nozzle Flange Around Static Dress-up Piping

Gap & Alignment Equipment
Nozzle Flange Around Rotating Review Field

Gap & Alignment Equipment Welding Joint
Vendor Piping Field Weld Joint

5.1 Spool & Valve Installation 1) U/G Piping
2) Sleeper & Main Pipe Rack
3) Sub-Rack
4) Around Equipment
5) Vendor Piping
Inspection Items Specification/ Format No. Responsibility

1. Erection and Installation QCP-710-10 ITP-AG-03 I (W) FP
SSP-3P-003
2. Inside Cleaning QCP-710-10 ITP-AG-03 I I FP
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Note 1: I= Inspection, R= Reporting results of Inspection, Examination or Test, D= Document Review, (W)= Random or
5.1 Spool Installation
1) Reference Documents:
a) Piping Plan/ISO Dwg
-Weld Joint Number (SW or FW)
-Spool Length
-Spool Number
-Tag Number
-Material Class
-Type of Support
-Handle Direction
-Flow Direction
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-Maintenance Spacer
-Location and Position for Pipe Lines
2) Installation
a)Measurement for the determination of required design position and the erected variation
from those positions may be made from local area reference coordinates and elevations.
b) Where variations from theoretical position occur, if the variations are within the
specified tolerances and the limitations, the system shall be considered to be erected as
designed.
c)Position variations beyond these tolerances shall be disposed after engineering review
by the authorized personnel responsible for engineering design.
d) Specified slope requirements for drainage shall be maintained as a minimum design
requirement for a system.
e)Position variations shall be considered and limited by the effect of the variations on the
location of high point vents and low point drains.
3) Threaded Connection
a) After threaded connection, 3-5 threads shall remain exposed.

b) Thread lubricants shall not applied when seal welding is required.
c) Exposed threads shall be entirely covered by weld metal.
5.2 Valve, Gasket & Bolt Installation
1) Reference Documents:
a) ISO Dwg
b) Approved Tag Index as per Piping Class
c) P & ID Dwg
d) Pressure test & Flushing Scheme
2) Flanged Connection
a) Flange joint for process lines shall be tightened in accordance with the gasket
manufacturer's recommended torque values.
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b)Gaskets for all joints shall be of such inside dimensions that no portions will project
into the ports of valves, pipe or fittings.
c) For each type and pressure rating of gasket, Piping Engineer shall receive the
recommended torque values to be used for joining the flanges from the gasket
manufacture.
d)Temporary gaskets may be used for leak testing.
e) Temporary gaskets shall be replaced with permanent gaskets.
f) Permanent gaskets shall be installed in dry condition.
3) Orifices Installation
a) The internal surface of pipe at the orifice location shall smooth, straight, and free
from scale, pits, or holes, reamer or holes, reamer or rifting, bumps, or other
irregularities.
b) The orifice and orifices flanges requires special handling flange surfaces and orifice
plates to protect from scratch or dent during installation.
c) The orifice plates may be replaced with dummy orifice plates during flushing.
d) After flushing, the dummy orifice plate shall be removed and the regular orifice plate
shall be installed.
e) The orifice plate shall be aligned and installed correctly with regards to direction of
flow.
4) Special Items Installation
Specialty items such as steam traps strainers; expansion joints shall be installed according
to the manufacturer's instructions.
5) Valve Installation
a) Prior to welding, the position of valve seat and disc shall be checked and maintained
in accordance with the manufacturer's instructions
b) Care shall be taken to prevent any arc strike between seat and disc.
c) If necessary, valve accessories should be dismantled to avoid the damage during pipe
installation period.
d) Direction of flow stamped on the body shall be consistent with the system flow.
e) Slings or chains shall never be placed around the handwheel, valve stem or limit
switch parts.
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f) Nylon slings may be placed around the handwheel or stem housing of large valve for
the purpose of balancing during rigging operations provided that no direct weight is
transmitted to this part.
g) Prior to installation and final closure, the interior of the valve shall be checked as
thoroughly as possible without disassembly to verify the cleanliness condition.
h) When handling or supporting the valve, care shall be taken to prevent damage to the
valve or its appurtenances (hand-wheels, drains, vents, etc...)
i) Temporary Gaskets shall be used for Pressure Test & Flushing
-Control Valve
-Check Valve (See Flow Direction)
-Orifice Plate
-Strainer Flange & Temp. Wire Mesh
-In line Instruments
-Corrosion Coupon
-Equipment Flange
-Temporary Spacer & Blind
-Vent & Drain Flange
6. Fit-up & Welding
1) Work Sequence
WPS & PQR Cutting & Beveling a) Gas Cutting

Welding Procedure b) Power Grinding
ITP & QAP c) Arc air Gouging
d) Plasma Jet
Cutting
Alignment/Fit-up
Preheating
(If Required)
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1) Welding material Tack-Welding

Control Procedure
Welding
Postheating
(If Required)
1) Inspection Format Inspection &

Acceptance
Sl-no Item Description Classification
6.1 Cutting & Beveling 1) Carbon Steel Pipes

2) Stainless Steel Pipes
3) Alloy Steel Pipes
6.2 Alignment/Fit-up 1) Welding Attachment

6.3 Tack-Welding 1) Welding materials
2) Socket Joint
6.4 Welding 1) WPS & PQR
2) Welding Process
3) Repair Welding of Defects
6.5 Inspection & Acceptance 1) Welding Inspection Report
Inspection Items Specification/ Format No Responsibility

Welding SSP-3P-001
SSP-3P-007
1. Welding Procedure QCP-710-20 ITP-WE-01A/B I I/R QC
2. Procedure Qualification QCP-710-22 ITP-WE-03A/B I I/R QC
3. Welder Qualification QCP-710-23 ITP-WE-04 I/R W QC
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4. Welder Control QCP-710-23 ITP-WE-05 I I/R FP

5. Welding Material Stock QCP-710-21 ITP-WE-06 I/R D FP
Control QCP-710-21 ITP-WE-07 I/R D FP
6. Welding Material Drying QCP-710-21 ITP-WE-08 I/R D FP
Control
7. Welding Material Issue
Control
6.1 Cutting & Beveling
Reference Procedure:QCP-710-10/20/21/22/23
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6.1.1 Cutting
1) Thermal cutting can be performed by arc cutting or oxygen gas cutting method.
a) When thermal cutting is performed to prepare weld joint, edge, or to remove

defective material or attachment, appropriate preheating suggested in applicable code
or specification shall be taken into consideration.
b) The cut shall be smooth and true, and slag and contamination should be cleaned from
the cut surfaces.
1) Flame cutting of austenitic stainless steel is not permitted.
a) Material shall be cut to shape and size by mechanical means such as machining,
shearing, grinding, or by gas cutting, the cut surface shall be ground to bright metal.
b) When low alloy steel is cut by thermal means, at least 1/16 inch(1.6㎜) shall be
removed by grinding.
3) Austenitic Stainless steel
a) Austenitic Stainless Steel material shall be cut by mechanical means, sawing, abrasive
disc, arc air gouging process or plasma arc cutting.
b) When arc air gouging is used for rough cutting, all remaining slag, scale or oxides
shall be removed by machining or grinding the cut end to sound metal.
c) No flame cutting in allowed
d) Power grinding wheels high speed cutting wheels and or brushes, which have been
used for carbon steel, shall not be used for the fabrication or installation of stainless
steel piping.
4) Carbon Steel
a) Carbon steel pipe may be cut by mechanical or thermal means.

b) The thermal cut end shall be ground to bright metal with a minimum metal removal
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of 1/8 inch to ensure complete removal of surface contamination.
6.1.2 Beveling
1) Welded Branch connection detail

a) Where welded Branch connection is applied, It shall be welded in accordance with the
following Figures (a), (b), (c), (d), unless otherwise specified on the Drawings.
b) Welded branch connection shall be inserted through an opening cut in the run wall
with its edge beveled and shall be welded as shown in figure (a), (figure (c) shall be
applied to welded branch connection having reinforcement).
c) When Figure (a) is not applicable, figure (b) shall be applied. (figure (d) shall applied
to welded branch connection having reinforcement).
FIRST, WELD THE PART 1 * AND FINISH OFF WELD SURFACE WITH GRINDER AND
THEN WELD PART 2*.
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W1 = 3/8 th (BUT NOT LESS THAN 6mm)

REMARKS : 1. THE SYMBOLS USED IN THIS PAR. ARE AS FOLLOWS :
t : NOMINAL THICKNESS OF RUN WALL
te : NOMINAL THICKNESS REINFORCEMENT
tn : NOMINAL THICKNESS OF BRANCH WALL
2. THE LOCATIONS OF WELDED BRANCH CONNECTION

REQUIRING REINFORCEMENT SHALL BE INDICATED ON THE
DRAWINGS AND/OR NOTES COLUMN OF PIPING DRAWING
6.2 Alignment & Fit up
1) Alignment requirements when inside surfaces are inaccessible

