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PROJECT : ENGINEERING, PROCUREMENT,

CONSTRUCTION AND COMMISSIONING
(EPCC) OF PGU-l GAS PIPELINE
REPLACEMENT PROJECT (GRAPHITE)

CLIENT : PETRONAS GAS BERHAD

CONTRACT NO. : PD&T/PGB/2019/326

DOCUMENT TITLE : PROCEDURE FOR PIPING FABRICATION

AND ERECTION WORKS

CODE 1

NO FURTHER COMMENT

1 27/08/2022 FINAL YGK HM MHMS MZA RBS NE

0 15/06/2021 FINAL HHH RJN MKAR SRS RKS SMS
Prepared Reviewed Approved Reviewed Endorsed Approved
By by By By By By
Construction Project Construction Construction Project
Engineer
Revision Date Description Manager Manager Engineer Manager Manager
MMCEC-MMCOG-SEW JV PGB
© 2021 PETROLIAM NASIONAL BERHAD (PETRONAS). All rights reserved. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of
the copyright OWNER.
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TABLE OF CONTENT

1. INTRODUCTION........................................................................................ 4
1.1 Project Overview ......................................................................................... 4
1.2 Purpose and Scope ...................................................................................... 5
2. DEFINITIONS AND ABBREVIATIONS ........................................................ 5
2.1 Definitions .................................................................................................. 5
2.2 Abbreviations ............................................................................................. 6
3. REFERENCES ............................................................................................ 6
3.1 Company References ................................................................................... 6
3.2 Contractor References ................................................................................. 6
3.3 Codes and PTS Standards............................................................................. 7
3.4 Order of Precedence of Reference Document .................................................. 7
4. RESPONSIBILITIES .................................................................................. 8
5. MATERIAL ................................................................................................ 9
6. METHODOLOGY ........................................................................................ 9
6.1 General ...................................................................................................... 9
6.2 Preparation and Material Receiving ................................................................ 9
6.3 Drawing and Document .............................................................................. 10
7. FABRICATION ........................................................................................ 10
7.1 General .................................................................................................... 10
7.2 Cutting .................................................................................................... 10
7.3 End Preparation ........................................................................................ 11
7.4 Alignment and Trimming ............................................................................ 12
7.5 Preheating................................................................................................ 13
7.6 General Requirement for Welding ................................................................ 14
7.7 Welding Rods ............................................................................................ 15
7.8 Welding ................................................................................................... 15
7.9 Identification of Joint and Numbering........................................................... 18
7.10 Identification of Spool Numbering ............................................................... 18
7.11 Storing & Inventory ................................................................................... 18
8. ASSEMBLING AND ERECTION ................................................................. 19
8.1 General .................................................................................................... 19
8.2 Flanged Joint ............................................................................................ 20
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9. OTHER PIPING SYSTEM .......................................................................... 20

9.1 General .................................................................................................... 20
9.2 Underground Piping ................................................................................... 20
9.3 Jacketed Piping ......................................................................................... 22
10. INSPECTION, EXAMINATION AND TESTING ........................................... 23
10.1 Extent of Inspection, Examination and Testing .............................................. 23
10.1.1 In-Process Inspection ................................................................................ 23
10.1.2 After Repair Inspection .............................................................................. 27
10.2 Non-Destructive Examination ...................................................................... 27
10.3 Blasting and Painting ............................................................................. 32
11. CLEANING AFTER PIPING ERECTION ...................................................... 32
12. WELDING REPAIR .................................................................................. 32
13. QUALITY ASSURANCE AND QUALITY CONTROL ...................................... 32
14. HEALTH, SAFETY AND ENVIRONMENT .................................................... 33
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1. INTRODUCTION
1.1 Project Overview
COMPANY intends to replace Existing NPS 36 PGU-I-Gas Pipeline with New NPS 36 PGU-I
Gas Pipeline (namely GRAPHITE) due to ageing facilities. New PGU-I pipeline will use better
route, eliminating hilly and graphitic soil via Loop 1 Right-of-Way (ROW).

The pipeline adapts like-to-like replacement including the pipe size of NPS 36, with length
of approximately 33 km from Gas Processing Kertih (GPK) until Bukit Anak Dara Kijal,
Kemaman. The works consists of Engineering, Procurement, Construction and
Commissioning (EPCC) of the facilities.

In general, the new pipeline will be installed alongside the existing NPS 36 Loop 1 Gas
Pipeline, NPS 12 Liquid Propane pipeline and two (2) x NPS 8 Liquid Butane pipeline. The
ROW varies from 90m then reduces to 40m width. Generally, the ROW corridor traverse
along light population village areas, railway & road crossings, palm & rubber estates and
hilly & undulating terrains.

