Fabrication and Erection Piping Procedure. - VT PDF

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PIPING FABRICATION AND ERECTION PROCEDURE

DOCUMENT NO: P-T5116-QC-07
ORIGINATED BY REVIEWED BY APPROVED BY DISTRIBUTION
- SDCC : Original
- All Div. : Copy
- All Dept. : Copy
Luqman/Dedy Ekka Luqman Hakim …………………….…

Construction Team QAQC Engineer PT. Linde Indonesia
EFFECTIV
REV. NO ISSUED DATE BRIEF OF REVISION
E DATE
0 08 Nov 2022 08 Nov For Review and Approval
2022
By Victor Tampubolon at 2:06 pm, Nov 10, 2022

DOCUMENT NO. :
PIPING FABRICATION AND ERECTION P-T5116-QC-07
ISSUED DATE :
PROCEDURE 08 Nov 2022
UNIT ISSUING : PAGE REVISION

Construction
APPROVED BY : 2 of 19 0
Team PT. LINDE INDONESIA
TABLE OF CONTENT
No. Descriptions Page
COVER PAGE 1 OF 19
TABLE OF CONTENT 2 OF 19
1.0 TITLE 3 OF 19
2.0 SCOPE 3 OF 19
3.0 REFERENCE 3 OF 19
4.0 DEFINITION AND ABBREVIATION 3 OF 19
5.0 GENERAL REQUIREMENT 3 OF 19
6.0 FABRICATION 4 OF 19
7.0 ASSEMBLING AND ERECTION 12 OF 19
8.0 INSPECTION & TESTING 16 OF 19
9.0 CLEANING OF PIPING SYSTEM 16 OF 19
10.0 PAINTING & WRAPPING 17 OF 19
11.0 ATTACHMENTS 17 OF 19
DOCUMENT NO. :
ISSUED DATE :

Construction
1. TITLE
PIPING FABRICATION AND ERECTION PROCEDURE
2. SCOPE
2.1 This procedure covers the general requirements for the CW piping
construction works which consist of fabrication, assembling and erection
for CW piping work at Smelting Project Gresik.
2.2 This procedure supplements or modifies to the requirement of ASME B31.3
“ Process Piping” for the piping system and Project Specification from
Linde, where applied
3. REFERENCES
3.1 Code and Standard
3.2.1. ASME Sect IX : Qualification Standard for Welding and Brazing, and
fusing Procedures; Welders; Brazers; and Welding and Brazing
Fusing Operators.
3.2.2. ASME Sect. II : Material Specification
3.2.3. ASME B31.3 : Piping Process
3.2 Specified Project Specification
4. DEFINITION AND ABBREVIATION
4.1. Client : PT. FI as user and owner, the authorized

representative of Company.
4.2. Contractor : PT. Linde Indonesia
4.3. Subcontractor : PT. Truba Jaya Engineering (TJE)
4.4. Depnaker : Indonesian Government body who responsible for
issuing approval and licenses for Boiler Construction
facilities (hereinafter is Indonesian Government
Manpower Department).
5. GENERAL REQUIREMENT
5.1. QUALIFICATION
5.1.1. Persons who are engaged for welding including tack welding and
support welding shall pass the qualification test as per procedure.
5.1.2. All welding works shall be performed in accordance with the
Approved Welding Procedure Specification supported with
Procedure Qualification Record.
DOCUMENT NO. :
ISSUED DATE :

Construction
5.1.3. Persons who are engaged for alignment, assembling, erection, etc.
shall be fully trained and shall have the qualification of Sub-
Contractor.
5.2. MATERIAL
5.2.1. All piping material shall be in accordance with project specification
or code & standard ASME Sect. II to be followed.
5.2.2. Temporary support are not to be tack welded to the pipe walls. In
cases where this is unavoidable the tack area is to be repaired and
check Visual.
5.2.3. All welding consumables selection shall be in accordance with
drawing and approved Welding Procedures. Consumables are to be
segregated as to type and are to be stored as the manufacturer
recommendation. The mill certificate of welding electrode shall be
filed and documented.
5.3. DRAWING AND DOCUMENT