2) The inside diameters of circumferential joints shall match each other within 1/16 inch(1.6
㎜).
3) However other variables not associated with the diameter of the component may result in
alignments that are offset rather than concentric.
4) Measuring devices such as ID micrometers or fit-up(HI-LO) gauge shall be used to
accurately gauge joint ID Dimension
5) When using open butt weld geometry, fit-up gap shall be inspected before tack welding to
ensure it meets the requirements of the code and welding procedure specification.
6.2.1 Welded Attachments
1) Clamps, welded clips, tack welds, or other appropriate means shall be used to properly
align the joint for welding.
2) Welded attachments used for fit-up shall be compatible with the base materials.
3) Preheating for welding of temporary attachments shall be in accordance with the
applicable WPS.
4) After completing fabrication, attachments shall be removed flush with the base metal
without encroaching on the required minimum wall thickness.
5) Breaking does not permit removal of attachments.
6) PT shall examine all areas from which temporary attachments have been removed or MT
after the surface has been restored.
7) Any defects found shall be removed by additional grinding and rewelding, if necessary.
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6.2.2 Socket Joint
1) The following steps should be followed for verification of the socket gap.
2) Before tacking and welding, the distance between the scribe line and the end of socket
depth shall be at least 1/16 inch but not greater than 1/8 inch.
t t=Pressure design thickness

Cx Cx(min.)=1-1/4t but not less than 3mm(1/8 in)
Cx
1.5mm(1/16in) Approx. gap before Welding
ASME B31.3 Fig.328.5.2C Minimum Welding Dimensions for Socket Welding Components
other than Flanges
6.2.3 Preheating & Post-heating
1) Preheating
a) Preheat shall be proceeded without interruption. If a weld is not completed and
preheats is specified, then the weld must be preheated again before recommencing
welding.
b) In principal, minimum preheat and interpass temperature for materials of various P-
No. shall be as specified in Attachment 1.
c) For welding of the dissimilar ferritic steels having different preheating temperatures,
the higher temperature shall be applied.
d) For welding a ferritic steel to an austenitic stainless steel, preheating shall be applied
only to the ferritic steel.
e) Preheating shall be uniformly carried out using a propane gas burner or electric
heating coils. For welding of P-No. 4 or 5 materials, which have large diameter and
heavy thickness, heating with electric heating coil is recommendable.
f) The preheating zone shall extend at least 25㎜ beyond each edge of the weld.
g) Preheat temperature shall be checked by use of temperature indicating crayons,
thermocouple or other suitable means at least 25㎜ beyond each edge of the weld.
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2) Post-heating
a) The Purpose of post-heating is to prevent delayed cracking due to the diffusible
hydrogen penetrated into the weld during welding.
b) Unless other wise specified, post-heating shall be carried out in accordance with the
Qualified Welding Procedure Specification, right after welding for min. 0.5 minutes
per 1㎜ in thickness of the welds(min. 5 minutes and max. 30 minutes) within the
temperature range of 300-400 C, then the weld shall be cooled slowly by the use of
insulation material.
c) Width of heating zone, heating method and check method of heating temperature shall
be the same as for preheating.
6.3 Tack-Welding
1) Tack welds shall have the same quality requirements as the final welds.
2) Qualified welders using qualified welding procedure shall make tack weld.
3) When tack welds are to become part of the finished weld, they shall be visually examined
and defective tack welds removed.
6.3.1 Welding Material
Main purposes of this WELDING MATERIAL CONTROL are to protect from mis-use of
electrodes and welding rods and to provide the welder with conditioned electrodes and
welding rods for the sound welds. Construction Contractor shall submit the detailed
procedure to the CMC considering the type and quantity of welding materials to be used for
construction.
6.3.2 Drying Condition of Electrodes/Fluxes
Drying Condition
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Applied Type of SFA AWS Temp (°C) Holding Keeping Remarks
Material Electrode Spec.No. Classification Time (min.) Temp (°C)
No.
High SFA 5.1 E 6010/6011 7-120 30-60 70-120

Carbon
Steel Cellulose SFA 5.1 E 70XX 300-350 30-60 100-150
Low Alloy Type
Low EXX15
Steel Hydrogen SFA 5.5 EXX16 325-375 60 100-150
Austenitic Type
Lime-Titania E308/308L-15/16
Stainless Type SFA 5.4 E316/316L-15/16 150-200 60 100-150
Steel E309-15/16
9% Nickel Lime Type SFA ENiCrFe-12 200-250 60 100-150
Steel 5.11
Fused Type — — 150-350 60 150-350 For
Submerged
Fluxes Bonded Type — — 200-300 60 200-300 Arc Welding
Note:*Manufacturer’s specified drying condition different from the above table may be proposed
By Construction
6.3.3 Reference Format (See Attached Appendix #1, QCP-710-21)
1) Welding Material Request Card

2) Welding Material Issue & Return Slip
3) Drying Temperature and Holding Time
4) Record of Welding Material Drying
5) Control Sheet for Welding Material(Log Book 1)
6) Welding Material Stock List(WMSL)
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6.4 Welding
6.4.1 General Requirement
1) Qualified WPS based on PQR shall be provided in accordance with the applicable Codes,
Standards and project specifications prior to any production welding.
2) WPS / PQR and Welder Performance Qualification Test made in accordance with the
requirements of 1962 edition or any later edition of ASME Code section IX or ASME B31
Code for pressure piping may be used without requalification of WPS / PQR.
3) Production welding shall be only performed by the qualified welder who have
demonstrated their welding ability determined satisfactory in accordance with the approved
WPS and project specifications.
4) The WPS or PQR and RWPQT may be submitted to the Customer for his approval, if
required.
5) For inter-company procedures or inter-organization, if both company or organizations are
same corporate or single organizational structure who are both following this quality /
technical procedures, the WPS, PQR and/or welders shall be allowed to be used without
requalification in both company or organization.
6) Prior to preparation of WPS or welding procedures, the followings shall be considered to
meet the specific requirements.
a) Compatibility of weld metal and base material.
b) Metallurgical properties and desired mechanical properties.
c) PWHT or other heat treatment.
d) Service requirements and welder's ability.
6.4.2 Control of Welding Work
1) Welding work will be performed in accordance with the flow chart of welding work.
2) For process control of the alloy and special line class, welding activity will be inspected
based on welding inspection record.
REV. NO. PAGE NO.
Flow Chart of Qualification Welder
Prepare Draft WPS  Review Construction

Spec. Dwg.
requirement, etc. Start
Weld Test Coupon  Coordinate with

Material department
Visual and RT No
(if req'd)
Yes
Prepare Test Specimen and

Mechanical (Laboratory) Test
Evaluate the result, No

Certify PQR
Yes
Qualify WPS
Yes
Welder & Welding Operator

Welder & Welding
Performance Test (Qualify each
Operator Training
welder as per qualified WPS)
Yes
R.T or Bend No
Test
Yes
Issue Welder ID Production

END
Card Welding
6.4.3 Welding Process

1) The welding process variables shall be as specified in the applicable WPS.
REV. NO. PAGE NO.
2) All pipe, storage tank and structural steel shall be welded using one or a combination of the
following methods.
a) Shielded Metal Arc Welding (SMAW)
b) Gas Tungsten Arc Welding (GTAW)
c) Gas Metal Arc welding (GMAW)
3) The welding of butt welds in carbon or low alloy steel pipe with a wall thickness of 3/4 inch
(19㎜) or greater may only be interrupted provided a minimum of at least 3/8 inch(9.5㎜)
thickness of weld deposit or 25% of welding groove, whichever is greater, is filled.
6.4.4 Filler Materials

Filler materials used in this procedure shall conform to the approved WPS and applicable job
specifications.
6.4.5 Shielding and Purging Gas.

1) The composition and flow rate of the shielding and purging gas shall be as specified in the
applicable WPS.
2) An inert backing gas(helium or argon) purge shall be used on 2-1/4Cr 1Mo and higher
alloys.
a) Root Pass Welding
b) Removal of Tack-Welding
c) Interpass Welding
d) Cover Pass Welding
6.5 Inspection and Acceptance.
Stage Inspection and Testing Acceptance Standard
Prior to (1) Material check To satisfy the requirement of piping material

Commencing specification
Work (2)Welder's performance (a)License (qualified by appropriate
qualification Authority)
(b)Welder's performance qualification
(1) Electrode certificate authorized by Client
(a) Material certificate (material name, brand)
(b) To satisfy applicable codes and standards
Prior to (1) End preparation - To satisfy the requirements.

Welding a) Shape and dimension - To be free from paint, oil, rust, scale or other
REV. NO. PAGE NO.
work b) Cleanliness foreign material.