The PROJECT will also involve scope of works as per following:

• Station piping tie-in points at KCS, B2, PK101, MLL104 and M1 Stations.
• Scraper launcher and receiver at B2 and M1 Station respectively.

In overall, FACILITIES for GRAPHITE project as illustrated below.

Figure 1: Right-of-way (ROW) of existing PGU-I and Loop 1

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1.2 Purpose and Scope

The purpose of this procedure is to describe the methodology (for pipe works design code
is ASME B31.8 for station piping and B31.3 for utilities line) and sequence to perform
fabrication and erection of station piping to meet the relevant requirements for the
construction of the FACILITIES and associated works for the PROJECT. The activities need
to be done as per outlined procedures in order to get a specified end product.

This document covers the procedure for fabrication and erection of station piping which
involves welding of branches, fittings and ancillary equipment to or from the mainline pipe
works at Scraper and Launcher Stations, Block Valve Stations and other relevant areas.

2. DEFINITIONS AND ABBREVIATIONS

2.1 Definitions
The following definitions are used as part of this document:

Term Explanation
COMPANY shall means PETRONAS Gas Berhad and as the project owner,
includes its representatives
CONTRACTOR shall means MMCEC-MMCOG-SEW Joint Venture which being
appointed to carry out the works in accordance with the Contract
SUB-CONTRACTOR shall means the Party to which CONTRACTOR has sub-contracted a
portion of the works under the Contract
VENDOR shall means Manufacturer/Supplier that manufactures or supplies
equipment and services to perform the duties specified by the
CONTRACTOR
FACILITIES shall mean all the equipment, pipeline, building and station related
details in this PROJECT
PROJECT shall means Engineering, Procurement, Construction and
Commissioning (EPCC) of PGU-I Gas Pipeline Replacement Project
(GRAPHITE)
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2.2 Abbreviations
The following abbreviations and terminologies are used throughout this document:

Acronym Definition
°C Degree Celsius
AFC Approved for Construction
DFT Dry Film Thickness
ITP Inspection and Test Plan
JHA Job Hazard Analysis
m Meter
mm Milimeter
NPS Nominal Pipe Size
PPE Personal Protective Equipment
PTW Permit to Work
PTS PETRONAS Technical Standard
QA / QC Quality Assurance / Quality Control
ROW Right of Way
SOW Scope of Work

3. REFERENCES
3.1 Company References

Ref. Document Number Document Title

1 GRAPHITE-PI-SPC-001
2 GRAPHITE-PI-SPC-002
3 GRAPHITE-PI-SPC-004
4 GRAPHITE-PI-SPC-006
5 GRAPHITE-PI-SPC-0010
Specification for Piping Material
Specification for Piping Design
Specification for Mechanical and Piping Installation
Works
Specification for Painting and Coating
Specification for Pipe Support

3.2 Contractor References

Ref. Document Number Document Title

6 GRAPHITE-DD-MMSJV- Piping Material Class Specification
KTHRO-PIP-SPC-001
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3.3 Codes and PTS Standards

Ref. Document Number Document Title

7 API Specification 5L Line Pipe
8 ASME B 31.3 Process Piping
9 ASME B 31.8 Gas Transmission and Distribution Piping Systems
10 ASME B 16.25 Butt Welding End for Pipes, Valves, Welding Neck
Flanges and Pipe Fittings
11 ASME B 16.5 Pipe Flanges and Flanged Fittings
12 ASME BPVC Section II Materials
13 ASME BPVC Section IX Welding, Brazing and Fusing Qualifications
14 API Standard 1104 Welding of Pipelines and Related Facilities
15 PTS 12.30.04 Pipe Supports
16 PTS 12.30.05 Shop and Field Fabrication of Piping
17 PTS 15.10.07 Specification for Linepipe (Amendments/
Supplements to API 5L)
18 PTS 15.12.04 Welding of Pipelines and Related Facilities

3.4 Order of Precedence of Reference Document

The hierarchy of Regulations, Codes and Standards applicable to engineering associated
with PROJECT is shown below:
a) PROJECT Specifications
b) PTS, including Standard Drawings and Standard Specifications
c) Relevant National and International Codes and Standards
d) Relevant Malaysian Law and Regulation, Local Authorities and By-Laws

Where conflict or inconsistency arises, it shall be brought to attention of COMPANY for

resolution whereby it shall be sought in accordance with main Contract agreement.
General practice is to adopt a more stringent design.
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4. RESPONSIBILITIES
The following describes the responsibilities of Contractor’s manpower to perform the
activities:

Construction Manager The construction manager shall be responsible for

ensuring that the works are managed and executed in
accordance with relevant procedures. He shall coordinate
with project planner, QA/QC and field engineer/supervisor
for implementation of this procedure. He shall ensure that
personnel are adequately trained, and that equipment is
fit for use to complete activities defined within this
procedure and project requirements.
Field Engineer The field engineer shall be responsible for the correctness
of the work to match the procedures and schedule. He
shall prepare and execute job planning documents that
define in detail the construction to be performed in
accordance to engineering procedure, drawing and
schedule. He is also responsible to review project planning
to improve on the completion date, if possible, during
implementation.
Supervisor The supervisor will be responsible for the overall
coordination and supervision of the activities. He will
provide the necessary information and liaise with PTW
Coordinator and responsible for applying the correct work
permits prior to commencement of works. The Supervisor
shall also be responsible for the overall implementation of
the Project Construction Plan.
Safety Officer The safety officer will be responsible for the
implementation of the HSE Plan and in compliance with all
statutory regulations that govern on all the activities
commenced at his assigned area. He will also be
responsible to conduct safety briefings and where
necessary initiating corrective action to maintain safety
performance.
QC Inspector The QC inspector will be responsible for control and
inspection of the work quality. He will inspect and ensure
that all the activities relevant to the works are in
accordance with the design, procedures and specifications.
Welding Superintendent He shall be responsible for job allocation and monitoring
/ Foreman welders, control and issue of welding consumables,
checking that all welding parameters confirms to the WPS,
conducting weld visual inspection and preparation of daily
welding progress report, attending repairs etc
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5. MATERIAL
All material shall comply with project requirements, specifications, specified codes and
standards and AFC drawings. CONTRACTOR shall submit full details, test report and
certificates for all materials delivered to site as evidence of soundness, that materials are
the origin and quality specified or approved.

6. METHODOLOGY
6.1 General
The works of all station piping is as per design code ASME B31.8 & ASME B31.3. (All station
piping works use ASME B31.8 and for utilities use ASME B31.3) i.e., fabrication and
installation of piping at stations, tie-in and tee-off. Welding Procedure & Welder
Qualifications for piping designed to B31.3 shall be ASME IX and designed to ASME B31.8
shall be either ASME Sec IX or API 1104.

Welding Procedure Specification and the Procedure Qualification Record as per GRAPHITE-
EXE-MMSJV-KTHRO-MEC-WPS-001: Welding Procedure Specification (PWPS) Piping shall
be obtained for welding work.

The fabricated spool pieces shall be prepared in such a way as to minimize the number of
field welds require to install the piping. All fabricated spool pieces shall be suitably marked
with identification of weld joints and spool, as per drawing prior to transportation from the
place of fabrication to the job site.

CONTRACTOR shall produce fabrication drawings and weld map prior commencement of
piping fabrication work.

The inspector nominated for the job must be a specialist or an expert in respective
examinations and licensed or qualified by an internationally recognized association and/or
by any statutory requirement applicable.

6.2 Preparation and Material Receiving

CONTRACTOR shall prepare temporary workshop(s) for pre-fabrication, fabrication, and
maintenance and testing of instruments/equipment, calibration etc., required for station
piping works.

All piping materials received at storage yard shall be checked physically about the size &
schedule, material grade, material test certificate, and quantity as per purchase order by
Material Controller.

The material test certificate shall be reviewed according to specification/standard and heat
no. / identification no. to confirm the identification and traceability.

Before installing the straight pipe at site, pipes directly shall be released for blasting and
painting. Painting shall be carried out as per respective painting system and approved
procedure.

Site engineer shall raise material request to stores for fabricating the respective spools.
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Site engineer shall issue a set of drawings which are to be fabricated. Piping engineer shall
prepare a weld map / cutting plans for all drawings whose materials has been issued in
Coordination with piping foreman or supervisor.

6.3 Drawing and Document

Drawing and document which cover the piping construction work shall be issued by
CONTRACTOR in accordance with “Drawing and Document List”.

Piping work shall be carried out with issued AFC drawing and document unless otherwise
specified. All the changes from approved AFC drawing, during shop fabrication and erection
at site will be captured and mark-up inside Redline mark-up drawing. This Redline mark-
up drawing will control by CONTRACTOR and shall be registered and initial by COMPANY.

7. FABRICATION
7.1 General
Fabrication requirement shall be in accordance with PTS 12.30.05, ASME B31.8 and API
STANDARD 1104 unless otherwise specified.

Fabrication shall be executed in accordance with the related Engineering Specification and
the drawings, document stated of this specification.