5.3.1. All Drawing and document which cover the piping construction work
shall be listed, issued, and control in accordance with “ Drawing and
Document Control Procedure”
5.3.2. Piping work shall be carried out in accordance with drawing and
document as “ Release for fabrication” or “ Release for
Construction”, unless otherwise instructed.
6. FABRICATION
6.1. GENERAL
6.1.1. Stainless steel or High alloy steel fabrication work shall be separated
from low alloy and carbon steel fabrication work.
6.1.2. Tools and equipment used in stainless steel fabrication shall be lined
by using suitable with stainless steel material (not affect the
properties) and not used on other than stainless steel fabrication.
6.1.3. The bolt holes of flanges shall be located symmetrically from a
vertical center line in a horizontal pipe line, and from plant north in
a vertical pipe line unless otherwise indicated in the drawing.
6.1.4. Piping materials shall be color-coded in accordance with the
procedure or project specification.
DOCUMENT NO. :
ISSUED DATE :

Construction
6.2. CUTTING
To mention all information 6.2.1. All of cuts are to be remarked as per procedure or project
about material preparation
stage before point 6.2 specification
Cutting
6.2.2. The schedule and heat number are to be transferred to all off cuts.
6.2.3. In case of gas cutting, cutting surface shall be ground off to remove
any edge and roughness and be made flush and smooth so as not
to harm welding quality. The angles of preparations shall be within
the code tolerances or welding procedure specification. In case of
unequal thickness there are to be no angle deviations around off
cut.
6.2.4. If pipe is cut using the oxy acetylene process all cut edges are to be
ground back to remove any drag lines or imperfections.
6.2.5. Abrasive disc used for cutting and grinding of austenitic stainless
steels or other high Cr-Ni steel shall be iron free.
6.2.6. Plasma arc cutting may be applied for stainless steel. After cutting
to add dimension control Check by plasma cutting, the cut edges are to be ground back to remove
and report after cutting Pipes
base on spool shop drawing
burnt areas and imperfections.
6.3. END PREPARATION
6.3.1. End preparation for groove weld specified in ASME B16.25 or any
other end preparation which meets the Welding Procedure
Specification are acceptable.
DOCUMENT NO. :
ISSUED DATE :

Construction
6.3.2. If piping component ends are bored, such boring shall not result in
the finished wall thickness after welding less than the minimum
design thickness.
6.3.3. If the piping component ends are upset, they may be bored to allow
for a completely recessed backing ring, provided the remaining net
thickness of the finished ends is not less than the minimum design
thickness.
6.3.4. Preparation of brand connection shall follow to Fig. 328.4.4. (ASME
B31.3) To Add Preparation of
Reinforcement Pad Works
(fit up, and Welding)
6.3.5. Drawing for template making brand connection see attachment I

6.3.5.1. Drawing Brand connection 32 x 16 inch
6.3.5.2. Drawing brand connection 32 x 20 inch
6.4. CLEANING to Deleted and input all information

to welding activity paragraph
Surfaces for welding shall be clean and shall be free from paint, oil, rust,
scale, or other material which is detrimental to welding.
6.5. ALIGNMENT AND TRIMMING

6.5.1. The inside diameters of piping components to be butt welded shall
be aligned as accurately as is practicable within existing commercial
tolerances on diameters, wall thicknesses, and out of roundness.
Alignment shall be preserved during welding. The internal mis
alignment of the end to be joined shall be according to the
approved WPS. 1.To Revised Alingment and
Trimming with Fit Up Works,
and Described all phased
activity during Fit Up the
Spools.
2. To add Dimension Control
Inspection prior to start
welding
DOCUMENT NO. :
ISSUED DATE :

Construction
6.5.2. When the internal misalignment exceeds the allowable, it is

preferred that the component with the wall extending internally be
internally trimmed per Fig. 328.4.3 (ASME B31.3).
6.6. SPACING Deleted and all information of spacing/gaps will

be placed to Fit up activity and welding
The root opening of the joint shall be given in the Welding Procedure
Specification.
6.7. FABRICATION TOLERANCES