(2) Tack weld - To be within the tolerance specified (Misal-
a) Root opening ignment is not more than 1.5mm)
b) Alignment
(3) Pre-heating - To keep the Pre heating temperature within
the tolerance specified.
(4) Electrode - To be in accordance with manufacturer's
a) Drying temperature standard
b) Drying time
After (1) Visual inspection of weld

Welding weld
Work a) Under cut - Less than 0.3mm, but for low temperature
service-and high temperature service
materials it is not permitted.
b) Overlap - Less than 1.0mm
- Over 0.7t
c) Throat thickness of fillet (t: thinner pipe thickness)
weld
d) Weld reinforcement or -Wall thickness. Max. (mm)
internal weld 6.4 Or under 1.6
protrusion over 6.4 upto 12.7 3.2
over 12.7 upto 25.4 4.0
over25.4, 4.8
e) Correction for jig mark - No harmful defect
(3) Non-destructive inspection
a) Radiograph - To be in accordance with ANSI B31.3.Para.
344.5
b) Liquid penetrant - To be in accordance with ANSI B31.3.Para.
344.4
c) Ultrasonic - To be in accordance with ANSI B31.3.Para.
344.6
(c) Post weld heat treatment - Temperature and holding time is satisfied in
accordance with the requirements.
Hardness (HB)
(d) Hardness(4) test against
all SR point P-No. Material Max.
REV. NO. PAGE NO.
3 C-0.5Mo steel
4 1 1/4Cr-0.5Mo steel
5 2 1/4Cr-Mo 5Cr-0.5Mo
225
241
The hardness after the post weld heat treatme-

nt shall be less than the specified value.
(1) Hydrostatic and pneuma- - No deformation and leak shall be acceptable.

tic pressure testing
(2) Leak test - No leak shall be acceptable.
(3) Measure wall thickness - Over minimum required wall thickness.
7. Hanger and Support
1) Work Sequence
Select Type 1) Shop Fabrication Applied Painting

Support Standard 2) Field Fabrication
Dwg/Document
Site Installation Location

Condition of Fixing
Gap & Clearance
Remove Temporary
Stopper & Lug
Follow-up Design Adjustment or
Engineer Instruction Setting
Inspection
REV. NO. PAGE NO.
7.1 Pipe Whip Restraint Support 1) Pipe Shoe

2) Pipe Saddle
3) Trunnion Support
4) Spring Hanger
7.2 Supplementary Support 1) Beam, Plate,
2) Angle, Channel
7.3 Non-Catalog Pipe support 1) Anchor & U-Bolt
2) Pipe Stanchion
3) Lug
4) Reinforced Pad

1. Piping Support Inspection SSP-3P-024 ITP-AG-03 I I FP
7-1. Hanger and Support

Reference Specification:SSP-3P-024
1) General
a) Assembly, field fabrication, installation, adjustment, inspection, and documentation for

supports of piping systems.
b) Fabrication and installation of supplementary structural steel or beam for supporting of
piping systems.
2) Definition
REV. NO. PAGE NO.
a) Pipe supports are those elements used to carry the weight of piping, contents,
insulation, and other loads as defined in the Power Piping Code, ASME B31.1 and
this specification.
b) Hanger or those elements : carry the load from above with the supporting members
being mainly in tension.
c) Support or those elements: carry the load from below with the supporting members
being mainly in compression.
d) Restraint or those elements: control or limit movement of the piping or any
combination of these support functions.
e) Cold setting: the indicator position or point to indicate blue sticker marked “C” on the
indicator scale when the plant is shut-down. This setting load is same as dead load
which consists of the weight of the piping components, insulation, protective lining
and coating, and other superimposed permanent loads.
f) Hot setting : the indicator position or point to indicate red sticker marked “H” on the
indicator scale when the plant is operation. This setting load is equal to the live load,
as determined by weight balance calculations plus thermal expansion load.
g) Travel stop : this device will lock the hanger against upward or downward movement
for temporary conditions of underload or overload, such as may exist during
hydrostatic test or chemical clean-out.
3) Spring Hangers
a) Spring hanger pin shall be removed only when the supported lines are ready for
start-up condition.
b) After plant has started operation, check the spring hanger position whether it is at
hot load position and confirm any excess variation from design load.
4) Prefabricated pipe support
Pipe supports which is located at high elevation may be prefabricated at shop under
supervision of piping field engineer. Piping field engineer will designate exact
dimension of above mentioned pipe supports for it's prefabrication.
5) Materials
Materials and hardware for use in pipe support works shall comply with the requirements
of applicable Codes and Standards, if required.
REV. NO. PAGE NO.
8. Nondestructive Examination
1) Work Sequence for Visual Examination
Direct Visual
Examination
a) Telescopes Remote Visual

b) Cameras Examination
2) Work Sequence for Liquid Penetrant Examination
Pre-cleaner a) Foreign Material Pre-cleaning

b) Contaminants
Penetrant a)10~30 Minutes Applying Penetrant

b) 16~50 C
REV. NO. PAGE NO.
Wiping the Surface Removal of Excessive

Penetrant
Developer 7~30 Minutes Application of Developer
5 Minutes Drying
Acceptance Post Cleaning
3) Work Sequence for Magnetic particle Examination
Oil Surface Clean & Dry

Sand
Loose Rust & Scale
Paint
Install Electromagnetic
Yoke
Testing Area Apply Magnetic Flux
Field Indicator Examination

REV. NO. PAGE NO.
Remove testing Medium Post Examination

Cleaning
Demagnetization
4) Work Sequence for Ultrasonic Examination
Basic Measurement Calibration Block
a) Sand/Coating Surface Cleaning

b) Loose Scale/Rust
Glycerine or Deionized Apply Couplant

Water
Moving search Unit Scanning

REV. NO. PAGE NO.
Level Sensitivity Monitoring
Record Acceptance
5) Work Sequence for Radiographic Examination
Welded joint Location Marking

Identification Number
Wall Thickness Select Penetrometer
Identification Number Place Penetrometer

(Lead Letter)
Film Distance Install Source
Surface Irregularities Visual Inspection

REV. NO. PAGE NO.
a) Single Wall Exposure

b) Double Wall
Developing time & Film Processing

Temperature
Film Review
Approved Codes Acceptance

8.1 Visual Examination 1) Direct Visual Examination
2) Remote Visual Examination
8.2 Liquid Penetrant Examination 1) Pre-Cleaning
2) Applying Penetrant
3) Removal of Excessive Penetrant
4) Drying
5) Application of Developer
6) Post Cleaning
8.3 Magnetic Particle Examination 1) Equipment
2) Calibration
3) Examination Method
8.4 Ultrasonic Examination 1) Equipment
2) Calibration Block
3) Examination Method
8.5 Radiographic Examination 1) Equipment & Material
2) Identification of Radiographs
3) Penetrameter
4) Source to Film Distance
5) Radiographic Technique
6) Film Density Limitation
7) Film Processing
8) Quality of Film
REV. NO. PAGE NO.

Nondestructive Examination QCP-015-10
1. RT Film Review and Report ITP-ND-01 I/R (W) QC

2. RT Report(Welder/2Weeks) ITP-ND-02 I/R D QC
3. RT Report(Contractor/2Weeks) ITP-ND-03 I/R D QC
4. RT Report(Defect/2Weeks) ITP-ND-04 I/R D QC
5. PT Examination and Report ITP-ND-05 I/R D QC
6. UT Examination ITP-ND-06 I/R D QC
7. MT Examination ITP-ND-07 I/R D QC
8.1 Visual Examination
1) Reference Procedure: QCP-015-10

2) Direct and indirect visual techniques for the examination of welds are described in this
procedure, with adequate test equipment to visual examination by various methods shall be
utilized as listed; Light meter Portable white light, Steel ruler, Magnifying glass.
8.1.1 Direct Visual Examination

1) Direct visual examination may usually be made when access is sufficient to place the eye
within 24 inches of the surface to be examined and at an angle not less than 30 deg. to the
surface to be examined.
2) Mirrors may be used to improve the angle of vision and aids such as magnifying lenses may
be used.
8.1.2 Remote Visual Examination

REV. NO. PAGE NO.
1) Remote visual examination may have to be substituted for direct visual examination using
such aids as mirrors, telescopes, fibreoptics, or cameras, provide that such systems can be
shown to have a resolution capability at least equivalent to that obtainable by direct visual
examination.
8.2 Liquid Examination

2) This procedure describes the requirements for color contrast technique of liquid penetrant
examination of the welds and materials.
8.2.1 Pre-cleaning
1) Check that the surface to be examined and adjacent areas within 1 inch shall be through
washed with precleaner in such a manner those foreign materials and contaminants are
removed.
2) Check that the examination surface shall be wiped dry with lint free cloths or absorbent
papers, allowing a minimum of 5 minutes for complete evaporation.
8.2.2 Applying the penetrant

1) Check that the minimum dwell time of the penetrant shall be 10 minutes at temperature between
16 degree C and 52 degree C, maximum dwell time shall not exceed 30 minutes.
8.2.3 Removal of excessive penetrant