The bolt holes of flanges shall be located symmetrically from a vertical center line in a
horizontal pipeline, and from plant north in a vertical pipeline unless otherwise indicated
in the drawing.

7.2 Cutting
Cutting line shall be marked on pipe. Where the material marking will become invisible
after cutting, additional material marking shall be provided.

In the case of gas cutting, cutting surface shall be grind off to remove any edge and
roughness and be made flush and smooth so as not to harm welding quality. In the case
of automatic or semi-automatic gas cutter, the cut edge may be beveled without such
grinding off.

In the case of gas cutting, cutting slag stuck inside pipe shall be completely removed,
especially for boring of pipe for weld branch. For small diameter (less than 2inch) opening,
gas cutting is not allowed.
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7.3 End Preparation

End preparation for butt weld shall be in accordance with Table 7.1, or any other which
meets the WPS.

(1) Welding Bevels for Butt Welds

Table 7.1
Unit: mm
Thickness of Pipe Type of End Shape of Groove

t<3 I t

37.5 ±
25

t ≤ 22 V
t

1.6 ±
08

10 ±
25
37.5 ±
25

t > 22 Double-V
t
19 ± 2

1.6 ±
08

(2) Shape of beveling other than mentioned in Table 7.1 shall be in accordance with the WPS
approved by COMPANY.
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7.4 Alignment and Trimming

Root gap for butt-weld shall be in accordance with the WPS.

In the case of butt-welding pipe and/or fitting having unequal wall thickness, of which the
difference is more than 3 mm in outer surface and/or 1.5 mm in inner surface, the end of
the thicker pipe shall be trimmed by grinding as per the Fig. 7.1 (a), (b) and (c) shown
below. The gradient of this trimming shall be less than 30° between worked and unworked
parts shown as below.

Unit: mm
(a)
Max. 30° 3.0 or Over

≥ tm

(b)

≥ tm

1.5 or
Max.

(c)
In case
ultrasonic

≥ tm tm or Over

Max. 30°
1.5 or

tm : required minimum wall thickness of pipe

Figure 7.1

Note: In the case that “Special End Detail” is specified in the Material Specification for
the pipe and/or fitting of which the nominal wall thickness is 30 mm and over, the
end preparation shall be in accordance with such provision.
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Branch connections which abut the outside surface of the run pipe shall be contoured for groove welds
which meet the WPS requirements [see Fig. 7.2 (a) and (b)].

Branch connection which are inserted through a run opening shall be inserted at least as far as the
inside surface of the run pipe at all points [see Fig. 7.2 (c)].

g = Root gap per WPS

m = The lesser of 3.2 mm or 0.5 Tb

Figure 7.2
When a pipe having a longitudinal weld seam is used in a horizontal line, the pipe shall be
laid so that the longitudinal weld seam is not on bottom or top of the pipe. Allocation and
relation among circumferential and longitudinal welds are shown in the Fig. 7.3.

(1) Circumferential joint

Note: L1 shall be five times the pipe thickness or over.

Figure 7.3

7.5 Preheating
Preheating shall be performed by propane flame or by another appropriate method prior
to commencement of welding including tack welding. Any flame heating shall be applied
as evenly all round as possible, avoiding hot spots.

Temperature shall be measured by surface thermometer or temperature indicating crayon.

Inter-layer weld temperatures shall be kept the same as preheat temperatures until the
welding is finished.
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When welding dissimilar metals, preheat temperature shall be in accordance with WPS,
notwithstanding the provisions above. The preheat zone shall extend at least 25 mm
beyond each edge of the weld.

Welding work shall be continuous. If interruption is unavoidable, measures to avoid sudden

cooling shall be taken and reheating shall be carried out before starting to weld again.

7.6 General Requirement for Welding

Requirement and criteria for welding shall be as follows, unless otherwise specified in the
drawings:

a) Welding shall be performed in accordance with approved WPS.

b) 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.

c) The bevel shall be fully cleaned so that there is no rust, oil, paint, sand, moisture, etc.
remaining. Where a bevel is not to be welded immediately it shall be protected to
prevent contamination.

d) Spatter, slag, etc. on the weld or in the heat affected zone, shall be thoroughly
removed to the metal surface.

e) Arc strikes on base metal shall be avoided at all times. Arc strike shall be ground flush.
Any defect shall be ground out and weld repaired.

f) Material of wire brush shall be properly selected for working on carbon steel or stainless
steel respectively. They shall always be kept separated and never used on anything
other than the designation.

g) Welding and heat treatment (preheating, post heating, and stress relieving) for a
welded joint valve shall be carried out with the valve opened.