6.7.1. The flanges mating to rotating equipment shall be no more
than 1/16 in. (1.5 mm) from being parallel to the
equipment flange, measured across any diameter. Also,
before bolt-up, the axial clearance between mating flanges
shall be equal with the initial gasket thickness 1/16 in. (1.5
mm). 1. to add 3-6 mm deep hole
on Reinforcement pad shall
be provided
DOCUMENT NO. :
ISSUED DATE :

Construction
6.7.2. The limits above shall also apply to all flanged joints made
with nonductile materials (for example, cast iron and
glass).
6.7.3. The lateral translation of flanges in any direction from the
specified location shall not exceed 1/16 in. (1.5 mm).
6.7.4. For all pipe sizes, the tolerances on linear dimensions shall
not exceed 1/8 in. (3 mm). Tolerances shall not be
cumulative
6.8. SOCKET WELD ASSEMBLY
In assembly of the joint before welding, the pipe shall be inserted into the
socket to the maximum depth and then withdrawn approximately 1/16
inch up to ¼ inch. (1.5 mm – 6 mm) away from contact between the end
of the pipe and the shoulder of the socket (See Fig. 328.5.2B). In sleeve
type joints without internal shoulder, there shall be a distance of
approximately 1/16 in. (1.6 mm) between the butting ends of the pipe.
Fig. 328.5.2B Typical Details for Double-Welded Slip-On and Socket Welding Flange Attachment
Welds
DOCUMENT NO. :
ISSUED DATE :

Construction
6.9. PREHEATING
6.9.1. Preheating, if required shall be in accordance with approved
WPS
6.9.2. Preheating temperatures are to be controlled using temperature
crayons or digital temperature.
6.9.3. Preheat shall be uniform and involve the entire weld preparation.
When electric resistance heaters are used, they shall be covered
with a minimum of 1 inch (25 mm) of insulation. Preheat shall
be verified with either thermocouples or temperature-indicating
crayons (for example, Temp sticks).
6.10. WELDING
6.10.1. GENERAL REQUIREMENT
6.10.1.1. Circumferential butt-welding shall be performed
without the use of backing ring. Back shielding with
argon gas shall be required according to the WPS.
6.10.1.2. The maximum inter-pass temperature shall be in
accordance with the approved WPS/PQR
DOCUMENT NO. :
ISSUED DATE :

Construction
6.10.1.3. Welding shall not be carried out in adverse weather

conditions where there is impingement of rain, snow,
sleet storm or excessive wind at the working area,
unless appropriate and adequate protection is
provided.
6.10.1.4. The bevel shall be fully cleaned so that there is no
rust, oil, paint, sand, moisture, etc. remaining. Care
shall be taken that stainless steel does not come into
contact with any form of zinc based material. Where a
bevel is not be welded immediately it shall be
protected to prevent contamination.
6.10.1.5. Spatter, slag, etc. on the weld or in the heat affected
zone shall be thoroughly removed from the metal
surface.
6.10.1.6. Arc strike on base metal shall be avoided at all time.
Arc strike if any, shall be ground flush and penetrant
test shall be provided.
6.10.1.7. Welding and heat treatment (preheating, PWHT) for a
welding end valve shall be carried out with the seat
opened to prevent seizing by thermal affect.
6.10.1.8. Weld internal protrusion at the weld neck joint of an
orifice flange, shall be removed flush and smooth with
grinder. Any concavity in the root shall be repaired
and than ground flush.
6.10.1.9. Socket welding shall be performed at least 2 layers
weld and end point of respective layer shall not be
over lapped.
6.10.2. WELDING
6.10.2.1. All welding work shall be performed by qualified
welders base on ASME Sect. IX and as per approved
Welding Procedure Specification
6.10.2.2. Establishing a badge system as per range qualification
shall identify all welders.
6.10.2.3. Tack welding shall be carried out as follows:
6.10.2.3.1. Either root or bridge tack welding
method may be applied.
6.10.2.3.2. Avoid improper fit-up which would cause
residual stress
DOCUMENT NO. :
ISSUED DATE :

Construction
6.10.2.3.3. Keep the correct root gap as per WPS.