1) Check that the excessive penetrant shall be removed by wiping the surface with clean, dry
and lint free cloths or absorbent papers until most traces of excessive penetrant have been
removed.
2) Check that flushing the surface with remover prior to application of the developer shall be
prohibited.
8.2.4 Drying
Check that the surface shall be completely dried, prior to application of the developer, for 5
minutes of drying time.
8.2.5 Application of developer

1) Check that after sufficient agitation of the pressurized container, a smooth and uniform
layer of the suspended powder shall be sprayed on the surface.
2) Check that interpretation of indications shall be made in minimum of 7 minutes to a
REV. NO. PAGE NO.
maximum 30 minutes after the developer has been applied.
8.2.6 Post-cleaning
1) Check that post-cleaning is necessary in those cases where residual penetrant or developer
could interfere with subsequent processing or with service requirement.
2) If post removal is necessary, that it be carried out as promptly as possible after
examination so that it does not fix on the part.
8.2.7 Acceptance Standard

The examined parts shall be unacceptable if liquid penetrant examination shows any type of
discontinuities given in related codes and specifications.
8.2.8 Reexamination After Repair

Check that repaired areas being removed the material containing unacceptable defect shall be
re-examined by the same liquid penetrant technique and procedure as was used originally.
8.2.9 Records
1) Reports shall be prepared and furnish to the Customer, shall be filed for the period
required as per Quality Records Procedure unless otherwise stated by the Customer.
2) Examination condition and interpretation shall be recorded on the report form attached to
this procedure.
8.3 Magnetic Particle Examination

2) This procedure shall be utilized for the wet magnetic particle examination of ferromagnetic
materials employing alternating current or direct current yoke technique and prod
technique where applicable, and direct contact techniques.
8.3.1 Equipment
1) AC electromagnetic yokes should have a lifting force of at least 4.5Kg(10 1bs) and DC
yokes 18Kg(40 1bs) at the maximum pole spacing where they will be used.
2) If used, prod type electrical equipment shall be used with a pole spacing 76 - 203mm(3 to
8inches) and the magnetizing current shall be applied in accordance with the requirement
of ASME Code, Sec. V, Art. 7.
8.3.2 Material
REV. NO. PAGE NO.
Wet magnetic particles shall be utilized as the testing medium. The color selected shall
provide adequate contrast with the surface being examined.
8.3.3 Calibration
1) The applicable block described below shall be used to verify proper operation of the
electromagnetic yoke.
2) A calibration block of a ferromagnetic material weighting a minimum 4.5 Kg(10 1bs)
shall be used to confirm the lifting power of AC magnetizing current, at the max. pole
spacing
3) A calibration block of a ferromagnetic material weighting a minimum 18 Kg(40 1bs) shall
be used to confirm the lifting power of DC magnetizing current, at the max. pole spacing.
8.3.4 Examination Procedure
1) Surface preparation
The surface being examined shall be clean and dry and shall be free from oil sand, loose rust,
loose scale. Thin paint must be removed at points where electrical contact is to be made.
2) Method
a) The electromagnetic yoke shall be applied twice in each testing area. The second testing
shall be conducted with the lines of magnetic flux approximately at right angles to the
first application. Overlap shall be sufficient to ensure the entire testing area is covered.
b) The magnetic particle shall be applied by either spraying or flowing it over the areas to
be tested.
c) The adequacy of magnetic field shall be demonstrated by field indicators. The operation
shall also use field indicators during testing to verify the adequacy of magnetic field.
d) All examinations shall be conducted using the "continuous method". The
electromagnetic yoke shall remain activated during the application and removal of
excess material
e) Variable electromagnetic yoke pole spacing shall be a maximum of 203mm(8 in)
measured on the material surface between the centerline of the poles.
3) Post-examination cleaning
Examination personnel shall conduct post-cleaning for removal of testing medium.
4) Demagnetization
When residual magnetism in the part could interfere with subsequent processing or usage, the
part shall be demagnetized any time after completion of the examination.
REV. NO. PAGE NO.
8.3.5 Acceptance Standards

1) Unacceptable defects and repair requirements
All linear discontinuities are unacceptable and shall be removed and repaired. Where a
linear discontinuity is removed by chipping or grinding and subsequent welding is not
necessary, care shall be taken to conture the surface so as to eliminate any sharp notches of
corners. When a defect appears to be removed, the area shall be reexamined by the same
method to verify that it has been removed completely. If repairs are made, the repaired area
shall be examined by the same method.
2) Treatment of imperfections believed non-relevant
Any indication of and imperfection, which is believed to be non-relevant, shall be regarded
as a defect unless on reevaluation it is shown by the use of other nondestructive methods.
And/or by surface conditioning that no unacceptable discontinuity is present.
3) Examination of areas from which defects have been removed
After a defect is thought to have been removed, and prior to making weld repairs, the area shall be
examined by suitable methods to ensure that the defect has been eliminated.
8.3.6 Records
Examination condition and interpretation shall be recorded on the report form attached to this
procedure.
8.4 Ultrasonic Examination

2) This procedure is limited to straight beam and angle beam method of ultrasonically
examining the welded joints, HAZ and adjacent base material using manual, contact and
pulse-echo ultrasonic techniques.
8.4.1 Equipment & Material
1) Equipment
a) The following equipment or equivalent shall be utilized for this examination.
b) The equipment shall be of the pulse-echo type.
c) The equipment shall generate receive and present the relevant pulses on a CRT in the
frequency range from 1 to 6 MHz.
d) The horizontal linearity shall be within ±5% of full screen height over the range of 10%
to 100% of full screen height.
REV. NO. PAGE NO.
e) The equipment shall have a calibrated gain control adjustable in discrete 1 or 2 dB steps
over a range of at least 60 dB. The accuracy of the gain control settings shall be within
±1 dB.
2) Search unit
a) Straight beam techniques
-Normal size of 1/2" x 1/2" or 1" x 1" search units with nominal frequencies of 2 or
2.25 MHz are utilized for this examination.
b) Angle beam techniques
-Projection angle of 45 deg, 60 deg,70 deg search units with nominal frequencies of 2 or 2.25
MHz are utilized for this examination.
3) Calibration block
Test equipment shall be calibrated using reference calibration blocks fabricated from
material that is acoustically similar to that being inspected and standard calibration blocks
to be used are as following:
a) IIW : standard calibration block
b) IOW : beam profile block
c) Standard thickness calibration block
8.4.2 Couplant
Couplant shall be water washable such as glycerine or deionized water with or without wetting
agent.
8.4.3 Calibration Of Equipment

1) The complete calibration for ultrasonic examination shall be performed prior to the
examination. For this purpose, the reject control shall be turned off.
2) Straight beam technique
Using the back reflections from an IIW block or applicable reference block, adjust the
material and range control of the instrument so that the sound path distance is displayed
linearly along the base line of the screen to included the anticipated examination distance
for a 0-degree longitudinal wave in the test material.
3) Angle beam technique

Using the radius reflections from an IIW block or applicable reference block, adjust the material
and range controls of the instrument so that the sound path distances are displayed linearly
along the baseline of the screen to include the anticipated examination distance for a 45
REV. NO. PAGE NO.
deg ±2 deg and 60 deg ±2 deg shear wave in the examination material.
4) Distance Amplitude Correction(DAC) curve

a) Straight beam technique.
Sensitivity calibration shall be accomplished by positioning the search unit for maximum
response from the 1/2 t hole to be 50 % ±5 % of full screen height. A straight,
horizontal line shall be drawn or the instrument screen at the amplitude of the primary
reference. This line shall extend the distance on the test piece.
b) Angle beam technique.
DAC curves shall be constructed by utilizing the responses from the basic calibration
hole. The initial position on the DAC curve is established by manipulating the search
unit to obtain maximum response from the nearest suitable hole. The gain control is
then set so that this response is 75 % ±5 % of full screen height.
8.4.4 Examination Procedure
1) Surface preparation
The surface from which scanning is to be achieved should be cleaned to remove all scale
or coating to assure continuous coupling during the examination.
2) Basic measurement
a) The thickness of each member from which is to be achieved should be determined and
recorded for use in the flow location determinations.
b) The entire area from which scanning is to be achieved should be examined by the
longitudinal wave technique to assure freedom from laminations or other laminar type
defects which could interfere with sound wave propagation.
3) Straight beam technique
a) Scanning
The weld shall be examined by moving the search unit progressively along and across a
sufficient contact area so as to scan the entire weld.
b) Sensitivity level
When possible, scanning shall be performed at a minimum gain setting of twice (6 dB)
the initial reference level. Evaluation of discontinuities shall be done with the gain
control set at the reference level.
REV. NO. PAGE NO.
3) Angle beam level
a) Scanning
The weld shall be scanned using the lowest numbered leg possible within the constraints
of avoiding interference between the transducer wedge and the weld bead.
b) Sensitivity level
The reference level sensitivity for monitoring discontinuities is the initial reference
response corrected for distance by the DAC curve. When possible, scanning shall be
performed at a gain setting of two times (6 dB) the reference level sensitivity.
All indications which procedure a response greater than 20% of the reference level shall be
investigated to the extent that the operator can determine the shape, identity and location of all
such reflectors and evaluate than in terms of the acceptance standards.
8.4.6 Records
1) A report from which clear identified the work and the area of examination shall be
completed by the ultrasonic examiner at the time of examination.
2) Examination condition and interpretation shall be recorded on the report form attached to
this procedure.
8.5 Radiographic Examination