h) Weld internal protrusion at the weld neck joint of an orifice flange, shall be removed
flush and smooth with a grinder. Any concavity in the root, shall be weld repaired and
ground flush and smooth.

i) Socket welding shall be performed at least 2 layers weld and end point of weld at each
layer.

j) Welding of dissimilar metals shall be carried out at fabrication shop, if applicable, as

per AFC drawing.

k) Full GTAW shall be employed as an alternative to combined process (GTAW & SMAW)
for pipe either in sizes of 10 inch and smaller, with thickness 10mm and below or any
bigger diameter size with thickness 10mm and below.
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7.7 Welding Rods

Specific welding consumables use shall be referred to document no. GRAPHITE-CON-
MMSJV-KTHRO-MEC-PRC-005 Procedure for Welding Consumable Control and approved
Welding Procedure Specification (WPS).

7.8 Welding
Tack welding shall be carried out as follows:

a) Fit-up welding shall be performed in accordance with WPS.

b) Avoid wrong fit-up which would cause residual stress.

c) Keep the correct root gap by using spacers according to WPS.

d) Welding condition of tack welding shall be in accordance with WPS.

e) Provide sufficient external pipe clamps or internal spiders for setting up.

f) Ensure the contact surface of the clamps or spiders are made of the same base metal,
or an inert compound.

Butt joint welding of pipes shall be performed as follows:

a) Welding shall be performed in accordance with approved WPS.

b) Circumferential butt welding shall be performed without the use of a backing ring
unless specified in WPS.

c) Before welding of the root, both ends of the root tack weld bead shall be prepared with
a grinder as shown in the following illustration in order to make complete fusion.

d) Full GTAW process shall be applied for piping NPS less than or equal to 4”.

Figure 7.4
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Branch connections shall be made by using the fittings as specified in the PTS 12.30.05,
ASME B31.8.

However, where the branch is to be welded directly to the main run in accordance with
Piping Arrangement Drawing, welding shall be performed, unless otherwise specified,
shown in following Fig. 7.5:

Notes: 1. Throat thickness “tc” shall be of 0.7Tb (minimum 6.4 mm).

2. The symbols used in these figures are as follows:
Th: nominal thickness of run pipe
Tb: nominal thickness of branch pipe
Tr: nominal thickness of reinforcement pad
3. At first, weld part  and prepare the weld surface with a grinder, then weld the part ,
examine the weldment and repair if necessary.
4. Where reinforcement is necessary, it is indicated in the Piping Arrangement Drawing and
Notes for Piping Drawings.
Figure 7.5
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Fillet welding of pipe to slip-on and socket weld flanges shall be performed as shown in following Fig.
3.8.4:

Notes: 1. T: thickness of pipe.

t: thickness of flange hub
2. If 1.4 T is larger than t, t shall be taken.
3. If T is larger than 6.4mm, 6.4mm shall be taken.

Figure 7.6

Socket welding of pipe components other than flanges shall be performed as shown in
following Fig. 7.7.

Figure 7.7
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7.9 Identification of Joint and Numbering

Joint numbering shall be sequential to control and monitor different types of weld and to
track weld joint history. Piping foreman shall mark the joint number and welder
identification number with a weather resistant marking crayon / permanent marker at the
location adjacent to the join (ensuring that it shall not be erased due to welding) prior to
welding the joint.

The joint number shall be followed by a two letter, SW and for shop weld and FW for field
weld:

Example:
For shop weld
SW1: Shop weld
SW1R1: when joint repair first time
SW1R2: when joint repair second time (if the second repair is not acceptable, the complete
weld shall be removed or repaired subject to COMPANY approval)
SW1RW1: when welded joint cut and re-welded

For field weld

FW1: for original joint number
FW1R1: when joint repair first time
FW1R2: when joint repair second time (if the second repair is not acceptable, the complete
weld shall be removed or repaired subject to COMPANY approval)
FW1RW1: when welded joint cut and re-welded

7.10 Identification of Spool Numbering

All pipe spools piece fabricated need to tag with spool numbers identification (ID).

The identification number of spools shall be marked on spool suitably by permanent

marker prior to welding and also the spool shall be tied with identification tag. Spool ID
number shall be punched on either stainless steel or aluminum tag. Prior to release for
blasting & painting, the identification tag shall be tagged to pipe not to flange.

7.11 Storing & Inventory

All piping materials, valves and prefabricated spools shall be stored in such a way
preventing damage or entry of abrasive material in valve, damage of external paint and
misplacing. CONTRACTOR shall include the handling / store of the prefabricated spools
and activity of lifting pipe spools.

Valves shall be specially protected by end protective cover. Piping and valves shall be
covered by good quality of tarpaulin to prevent entry of dust, soil and rainwater. Fittings,
gaskets and instruments shall be store inside container storage with lock and key.