6.10.2.3.4. Provide sufficient external pipe clamps
or internal spiders for setting up
6.10.2.3.5. Bridging pieces shall never be
hammered off and shall be removed by
grinding. The bridging material shall be
the same P numbers as the parent
material.
6.10.2.3.6. Tack Weld shall be performed by
qualified welders
6.10.2.4. Butt joint welding of the pipes shall be performed as
per WPS
6.10.2.5. Branch connection shall be welded as per drawing or
project specification, standard & code.
6.10.2.6. Fillet welding of pipe to slip-on or socket weld flanges
shall be performed as per Fig. 328.5.2B (ASME
B.31.3)
Fig. 328.5.2B Typical Details for Double-Welded Slip-On and Socket
Welding Flange Attachment Welds
6.10.2.7. All piping components for which welding has been

completed shall bear the painted marking with the
identification symbol of the welder as confirmation.
6.10.2.8. Spool piece no. shall be clearly marked on fabrication
and shall be have clearance inspection and heat
treatment (if any) before erecting to site.
to Add Paragraph Number for Leak Testing for Reinforcement Pad after
NDT
Where Paragraph for NDT
Activity and NDT
Requirements
DOCUMENT NO. :
ISSUED DATE :

Construction
6.10.3. HEAT TREATMENT

If any preheating required and PWHT work required by WPS ,
the heat treatment method shall be follow to procedure or
project specification.
6.10.4. Marking & Storing

6.10.4.1. All piping components where welding has been
completed, shall be the paint marked with the
identification symbol of the welder as confirmation.
6.10.4.2. Spool piece identification shall be clearly marked on
fabrication.
6.10.4.3. Inside of fabricated components shall be cleaned.
6.10.4.4. Openings shall be covered to prevent foreign matter
such as sand and dust etc. from entering into piping
components. Bevels ends, flanges faces and threaded
ends, shall be protected to prevent damage due to
cleaning work and handling of storing.
6.10.4.5. Pipe spool are to be neatly stored and are not to be
piled one on top of the other
6.10.4.6. Pipe spooling is to be kept unit segregated
6.10.4.7. Pipe is to be kept off the ground at all times and
stacked on correct type.
6.10.4.8. Flange faces are to be protected at all the time
7. ASSEMBLING AND ERECTION
7.1. GENERAL
7.1.1. Fit-up tolerances shall be kept as per WPS or project
specification.
7.1.2. If hot work to be performed in the vicinity of instrument control
or power cable duct, an adequate protective cover shall be
provided in advance so as not to damage the cables.
7.1.3. When work is carried out in the vicinity of piping made of, or
lined with special materials such as plastics, rubber, glass, etc.
care shall be taken so as not to damage them.
DOCUMENT NO. :
ISSUED DATE :

Construction
7.1.4. Valve shall be assembled in clean condition, they shall not be

opened during piping erection except that welding and heat
treatment or a welded valve joint shall be carried out with valve
opened.
7.1.5. Pipe shall be cleaned out spool by spool after fabrication.
7.1.6. Thermal straightening of pipe supports will not applied without
prior review and approval of procedure by Contractor.
7.1.7. Valves having flow direction shall be installed to conform the
flow direction in accordance with piping drawings. Care shall be
taken to the valves in case valve flow direction is reversed
against the flow direction of pipeline.
7.2. FLANGE JOINTS

7.2.1. Flanged joints shall be bolted up, after checking the alignment of
the flange centers and the parallel ness of flange faces, to
ensure that the contact faces bear informally on the gasket.
Bolting-up shall ensure that bolt tension is spread uniformly
around the flange.
7.2.2. Excessive stress shall not be allowed to the nozzles of rotating
machine when the flange of fabricated component is connected,
such work shall be carried out in the presence person in charge
of the mechanical work. And openings such as flanged joints of
a pump, compressor, etc. shall be kept covered with thin metal
plate or other solid blinds with handle to prevent dust and/or
foreign material from entering into the machine.
7.2.3. Particular care shall be exercised to insure that all bolt, nut and
gasket are correctly installed in accordance with procedure or
project specification.
7.2.4. Openings such as flanged joints of equipment shall be kept
covered with thin metal plate or other solid blinds with a handle
to prevent dust and / or foreign material from entering into the
machine.
7.2.5. The flange mating to rotating equipment shall be concentric with
and not more than 1.5 mm (1/16 inch) from being parallel to the
equipment flange, measured across any diameter. Also, before
any flange bolt-up, the axial clearance between mating flanges
shall equal to the initial gasket thickness  1.5 mm (1/16 inch)
DOCUMENT NO. :
ISSUED DATE :