2) The requirements of radiographic examination for the materials and welded joints are
described in this procedure.
8.5.1 Radiation source

1) Responsible authority and/or customer shall approve radioisotope handling equipment and
radiation generating devices.
2) Radiographic machine with adequate voltage and radiation output.
3) Radioactive isotopes such as Iridium 192 and Cobalt 60.
8.5.2 Calibration of equipment

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All X-ray devices shall be calibrated at least every three months by comparing the difference
of densities between two sequence radiographs gained at each calibration shooting.
8.5.3 Materials
1) Film
Radiographs shall be made using in accordance with ASME Code, Sec. V.
2) Intensifying screen
A front and back lead intensifying screen shall be used in accordance with the referencing
codes and shall be in direct contact with the film.
3) Film cassette
The film cassette shall be firmly fixed and maintained as closely as practical against the surface
of the component during exposure.
8.5.4 Identification of Radiographs
1) System of identification
A system shall be used to produce permanent identification on the radiograph traceable to the
contract, component, weld or weld seam or part numbers, as appropriate. In addition, the
manufacturer's symbol or name and the date of the radiograph shall be plainly and
permanently included on the radiograph. in any case, this information shall not obscure the
area of interest.
2) Location markers
Location markers, which are to appear as radiographic images on the film, shall be placed
on the part -not on the exposure holder/cassette- and their locations shall be marked on the
surface of the part being radiographed or on a map in a manner permitting the area of
interest on a radiograph to be accurately located on the part, and providing evidence on the
radiograph that the required coverage of the region being examined has been obtained.
Location markers shall be placed in accordance with the referencing codes.
8.5.5 Penetrameter ( Image Quality Indicators )
1) Selection
The thickness on which the penetrameter is based is the nominal single wall thickness plus
REV. NO. PAGE NO.
the reinforcement permitted by the referencing codes section.
2) Placement
a) For welds, a source side penetrameter shall be placed adjacent to the weld seam.
For materials other than welds, a source side penetrameter shall be placed in the area of
interest.
b) He penetrameter shall be placed on the film side of the part, and a lead letter "F" at least as
high as the identification number shall be placed adjacent to the penetrameter.
3) Number
a) One penetrameter shall be used for each radiograph.
b) If the requirements are met by using more than one penetrameter, one shall be
representative of the lightest area of interest and the other the darkest area of interest.
8.5.6 Source To Film Distance ( SFD )
1) Minimum SFD shall be determined by geometrical unsharpness requirements. Geometrical

unsharpness equals source size times thickness over object to source distance.
2) The recommended distance should be adhered to unless precluded by geometry of the part
being examined. In this instance, the maximum SFD that is permitted by the geometry of
the piece should be used.
a) Prior to marking the exposure, the area to be radiographed shall be visually inspected for
surface irregularities which may interfere with proper radiographic interpretation.
b) Any such irregularities which are revealed through the above visual examination shall
be removed prior to marking the exposures.
8.5.7 Film Density Limitations
The transmitted film density through the radiographic image of the body of the appropriate
penetrameter and the area of interest shall be followed in accordance with the applicable
codes and project specifications.
8.5.8 Number of films

Number of films to be taken for one girth butt weld joint at radiographic inspection shall be as
follows :
Nominal diameter of Pipe Number of films

REV. NO. PAGE NO.
2-3B 150mm x 2 sheets

4-6B 300mm x 3 sheets
8 - 12 B 300mm x 4 sheets
14 B 300mm x 5 sheets
16 - 18 B 300mm x 6 sheets
20 B 300mm x 7 sheets
22 - 24 B 300mm x 8 sheets
26 B and over With film overlap of 25mm or more, number of
films shall be decided according to the
circumferential length of the pipe.
Interpretation may be accomplished using either single or composite viewing. Acceptance shall
be as the referencing codes or project specifications.
9. Post Weld Heat Treatment and Hardness Test
1) Work Sequence
Thermocouple Before PWHT

Heating Pad
Warm Material
PWHT Rise-up Temperature

Holding Time/
Temperature
3) Cooling Rate
Record Chart After PWHT

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Radiographic
Examination
Accepted R/T
Hardness Test
9.1 Heating Element 1) Thermocouple

2) Heating Pad
3) Warm Material
9.2 Holding & Cooling 1) Rise-up temperature
2) Holding time/temperature
3) Cooling rate
4) Record chart
9.3 Hardness test 1) Heat affected zone
2) Brinell Hardness value or Eruivalent
2) Inspection and Test items

Post-weld Heat Treatment QCP-710-24 ITP-AG-01 I/R D QC
9.1 Heating element
1) Heating element made of nichrome wire shall be wrapped on the full length of the weld to
be heat-treated, on the width of at least two(2) inches from the each side of the weld.
2) Heating element shall be wrapped on its full length and width by the insulation material
made of glass wool or ceramic fiber.
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3) The connection of a heating element (coil) and a cable shall be wrapped by asbestos cloth
and fixed by a friction tape for safety.
9.1.1 Heating
1) Heating for PWHT shall be made by the electric machine which produces the energy from
the electric resistance of nichrome wire (heating element).
2) Heating rate shall be max. 200℃ per hour and in accordance with the qualified Welding
Procedure Specification.
3) The temperature and time for each weld shall be automatically recorded on chart by
electric machine. And the required number and location of thermocouples to record the
temperature and time are as follows.
Pipe Size Number and location

Up to and including 10" Two - 180。 apart
12" and 14" Three - 120。 apart
16" thru 24" Four - 90。 apart
26" and over A minimum of four but not
more than 24" apart
4) To prevent the twist of pipe spool during heating, it shall be correctly positioned on
supports.
9.2 Holding and Cooling
1) Holding temperature and time shall be in accordance with Attachment 2.

2) Cooling rate shall be max. 200℃ per hour and in accordance with the qualified Welding
Procedure Specification. But cooling rate shall be controlled by electric machine upto
350℃ and from 350℃ to ambient temperature, cooling may be done by air-exposure.
9.3 Hardness test
1) The hardness limits in Attachment 2 shall be applied to both the weld and heat affected zone.
2) Hardness tests of heat affected zone shall be made at a point as near as practicable from the
edge of the weld.
3) The weld to be tested shall be flat finished by grinding and removed the impurities.
4) The hardness of the weld and heat affected zone shall be tested by one point per one weld
which performed the PWHT.
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5) The hardness shall be obtained by portable hardness tester in BRINELL HARDNESS value
or equivalent.
9.4 Reference Format (See Attached Appendix #1, QCP-710-24)
1) Preheating temperature
2) Post Weld Heat Treatment
3) Work Flow of PWHT
4) Inspection Requisition Sheet for “PWHT”
5) Instruction of PWHT Work
6) Record of Heat Treatment
7) Log Sheet of PWHT
10. CRITICAL CHECK POINT
10-1. 중점 관리 ITEM
SEC. I, Shop prefabrication 참조
10-2. 주요 현장 문제점 및 조치사례
Description 문 제 점 조치 사례
1 Traceability For 모든 배관자재의 추적성(Traceability) Client 요청은 Over Requirement로

Piping 을 기록 하기 위하여 Shop Drawing Daelim은 Job Specification에 따라 Color
Material 상에 자재의 Heat No.를 관리해 달라는 Code, Marking and Tagging으로 모든
Client 의 요청 자재를 Identify시키고, Client에서 계속
요청하면 Extra Work으로 처리하겠다는
Letter 발송 후 관련 File를 Close하였음.
2 Color Code 자재, 특히 Piping Material에 대한 NCR를 작성 구매부서 및 Vendor에
REV. NO. PAGE NO.
Identification 을 위하여 Color Code를 통보했으며 Disposition 은 Taxas Nuclear