Welding consumables especially low hydrogen electrode once open shall be stored in
calibrated oven maintained at suitable temperatures recommend by manufacturer.

Make sure all pipes are securely kept on saddles to avoid moving.
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8. ASSEMBLING AND ERECTION

8.1 General
Prior to start fabrication and erection of all piping works for station scope of works, test
packages will be developed. Test packages system are purposely for controlling and
monitor piping station completion and smooth turnover process from construction to pre-
commissioning stage. Test packages will be developed from approved test block from P&ID
and isometric piping drawing. Two main criteria for developing test package are test
pressure and specification break which will be taken into consideration. During fabrication
and site erection all the physical reports related will be compile inside test packages.
Transition stage from construction to pre-commissioning (Hydrostatic testing), line check
will be done with COMPANY and all the punch lists will be recorded according to test
packages. Punchlist category A must be close prior to hydrostatic test (HT).

Before assembling of piping, actual tolerance causing from foundation, steel structure,
equipment installation work shall be considered for the piping assembling work.

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.

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.

Valves shall be assembled in clean condition; they shall not be opened during piping
erection except that welding and heat treatment of a welded valve joint shall be carried
out with valve opened.

If cutting, making of holes to the assembled piping and such kind of work is carried out at
assembled place due to the reason of modification, improvement, etc., cut piece and
foreign materials shall be removed from inside of piping and it shall be confirmed that the
inside of piping is cleaned.

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.

It is prohibited to use small size piping, pumps, instrument etc. as scaffolding or working
stage.

The following requirement shall be observed for piping support.

a) Pipe supports shall be fabricated and installed in accordance with Typical Pipe Support
Details.

b) As a rule, the location of pipe-supports shall be in accordance with the Piping

Arrangement Drawing and Hook-up Drawing.

c) The pre-setting pieces of the pipe hanger shall be removed after completion of leak
test of the pipeline. However, pipelines which will be insulated, it shall be removed
after completion of the insulation work.
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d) A shoe support shall be attached to the pipe in accordance with the drawings. It is not
permitted to tack-weld a shoe support to the pipe rack, where the shoe support is not
to be permanently fixed to the pipe rack.

e) When supports are installed on building or such kind of structure, permission of

installation shall be given by COMPANY before installation.

8.2 Flanged Joint

Any damage to the gasket seating surface which would prevent gasket seating shall be
repaired, or the flange shall be replaced.

Flanged joints shall be bolted up, after checking the alignment of the flange centers and
the parallelness of flange faces, to ensure that the contact faces bear uniformly on the
gasket. Bolting-up shall ensure that bolt tension is spread uniformly around the flange.

Particular care shall be exercised to ensure that all bolt, nut and gasket are correctly
installed in accordance with the requirements of GRAPHITE-PI-SPC-004 Specification for
Mechanical and Piping Installation Works.

When assembling flange connections, paste shall be applied to the gasket and bolts. These
prevent seizure of nuts and adherence of gaskets. Reference of pastes and their
applications shall be in Specific Job Requirement.

9. OTHER PIPING SYSTEM

9.1 General
Construction of the following piping systems shall be in accordance with the following
requirements in addition to the relevant section of Sect. 7 and 8 of this procedure
including, but not limited to, cutting, bending, threading, end preparation, branch
connections, preheat application, welding rods, and PWHT.
9.2 Underground Piping
Wrapping shall be performed as follows:

a) Underground pipe coating materials shall be in accordance with project specification

and approved procedure. Coating may be done at manufacturer’s yard or on the field.
Particular care shall be exercised at all times during handling and laying, so as to avoid
damage.

b) Then coating shall be applied to surfaces after they have been cleaned. The cleaned
surface shall be primed as soon as possible after inspection. If the surface is to be left
open to atmosphere, then protection from contamination by dust, oil, moisture etc.
shall be applied.

c) Wrapping and applicable inspection shall be carried out in accordance with

manufacturer’s instruction.
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d) A holiday detector shall be used during the coating to ensure the validity of the
application. All defects acquired during transportation or installation shall be repaired,
then retested.

e) All repair work to coating shall comply fully with the original installation requirements.

Excavation shall be performed in accordance with the following requirement:

a) Execution of works shall be started after pegging out and confirmation for the position
of trench to be excavated, referencing the appropriate benchmarks and ensuring the
route is sufficiently clear for safe working.

b) Before commencing the excavation work, it shall be confirmed that there are no other
buried objects around the place of excavation, and that the location proposed for the
excavated soil shall have no bearing load on the excavated trench.

c) Depth of buried pipes shall be in accordance with the piping drawing. Excavation work
shall be performed considering the safety aspects of the work, especially if the depth
of excavation is over 1.5 m in an unbattered trench. The piping work in the excavated
trench shall be carried out only after proper protective measures have been taken to
prevent the collapse of the excavated trench.