Construction
7.2.6. Gasket in flanged connections that must be opened after testing

or cleaning shall not be reused. A new gasket must be installed
and any damaged bolting also replaced.
7.2.7. When installing spiral wound gasket, ensure that all flange faces
are completely clean. Do not use grease or gasket compound on
either gasket of flange faces.
7.2.8. Tightening sequence ( studs numbered clockwise around flange)
- 4 bolt flange : 1,3,2,4
- 8 bolt flange : 1,5,3,7,2,6,8,4
- 12 bolt flange : 1,7,4,10,2,8,5,11,3,9,6,12
- 16 bolt flange : 1,9,5,13,3,11,7,15,2,10,6, 14,12,8,16
- 20 bolt flange : 1,11,6,16,4,14,19,9,2,12,17,7,20,10,5,
15,3,13,18,8
7.2.9. Summary of Stud Bolt Tightening Requirements
Bolt Size Flange Rating Flange Rating

(Inches) Class 600 & Lower Higher than Class 600
5/8 Manual Torque wrench
3/4 Manual Torque wrench
1 & Larger Torque wrench Torque wrench
DOCUMENT NO. :
ISSUED DATE :

Construction
7.2.10. Summary of stud bolt tightening requirements
Nominal Dia. No. of Bolt stresses in MPA

of stud (mm) threads
or (inches) (per (1) (2) (3) (4) (5)
inches) 207 260 310 345 380
6.35(1/4) 20 5.4 7 8 9.5 11
7.95(5/16) 18 11 13.5 16 19 20
9.5(3/8) 16 16 20 25 27 30
11.1(7/16) 14 27 34 40 45 50
12.7(1/2) 13 40 52 60 68 75
14.3(9/16) 12 60 77 92 102 113
15.9(5/8) 11 80 102 122 135 150
19(3/4) 10 136 170 203 225 248
22.2(7/8) 9 217 270 325 363 397
25.4(1) 8 332 415 500 555 610
28.6(1 1/8) 8 480 602 723 803 883
31.8(1 ¼) 8 678 847 1017 1197 1243
34.9(1 ¼) 8 922 1152 1383 1535 1690
38.1(1 ½) 8 1085 1355 1627 1807 1990
41.3(1 5/8) 8 1490 1795 2237 2485 2735
44.5(1 ¾) 8 2035 2542 3052 4490 3730
47.6(1 7/8) 8 2710 3390 4067 4520 4565
50.8(2) 8 2985 3728 4475 4565 5468
57.1(2 ¼) 8 4310 5390 6467 7185 7905
63.5(2 ¼) 8 5965 7457 8948 9942 10937
70(2 ¾) 8 8025 10033 12040 13377 14715
76.2(3) 8 10465 13083 15700 17445 19188
7.2.11. NOTE
(1) following system hydrostatic, this is the minimum acceptable
torque for a flanged joint containing a spiral wound gasket.
(2) Recommended minimum for ASTM A 193 B7M stud Bolts.
(3) Recommended minimum for ASTM A 193 B stud Bolts.
(4) Recommended minimum for ASTM A 193 B7 bolts in system
operating at temperature of 500oF or higher.
(5) The torque data is based upon the nut bearing surfaces
being in good condition and the bolt threads and nut bearing
surfaces being well lubricated.
DOCUMENT NO. :
ISSUED DATE :

Construction
7.3. ASSEMBLY AND ERECTION TOLERANCES

7.3.1. The flanges mating to rotating equipment and air coolers shall
be no more than 1/16 in. from being parallel to the equipment
flange, measured across any diameter.
7.3.2. Flange bolt holes shall be aligned with 1/3 in. maximum offset.
7.3.3. Before bolt-up, the maximum axial clearance between mating
flanges shall equal the initial gasket thickness (+/-) 1/16 in.
7.3.4. Tolerances shall be attainable after all permanent supports and
guides have been installed between the equipment and the first
anchor point and after all temporary devices such as chain
blocks, come-a-long, etc. shall have been removed.
7.3.5. All piping shall be installed square and plumb, except where a
slope is required for drainage.
8. INSPECTION & TESTING
Prior, during, and after completion of the work of piping system , the inspection
and test shall be performed in accordance with procedure, inspection & test
plan (ITP) or project specification.
9. CLEANING OF PIPING SYSTEM