실시하는데, Vendor에서Marking되어 Analyzer로 Verify 시킨 후 NCR File을
들어오는 Fitting류 중 C.S 및 SUS Close 하였다.
자재에 대한 Impact Test가 합격된 Low
Temperature 자재에 많은 NCR이
발생되었음.
3 Corroded – Italy Troiven Coven 회사로 부터Supply 중간검사(Source Verification)를
Pipe(T&C) 된 Pipe가 장기저장으로 인한 심한 실시하지 않았으며 Supplier의 Mill
부식으로 Pipe내부에 곰보(Pitty)가 Certificate를 검토하지 않아서 이와 같은
발생 사용 불가 판정됨. 결과를 초래 하였음.
4 Supplied Wrong Pipe Fitting류 중 태광산업㈜에서 태광산업㈜에서 공급된 모든 Stainless
Material Supplied 된 SUS 316L Elbow가 Steel Fitting에 대하여 전체적으로 Texas
Marking, Tagging 또는 관련 서류 P.O Nuclear Analyzer로 Verification 작업을
및 Mill Certificate 상에는 아무런 실시하여 잘못된 3" Elbow 3EA를 찾아
이상이 없었으나 Texas Nuclear 관련사항을 재시공 후 NCR를 Close
Analyzer로 Welding Joint Verification 시켰다.
도중 SUS 304로 판명 되었다.
5 Shortage Material 설계 변경으로 인한 자재 부족과 공기 설계 변경에 따른 Material Mto을 UpDate
지연 하고 자재 재고 및 P/O여부를 확인 한다
6 배관 내부 이물질 SUS 배관의 경우 Purge Paper를 용접시 용접 검사 시 관내부 검사를 필수로

검사 사용하는데 간혹 Masking Tape을 Purge 실시하도록 배관 Inspector에 지시해서
Paper와 함께 사용하고 떼지 않음 이물질을 확인 및 제거
7 Valve Pipe Material Class에 따른 Valve Tagged Items은 시공 전 작업자 교육 및

Symbol을 복사하여 현장에 시달 책임자를 별도 선임 및 확인하고, 담당
되었으나 많은 Valve가 시공 잘못 Supervisor는 수시로 확인
되었음
8 Gasket Pipe Material Class에 따른 Gasket 초기에 Color Code를 적용하고, 작업자
잘못 설치 된 곳이 많음 교육 및 확인 책임자 선정
9 재 작업으로 인한 Precomm. 시 많은 Gasket가 많이 시공 초기부터 Precomm. Scheme을 숙지
자재 절약 소모되고 있음 Flushing Joint 나 Blowing Joint을 필히
Temporary Gasket 사용으로 자재를
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절감과 회사 경쟁력 강화
10 Bolts & Nuts 초기에 Bolts 자재 조달이 늦어져 다른 초기부터 Bolts & Nut를 Expedite를 하여
Size를 임시 설치 후 Replace가 제대로 추가 Replace 문제를 극소화 하고, 임시
되지 않음. 설치는 반드시 기록으로 혼선 방지 및
입고된 자재는 Piping Material Class 별로
Color Code 적용 후 현장 불출.
11 Dissimillar Cracking Furnace의 welding Process중 [별첨 #1]Proposal대로 Client 승인을
Welding (P4+P8) Heater Coil Outlet(SUS304)와 득하여 재시공
Interconnection (Cr, Mo) 이종 금속
용접으로 Code violation 발생됨. 즉 P4
Material(Cr-Mo)는 Dissimillar Welding
후 ASME B31.3 Para 331.2에 의거 720
℃, 2HRS Holding Time으로 열처리를
실시 해야되나, Stainless Steel은
500∼800 ℃로 열처리 시행할 경우 Cr.
이 석출되는 예민화 현상(Sensitization)
이 발생하므로, 이 문제점으로 인하여
Welding이 기 완료된 Cracking Furnace
Interconnection Line (72 Joint)를 제
시공 했으며, 도면을 Revision 시켰음.
12 Welding For 영국 Paralloy 회사로 부터 공급된 Stone & Webster의 Welding Engineer,
Paralloy (Furnace) Furnace Transfer Line Paralloy(Cr 39w) Paralloy Vendor의 Welding Specialist의
Welding중 Crater Crack 및 Fine Crack 자문 및 Vendor Welder Mob. 등
발생으로 가장 어려웠던 Welding 최종적으로 Vendor 주문에 의한KEMPPI
작업이었음.<참조> Paralloy : Cast Heat 회사의(Water Cooling Type) Welding
Resisting Alloy로 Chemical Composition Machine을 구입하여 Welding Defect를
은25/35 Cr/Ni+1.2/0.1 Nb/C임. Clear 하였음.
13 Status For C.S 및 일반 SUS 용접봉은 Hyundai 1)Status For Welding Rod [별첨 #3]참조.
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Welding Rod 생산품을 사용했고 Alloy 계통은 2)상대적으로 가격이 저렴한 국내

KOBE Welding Rod를 사용했음. Welding Rod를 사용 검토
KOBE는 Local 내에 Agent가 있으나 3)WPS 작성시 Recommend Welding Rod
Hyundai는 Agent가 없어 Final Balance or Equivalent로 표기하여 동종의
는 C.S 용접봉도 KOBE Welding Rod를 Welding Rod를 사용가능토록 조치.
사용했음.
14 Welder Project Spec.은 ASME Sec.IX에 의하여 Project Spec. 및 Code 요건에 따라(별첨
Qualification 기능 Test 를 하게되어 있으나 Client는 #4) Proposal for Welder Qualification Test
Alloy 및 SUS도 C/S와 같이 Test 시행 와 같이 시행 협의
요구(Table 참조)
15 Welding Process 배관 용접 기법은(Welding Process)중 SEC. I. Shop prefabrication
수동(Manual)용접은 많은 물량의 “Welding process 참조”
Fabrication을 위한 Shop Welding으로는
많은 인력과 시간이 소모되어 SAW
(Submerged Arc Welding)용접이 검토 (특히 Alloy 및 SUS Heavy Wall
되어야함 반영요망)
16 Support Marking Piping Plan DWG에는 Support의 Type 및 배관공사의 모든 ISO DWG은 Spool No.가
on ISO Drawing 위치가 표시되어 있으나 ISO DWG 표시되는 Shop 제작 및 설치를 위하여
상에는 표시되어 있지 않아 Hydro Test Welding Joint No. 및 Spool DWG을
Package 검토 및 Line Check시 어려움이 작성해야 된다. 현장
많았슴. 규모에 따라 다르지만 통상 ISODWG으로
Shop DWG을 작성하여Validation이
끝나면, TOC의 경우 12매 정도 Copy를
해서 Client, 해당부서 및 Subcontractor로
분배해야 되는 상황으로 볼때 품질 및
공사관리를 위하여Support Marking 은
Shop Drawing 제작 전 ISO DWG에 표시
되어야 한다.
17 Dummy & Pipe Class과 동일 재질을 사용해야 하나 Pipe Support용 자재는 Main-Contractor가
Trunnion Support 현장에서 별도 구매 시 공기에 지장이 공급하는 것이 바람직함
있음
18 Hanger & Special 현장에서 제작 불가 Fabricated Support(Tagged Items)는 Main-
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Sup’t Contractor가 공급하는 것이 바람직함

19 Hanger Hydro-test 후 무리한 Cold setting으로 Spring Hanger Adjusting 작업 순서를
Pipe에 stress가 발생 작업자에게 충분한 교육 및 문제 발생시
Piping Field Design Engineer와 협의 한다
20 Support Plate Gap Punch List 작성시 Resting Support의 1) Shop에서 제작시 같은 종류의 Support는
으로 인한 재작업 Plate가 철골에 밀착되지않아 재작업과 치수가 동일하게 제작되었는지 확인
이로 인한 공기지연 사유가 생김 2) Fab. Spool과 연결시 Stress가 받고
않도록 한다
3) Temporary Support를 고일 경우 Support
와 동일한 높이를 유지 한다
21 Qualified Client가 현장에 전입 되는 모든 Korean ASME의 NA, NPT 및 ISO-9002 관련