Laying of piping shall be performed as follows:

a) Before laying pipe is carried out, protective measures to prevent accidents such as
trench collapse or landslide, flooding, danger to workers in the area, etc. shall be taken
into full consideration.

b) During laying of piping, full care shall be taken to prevent soil, water, sand, etc. from
flowing into the pipes. Pipes shall be anchored sufficiently to prevent floating due to
groundwater or rainwater.

c) Bedding shall be installed to prevent subsidence or movement of pipes. Position and

method of piping support shall be as indicated in the drawings.

d) Underground pipes equipped with mechanical joints or sockets shall be sufficiently

supported to prevent the pipes from moving out of the position indicated in the
drawings.

To avoid any damage on wrapped surface of the piping, initial backfilling shall be carried
out with small-grain sand, for the part in direct contact with the pipes, as shown in Fig.
9.1.
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Figure 9.1

Where road crossings or the similar are specified in the drawings, particular precautions
shall be taken to ensure installation, testing, backfill and compaction are correctly carried
out.

Pipeline welds and mechanical joints shall not be placed at road crossing or the similar. If
such condition cannot be avoided, the joint shall be examined prior to back filling by
suitable examination.
If leak test for whole piping system at one time cannot performed, the system may be
divided into any blocks as block testing. However, the joint between block shall be
examined by suitable examination method instead of leak test.

9.3 Jacketed Piping

Assembling of piping shall be performed such that inner pipe of each section shall be
fabricated within proper length for assembling and then outer piping shall be fabricated.
Since fabrication of outer pipe must be such that leak test of inner pipe can be performed.

Fabrication of inner pipe shall be made separately within the extent which allows insertion
of outer pipe. Especially in case of three-dimensional bent components, separation of outer
piping components shall be carefully decided by taking the actual procedure of the work
into consideration.

Inner piping shall be leak tested before assembling of outer piping.

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Cutting of outer piping or other work which may influence bad effect to inner piping shall
be prohibited after assembling of outer piping has been completed.

Inside of outer piping shall be cleaned before its assembly.

10. INSPECTION, EXAMINATION AND TESTING

10.1 Extent of Inspection, Examination and Testing
Prior, during and after completion of the works, the following examination and tests shall
be performed:

10.1.1 In-Process Inspection

(1) Prior to Commencement of Work

Examination and Testing Acceptance Criterion

(a) Material check
(b) Welding Procedure Specification
(c) Electrode and welding consumable
To satisfy the requirement of Engineering Specification of
Piping Material refer to GRAPHITE-PI-SPC-001
To satisfy the requirement of Construction specification for
WPS & WPQR refer to GRAPHITE-PI-SPC-004
Material certificate (material name, brand).
To satisfy applicable codes and standards.

(2) Prior to Welding

(3) During fabrication and assembling

(1)
Flattening ratio and reduction of thickness acceptance criteria, which shall be decided in accordance with
practical conditions, shall not be applied for steam trace piping.
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Figure 10.1
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(4) After Welding

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(2)
Hardness test for P-No.1 carbon steel will not be required unless otherwise specified.

(5) After Completion of Work

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10.1.2 After Repair Inspection

When an unacceptable defect of welds is revealed, the following remedial action shall be
taken:

a) The repair shall be carried out, then the new work shall be re-examined in accordance
with this specification.

b) If the repair is again found to be unacceptable, then it shall be carried out once more.
Permissible number of welding repairs at the same place shall be a maximum of 2
(two). If a further repair is required, then a cut out shall be the sentence. The welder
concerned who made repair more than 3 times shall be retrained and re-qualified.

10.2 Non-Destructive Examination

The weld joints of piping shall be examined to the extent specified in Table 10.1 with the
following random examination procedure:

a) The examination made at random shall consist of examining not less than one
production weld joint selected from each production weld joint lot made by the same
welder or welding operator defined as follows.

The above each production weld joint lot means.

• each 20 production weld joints or less for 5 % random examination,
• each 10 production weld joints or less for 10 % random examination and
• each 5 production weld joints or less for 20 % random examination, respectively.

b) The examination shall be applied to the entire length of weld of the selected joint,
except as provided in (d) hereof.

c) The weld joints between dissimilar materials shall be examined by the method used
for the material requiring the more stringent examination.

d) Not less than one shot (with a 150 mm weld length) on one in each 50 girth butt weld
joints by each welder or welding operator for Category D Fluid Service as designated
in the Specific Job Requirements, shall be examined by the spot radiography.