Piping systems shall be cleaned by one of the following methods :
9.1. Water Flushing
This is generally use on most lines, except for :
9.1.1. Steam Lines
9.1.2. Air Lines
9.1.3. Large diameter lines where a water velocity of 1.5 m/sec. ( 5
ft/sec.)
9.1.4. Piping systems where water is not permitted
9.2. Air Blowing
Generally used for air lines and other systems where water flushing is not
feasible
9.3. Hand Cleaning
Used for large diameter lines that can be manually
9.4. Used for cleaning of positive displacement compressor piping and certain
other systems requiring a high level of cleanliness
DOCUMENT NO. :
ISSUED DATE :

Construction
All flushing works (Water, Air Blowing, Hand Cleaning, Chemical Cleaning)
shall be follow to Procedure or project specification.
10. PAINTING & WRAPPING
All painting and wrapping works shall be performed as per procedure or project
specification
11. ATTACHMENTS
11.1.Attachment 1, Drawing Brand Connection 32x20 inch and 32x16 inch
1.To Add Work Flow Chart To Add Work Flow Chart

During Spool Fabrication @ During Spool Erection On
Site
Workshop
DOCUMENT NO. :
ISSUED DATE :

Construction
ATTACHMENT 1
Attachment Brand Connection 32 x 20 inch

DOCUMENT NO. :
ISSUED DATE :

Construction
Attachment Brand Connection 32 x 16 inch

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PIPING FABRICATION AND ERECTION PROCEDURE

ORIGINATED BY REVIEWED BY APPROVED BY DISTRIBUTION

Luqman/Dedy Ekka Luqman Hakim …………………….…

By Victor Tampubolon at 2:06 pm, Nov 10, 2022

UNIT ISSUING : PAGE REVISION

Team PT. LINDE INDONESIA

No. Descriptions Page

4.0 DEFINITION AND ABBREVIATION 3 OF 19

5.0 GENERAL REQUIREMENT 3 OF 19

7.0 ASSEMBLING AND ERECTION 12 OF 19

8.0 INSPECTION & TESTING 16 OF 19

9.0 CLEANING OF PIPING SYSTEM 16 OF 19

10.0 PAINTING & WRAPPING 17 OF 19

UNIT ISSUING : PAGE REVISION

Team PT. LINDE INDONESIA

PIPING FABRICATION AND ERECTION PROCEDURE

3.2 Specified Project Specification

4. DEFINITION AND ABBREVIATION

4.1. Client : PT. FI as user and owner, the authorized

UNIT ISSUING : PAGE REVISION

Team PT. LINDE INDONESIA

5.3. DRAWING AND DOCUMENT

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Team PT. LINDE INDONESIA

6.3. END PREPARATION

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Team PT. LINDE INDONESIA

6.3.5. Drawing for template making brand connection see attachment I

6.4. CLEANING to Deleted and input all information

6.5. ALIGNMENT AND TRIMMING

UNIT ISSUING : PAGE REVISION

Team PT. LINDE INDONESIA

6.5.2. When the internal misalignment exceeds the allowable, it is

6.6. SPACING Deleted and all information of spacing/gaps will

6.7. FABRICATION TOLERANCES

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6.8. SOCKET WELD ASSEMBLY

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6.10.1.3. Welding shall not be carried out in adverse weather

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6.10.2.3.3. Keep the correct root gap as per WPS.

6.10.2.7. All piping components for which welding has been

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6.10.3. HEAT TREATMENT

6.10.4. Marking & Storing

7. ASSEMBLING AND ERECTION

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7.1.4. Valve shall be assembled in clean condition, they shall not be

7.2. FLANGE JOINTS

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7.2.6. Gasket in flanged connections that must be opened after testing

7.2.9. Summary of Stud Bolt Tightening Requirements

Bolt Size Flange Rating Flange Rating