Inspector QC Staff의(Test & Evidence) Qualified Procedure에 의거 교육, 경력, 훈련 및
Certification을 요청. 자격시험을 근거로 하여 Company Level
Ⅱ Certificate를 발급했다. 차후 해외 및
국내현장에 파송되는 QC 요원은 품질
보증부에서 제정된 QC요원 자격시험
절차서에 의하여 해당 자격증 (Company
Level Ⅱ)을 발급받고 현장에 파송 될 수
있도록 제도화 요망.
22 R.T Additional ASME Code B31.3 Para. 300.2에 따라 당초 ISO DWG상 R.T 적용 0% 에 따라
Application Category "D" Fluid로 적용될 수 없는 Welding은 B급 용접사를 투입하였고
Line Class가 ISO DWG 상 에는 "D" Welding Joint Inspection은 Visual로 시행,
Fluid로 간주되어 R.T 적용 0%로 되어 Line Check를 완료하였으나 R.T 5%
있었으나 Hydro Test Package 검토중 또는 10% 적용으로 Repair가 발생 되어
Client측의 Comment에 따라 5% 또는 이에 따른 ASME Code B31.3
10%로 Revision됨. Para.341.3.4 Progressive Examination
적용으로 품질 및 Hydro Test 공정에
막대한 지장을 초래하였음.
23 P.T for Job Specification 및 Code(ASMEB31.3 Pipe Design에 대한 Factor를 검토하여
Reinforcing Pad para 328.5.4)에 따라 Branch Pipe를 충분한 Safety Factor를 입증하고 아울러
용접한 후 Full Penetration 상태를 일부 Line은 Hydro Test Presssure를
Check 하기 위하여 해당 Line Class( 요구치 보다 크게 적용 하여 실시한
일반적으로 SUS)의 Root Pass Welding 후 NCR File을 Close했음.
후 P.T를 시행하지 않고 Reinforcing
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Pad를 부착시켜Welding 을 완료
시켰음(약100소).
Disposition으로 R.T 및 U.T를
실시했으나 R.T는 Source 위치 및 Film
부착이 용이하지 않아 R.T Shooting
결과, Film 판독이 불분명 하였고, 또한
U.T도 Branch Pipe의 Wall Thickness가
6㎜ 미만으로 Beam 각도가 나오지
않아 시행 불가능 하였음.
24 Electric Shock by P3, P4 and P5(Alloy Steel)의 NDT(R.T) Heating Pad에서 Damage Ceramic부분의
Damaged Heating 는 ASME B31.3 Para 341.3에DML하면 Heating Element가 Base Material에 Shock
Pad PWHT 전후에 실시하게 되어있다. 발생 시킴. Damaged Ceramic Element
PWHT 후의 R.T 결과 Defect가 교환 및 Pad Repair 후 정기적인 Pad
나타나면 Repair후 재열처리를 Element Testing을 실시 하였으며 또한
시행해야 되기 때문이다. R.T에 Accept 모두 열처리 작업은 Ready for S.W on
된 Welding Joint를 PWHT시행했는데 상태에서 Inspector이 확인 후 S.W On
열처리 (PWHT)후 Welding Joint에 실시했음.
심한 Arc Strike와 같은 흠집이 생겼음.
별첨 #1
Procedure for Dissimilar Welding
(Dissimilar welding P4+P8)
1. Verify the type of disposition
2. Marking on welding joint for identification of disposition(Type "A" and "B")
3. TYPE "A"(375 RETURN LINE)
1) CUT OUT THE COUPON AS PER TYPICAL dwg Type "A"
2) Fabricate and replace the coupon(A) as per typical DWG.
3) Preheateing and welding based on PQR CF-04
4) PWHT on(a) side only
5) R.T and P.T on both side (a) and (b)
4. TYPE "B" (550 OUTLET LINE)
1) Cut out the P8 stainless steel coupon(0) as per typical DWG, type "B" on both side (a) and (b)
2) PQR will be performed based on build up welding to support WPS
3) Qualify WPS
4) Beveling the welding joint on both side (a) and (b)
5) Preheating will be performed before build up welding
REV. NO. PAGE NO.
6) Build up welding will be performed min 2 layer(5mm) on joint (a) with inconnel 82 according to
approved WPS
7) PWHT is required on joint (a) after build up welding
8) P.T will be performed before weld out
9) Rebeveling and grinding the P8 coupon(b) which was cut out to be confirmed the coupon was not
performed PWHT
10) Fit up the coupon(B)
11) Welding out according to approved procedure
12) R.T and P.T will be performed after welding on both side(a) and (b)
11. REFERENCE
11-1. 1,000,000 Dia-Inch Project(Based on Nominal Dia-Inch)
- Reference GPP Project.(Excepted U/G & Off-Site Portion)

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11-2. 800,000 Dia-Inch Project(Based on Nominal Dia-Inch)
- Reference Olifins-III Project.
11-1. 1,000,000 Dia-Inch Project(Based on Nominal Dia-Inch)
a) Reference GPP Project.(Excepted U/G & Off-Site Portion)

REV. NO. PAGE NO.
b) Organization Chart
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REV. NO. PAGE NO.
c) Final Bill of Quantity of GPP Project
Description Work Unit Qty Remarks

Mechanical Piping Work Ton 18,169
Equipment Ton 30,574
Steel Structure Ton 7,087
Painting Work M2 613,866
Insulation-Equip M2 30,793
Insulation-Pipe M 73.165
U/G Piping Work M 33,445
Q/C NDT Sht 225,797
Q/C PWHT Dia-Inch 183,038
d) Equipment Mob. Status of GPP Project(Included Sub-contractor)
Description Unit Plan Actual Remarks
Crane(all kinds) Month 768 1,791
Truck 452 1,686
Forklift 172 389
Wheel loader 82 188
Excavator 81 1,806
Generator 378 1,286
Air compressor 297 1,030
Welding M/C 3,562 7,082
e) Bulk & Consumable P/O Status of GPP Project

REV. NO. PAGE NO.
Description Unit Total Qty Remarks

Acetylene Gas Cyl 5,695
Argon Gas Cyl 15,337
Bar Ea 3,003
Beam Mt 53,152
Cement Bag 33,607
Asbestos Gasket Sht 3,300
Gravel M3 771,717
Grinder wheel Ea 421,461,
H.tensile deformed steel round bar Ton 634,539
Interlocking block Pcs 3,327,040
Miscellaneous article Ea 89,490
Nitrogen Gas Cyl 1,340,674
Oxygen Gas Cyl 14,231
Paint Btl 4,609
Plywood Sht 29,773
Remicon Ea 150,947
Steel Plate Sht 31,393
Sand M3 134,393
Terminal Lug Ea 33,487
Timber Ea 552,115
Welding Rod Kg 426,683
Water Stop Rl 16,576
Wire Mesh; Galvanized Mt 13,240
Material Paint Ltr 53,805

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f) Labor Mob. Status of GPP Project
Description Unit Total Remarks
Mechanical Sub-Contractor Man/Month 26,537
Mechanical Direct Control 26,695
g) Labor Mob. Status for Piping Dep’t of GPP Project
Description Unit A&B 111/115 118/119 C&D Remarks

Foreman Man/Day 10,853
Pipe fitter 111,597
Rigger 24,530
Welder 54,685
Electrian 317
Common labor 7,491
Common labor 18,781
Iron worker 18,069
Scaffolder 22,699
Total 269,022 150,870 62,772 Sub-con
11-2. 900,000 Dia-Inch Project for Olefins-III(Included Factor Dia-Inch)
a) Pipe Welding Dia-Inch Status (Nominal Pipe Dia-inch=800,000)

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Sl-no Description Unit Qty Remarks
1 A/G Piping
1.1 Carbon Steel
1) 1-1/2” and Smaller D-In 105,170
2) 2” and Larger D-In 589,312
S-Total D-In 694,482
1.2 Stainless & Duplex Stainless Steel
1) 1-1/2” and Smaller D-In 17,849
S-Total D-In 82,293
1.3 Alloy Steel
1) 1-1/2” and Smaller D-In 2,550
S-Total D-In 19,445
1.4 Galvanized Steel
1) 1-1/2” and Smaller D-In 37,852
S-Total D-In 107,833
G-Total D-In 904,057 Weight=10,000 Pipe ton
1) Pipe Shop Fabrication D-In 448,959
2) Field Welding D-In 455,098
1.5 Pipe Support(Fabrication) Ton 616
Pipe Support(Installation) Ton 1,030

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Pressure-Test Package Pkg 2,372
b) Staff Mob. Status for Piping Works
Sl-no Description Korean Unit Qty Remarks

/Tcn
1 Piping Superintendent Korean M-mth 74
2 Piping Supervisor Korean M-mth 294
S-Total 368
3 Piping Shop Supervisor Tcn M-mth 58
4 Piping Inspector(Punch) Tcn M-mth 48
5 Piping Supervisor Tcn M-mth 137
S-Total 243
G-Total M-mth 611
c) Labor Mob. Status for Piping Works
Sl-no Description Unit Qty Remarks
1 Foreman M-mth 1,101
2 Pipe Fitter M-mth 3,726
3 Pipe Welder M-mth 3,102
4 Plate Welder M-mth 336
5 Rigger M-mth 3,542

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6 Iron Worker M-mth 812
7 Others M-mth 6,437
Total M-mth 19,056
d) Equipment Mob. Status for Piping
Sl-no Description Capacity Unit Qty Remarks
1 Crane 100 Ton M-mth 28
Crane 25 Ton M-mth 1
Forklift 7 Ton M-mth 47
Trailer M-mth 57
Welding M/C DC M-mth 2728
Welding M/C AC M-mth 587
CO2 Welding M/C M-mth 24
Engine M/C M-mth 63
Auto Welding M/C M-mth 12
Miller(8Pack)Welding M/C M-mth 100

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Generator 365 kw M-mth 41
Pick-up M-mth 94
Boom-Truck M-mth 61
Compressor M-mth 65
Sedan M-mth 4
Service Bus M-mth 17
Mini Bus M-mth 12
e) Welding Rod Status for Piping Works
Sl-no AWS Class Product Name Size Unit Qty Remarks