When a random or spot examination of weld joints reveals a defect, the progressive
examination for the same lot defined in Section 10.1.2 shall be carried out as per the
following procedure:

a) Two additional weld joints of the same lot, by the same welder shall be given the same
type of examination; and

b) If the weld joints examined as required by (a) above are acceptable, all items
represented by this additional examination shall be accepted; but

c) If any of the items examined as required by (a) above reveals a defect, two further
weld joints of the same lot by the same welder shall be examined for each defective
item found by that examination; and
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d) If all the items examined as required by (c) above are acceptable, all items represented
by this additional examination shall be accepted; but

e) If any of the items examined as required by (c) above reveals a defect, all items
represented by the random examinations shall be fully examined and repaired or
replaced as necessary to meet the requirement of this specification.

f) The defective item(s) revealed during progressive examination, shall be repaired, or

replaced and re-examined at above each step as specified in Section 10.1.2.

The requirement for radiographic examination shall be as follows:

a) Film quality requirement shall be follows:

• Ultra-Fine grain film (Class I) for gamma-ray
• Fine grain film (Class II) for X-ray.

b) For P-No.3, 4 and 5, radiographic examination shall be carried out after completion of
any heat treatment. For P-No. other than the above, the examination for the weld
joints for which PWHT is required, shall be carried out before PWHT unless otherwise
specified.

c) Prior to the radiographic examination, the scattering radioactivity around the area shall
be measured and the controlled area of the radioactivity shall be established, providing
sufficient countermeasures to prevent hazard of radioactivity.

d) Radiographic examination by using Co 60 or Ir 192 will be instructed in accordance

with government regulations.

e) Number of films to be taken for one peripheral joint at radiographic examination shall
be as follows:
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Requirement for liquid penetrant examination shall be as follows:

a) Liquid penetrant examination shall be carried out at root pass for girth butt weld except
the weld which require preheating and at cover pass for branch weld, socket weld
attachment weld and girth butt weld require preheating.

b) Numbers for random examination shall be in accordance with Section 10.2 of this
procedure.

Magnetic particle and/or ultrasonic examination may be applied supplementary if the

welding quality cannot be assured at, or may be applied instead of, radiographic
examination or liquid penetrant examination if COMPANY decided.
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Table 10.1: Non-Destructive Examination Table (Refer to PTS 12.30.05 Shop and Field Fabrication of Piping)
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10.3 Blasting and Painting

Blasting and painting shall be carried out as per COMPANY approved procedure GRAPHITE-
CON-MMSJV-KTHRO-PIP-PRC-004.

All weld joints painting shall be done after hydro/pneumatic test.

11. CLEANING AFTER PIPING ERECTION

Cleaning work after piping assembling and erection shall be performed in accordance with
GRAPHITE-CON-MMSJV-KTHRO-PIP-PRC-002 Procedure for Piping Pre-Commissioning.

12. WELDING REPAIR

Welding repair work shall refer to WPS for Repair:

a) NDE Inspector / Welding Inspector shall trace the repair location from radiographic
film.

b) Welding foreman shall mark the repair location on the pipe through the tracing.

c) Welding foreman shall be responsible to allocate the suitable grinder and welder to
carry out the repair works.

13. QUALITY ASSURANCE AND QUALITY CONTROL

Quality assurance and quality control shall be as per checklist and corresponding ITP for
piping fabrication and erection works. The result of inspection shall be recorded in
designated weld traceability record summary.

CONTRACTOR shall give sufficient notice to COMPANY prior to joint inspection at least 24
hours’ notice.
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14. HEALTH, SAFETY AND ENVIRONMENT

The works will be monitored for compliance to the HSE Plan.
• All personnel shall strictly observe and comply to COMPANY’s Safety Regulations
and Occupation Safety, Health and Environmental Plan.
• All required PTW and/or certificate shall be obtained prior to work commencement.
Safety aspects shall be observed and followed strictly in accordance with the
approved JHA.
• HSE representative shall check the machineries and equipment prior entry to site.
Valid inspection sticker shall be updated and displayed at all time before and during
utilization.
• All personnel on site shall be provided with PPE that complied to COMPANY’s
requirement.
• Safe working platform must be provided for working at height. Fall protection
equipment must be used while working above 2m height.
• All personnel involved in work shall be briefed on site safety regulations and
potential hazards prior to work commencement.
• Good housekeeping practices shall be followed. Scrap and debris shall not be
littered in working area. It shall be collected and kept at designated dump location.

~ End of document ~