(mm) (kg)
1 ER70S-2 No.65G 2.4 Kg 19,195
2 ER70S-2 Lincoin 70S-2 2.4 Kg 2,563
3 ER70S-2 Raco 70S-2 2.4 Kg 204
4 E7018 LB-52-18 2.6 Kg 12,000
5 E7018 LB-52-18 3.2 Kg 57,530
6 E7018 LB-52-18 4 Kg 25,560
7 E7018-1 Lincoin 7018-1 2.6 Kg 3,120
8 E7018-1 Lincoin 7018-1 3.2 Kg 4,654
9 E7018-1 Lincoin 7018-1 4 Kg 179
10 ER70S-G TGS-1N 2.4 Kg 996
11 ER80S-Ni1 LNT Ni1 2.4 Kg 323

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12 E7016-G LB-52NS 3.2 Kg 3,870
13 ER80S-G TGS-1CML 2.4 Kg 300
14 E8018-B2 CMB-98 2.6 Kg 140
15 E8018-B2 CMB-98 3.2 Kg 890
16 E8018-B2 CMB-98 4 Kg 270
17 ER80S-G TGS-2CML 2.4 Kg 380
18 E9018-B3 CMB-108 3.2 Kg 2,460
19 E9018-B3 CMB-108 4 Kg 4,300
20 E9018-B3 LH-9018-B3 4 Kg 1,020
21 ER308L TGS-308L 2.4 Kg 1,400
22 ER308L Mckay 308L 2.4 Kg 730
23 ER308L WEL TIG 308L 2.4 Kg 250
24 ER308L TECH 308L 2.4 Kg 50
25 E308L-16 NC-38L 2.6 Kg 450
26 E308L-16 NC-38L 3.2 Kg 497
Sl-no AWS Class Product Name Size Unit Qty Remarks

(mm) (kg)
27 ER308 WEL TIG 308 2.4 Kg 265
28 E308L-16 WEL 308 3.2 Kg 100
29 ER316 TGS-316 2.4 Kg 410
30 E316-16 NC-36 2.6 Kg 120
31 E316-16 NC-36 3.2 Kg 620
32 E71T-1 DW-100 1.2 Kg
33 ER309L TGS-309L 2.4 Kg 30

REV. NO. PAGE NO.
34 ER309L WEL TIG 309L 1.6 Kg 1
35 ER309L WEL TIG 309L 2.4 Kg 64
36 E309L-16 Mckay 309L 2.4 Kg 9
37 E309L-16 Mckay 309L 3.2 Kg 36
38 E309L-16 Stoody 309l-16 3.2 Kg 23
39 E309L-16 NC-39L 2.6 Kg 8
40 E309L-16 NC-39L 3.2 Kg 10
41 ERNiCrMo-3 LNT Nicro 60/20 3.2 Kg 4
42 ERNiCr-3 LNT Nicro 70/19 2.4 Kg 36
43 ERNiCrCoMo-3 ERNiCrCoMo-1 1.6 Kg 6
Total 145,073
1) Total Pipe Weight=10,000 ton, Welding Rod=145,073 kg=
14.5kg/ton(Required Welding Rod)
2) Total WDI=904,057, Welding Rod=145,073 kg = 6.2 D-in/kg(Required welding Rod)
f) Welding Material Storage Plan for Olefins-III
ER70S-2 E7018 Temporary Storage ER- ER80S-G ER80S-G
(3.2mm) 70S- (TGS- (TGS-
G 1CML) 1CML)
REV. NO. PAGE NO.
E9018-B3
1000
ER318L
Dry Desk
Oven#1 ER316
Dry E8018-B2
E7018 E7018(4.0 Oven#2 Desk
(3.2mm) mm)
Dry
4800
Oven#3 E316-16
Dry Re-Use
Oven#4 Box E7016G
Dry
Oven#5
E7018 Dry E308L-16
(2.6mm)
Oven#6
600 1000 600 4000 600 1000 600
Storage for Carbon Steel Welding Welding Material Issue & Storage for Alloy Steel & Stainless Steel
Material Return Welding Material
g) Tool & Consumable List for Olefin-III
Sl-no Description Size Unit Remarks

(Ea,Set)
1 Adjustable Wrench 24” 3
4 Air Conditioner 3
5 Air Pac. Resparator(SPT) 1

REV. NO. PAGE NO.
6 Argon cut hose 5

(Ea,Set)
7 Bench Vice 1
8 Chain Block 5 ton 2
9 Chain Block 1.5 ton 3
10 Chair 4
11 Chairs 43
12 Chipping hammer 5
13 Claw Bar 2
14 Cleaning Tool 1
15 Container 6m x 2m 4
16 Desk 2
17 Drill Elec. M/C 2
18 Dust Bin 10
19 Elect. Air Plasma “Maengha” 1
20 Elec. Grinder 7” 16
21 Elec. Grinder 4” 12
22 Elec. Oven 1
23 Fence Pole w/ Foundation 42
24 Fence w/Base Plates 410
25 File Cabinet (4 Drawers) 6
26 File Round 10
27 Film Viewer DF-2bo21165 1

REV. NO. PAGE NO.
28 Fire Blanket 10
29 Fire Extinguisher 2
30 Fire Extinguisher 12
31 Flat File 10
32 Flat Half Round 20

(Ea,Set)
33 G.I Shackle 1” 2
34 G.I Shackle 1-1/4” 2
35 H/E Elect. Container 4m x 4m 1
36 Hammer Ball 3
37 Hammer Claw 3
38 Hilti M/C 4
39 Hydraulic jack 6
40 Jig saw M/C 1
41 Kitchen Cabinet 1
42 Kitchen Tool 1
43 Meeting Table 4
44 Monkey Plier 2
45 New Fence, Foundation 236
46 Notice Board 12m x 4m 7
47 Office porter cabin 18
48 Oxy/Ace Gauge 10
49 Paper tray 7
REV. NO. PAGE NO.
50 Photocopy M/C EP6001 1
51 Pipe Clamp 4” 3
54 Pipe Cutting M/C 4
55 Pipe Cutter 2”-4” 1
56 Pipe Wrench 14” 3

Field Installation Work Procedure - Piping

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Field Installation Work Procedure - Piping

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PIPING WORK MANUAL DOC.NO.

II. FIELD INSTALLATION

1. OVERALL WORK FLOW

3. PLANNING & PREPARATION

5. INSTALLATION FOR SPOOL & VALVE

6. FIT-UP & WELDING

7. HANGER & SUPPORT

9. PWHT & HARDNESS TEST

10. CRITICAL CHECK POINTS

1. Overall Work Flow

1) Die-Stamp & Staincil

Material Warehouse Painting Shop Color Code

Pipe Shop Identification

1) Pipe spool Erection &

1) Pipe Spool Welding 1) Cutting & Beveling

Daily Welding Preheating

1) Visual Examination NDE 4) Ultrasonic Examination

Sl- Work Flow Item Description Responsibility

7.2 Holding & Cooling QC FP

3. Planning & Preparation

Reference Document Planning Field Piping Project Management

Sl-no Item Description Detailed Activities

3.1 Reference Document 1) Code & Standard

3.2 Planning Field Piping Installation 1) GPP Project (Malaysia)

3.3 Project Management System(Soft ware) 1) Material Control system

3.1 Reference Document

1) Code and Standard

a) ASME B31.1. Power Piping

2) Specification & AFC Dwg

a) Client Technical Specification

-SSP-3P-002 Construction Work for Piping

c) Approved Piping Plan Dwg

a) Daelim QA Standard Procedure

-QAP-C-013 Rev.3 Indoctrination and Training Procedure

b) Daelim QC Standard Procedure

3.2 Planning for Field Installation (See Attached Reference Data)

1) GPP Project (Malaysia)

2) Olenfins-III Project (Saudi Arabia)

3.3 Daelim Soft Ware Status

3) DWRS Daily Work Report System

Warehouse Pipe Shop Non-Painted Identification

Painting Shop Painted Spool Color Code

Field Piping Tagged Piping Class

Sl-no Item Description Detailed Activities

4.1 Requisition of Piping Material 1) Non-Painted Spool

2) Inspection and Test Plan

Inspection Items Specification/ Format No. Responsibility

Code Cont Client Action by

4.1 Requisition of Piping Material

1) Non-Painted Spool, Painted Spool, Bare Material

4.2 Receiving Inspection for Spool and Raw Materials

1) Color Code &

2) Identification Mark & Stamp

3) Protect Flange & Spool End

a) Breaking shall not permit removal of the temporary attachments.

4.3 Transportation of Material to Site

4.4 Spool Storing on Site

5. Spool & Valve Installation

Progress Schedule U/G Piping Wrapping & Coat

Main Pipe Rack

Nozzle Flange Around Static Dress-up Piping

Nozzle Flange Around Rotating Review Field

Vendor Piping Field Weld Joint

Sl-no Item Description Detailed Activities