METHOD STATEMENT FABRICATION AND INSTALLATION PIPING SYSTEM AVIATION FUEL FARM

PT. SAFEMAX INDONESIA

GRAHA KOMANDO
Jl. Raya Cipinang Indah No. 1, Jakarta Timur
 Method of Statement
for Fabrication and Installation Piping System
Aviation Fuel Farm

Prepared By Reviewed By Approved By Distribution

Dade M Joni Hendri Fajar R.D M. Iskandarsyah

Engineer Const. Manager Project Manager Director

Brief Revision

Rev. Issued Date Effective Date

0 21 November 2023 22 November 2023

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 TABLE OF CONTENT
COVER ..................................................................................................................... i
METHOD OF STATEMENT......................................................................................ii
TABLE OF CONTENT.............................................................................................iii
1. General......................................................................................................... 1
1.1 Scope ...................................................................................................................... 1
1.2 Code ..........................................................................................................................1
1.3 Standard Unit ............................................................................................................ 1
2. General Requirement General.................................................................... 2
2.1 Qualification .............................................................................................................. 2
2.2 Material ..................................................................................................................... 2
2.3 Drawing and Document..............................................................................................2
3. Fabrication................................................................................................... 2
3.1 General..................................................................................................................... 2
3.2 Cutting...................................................................................................................... 3
3.3 End Preparation........................................................................................................ 4
3.4 Cleaning .................................................................................................................. 4
3.5 Alignment and Trimming .......................................................................................... 5
4. Assembling and Erection ........................................................................ 10
4.1 General................................................................................................................... 10
4.2 Flange joint ............................................................................................................ 13

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1 GENERAL
1.1 Scope
This method was created to explain the procedures that will be used in the
fabrication and installation of piping systems at the Dhoho International Airport
Aviation Fuel Depot Project. In addition, this method is used to ensure that the
work to be performed strictly complies with the requirements specified in the
specifications, procedures and related drawings.

1.2 Codes And Standard

This specification supplements or amends the requirements of document No.
23N001-DB-40-001 "Basic Piping Design of Dhoho International Airport
Aviation Fuel Depot Project" when applied.

1.3 Units
The metric units shall be applied as the measurement system in documents
and drawing. Nominal size piping components shall be measured in inches for
wich abbreviation of NPS.

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2 GENERAL REQUIREMENT
2.1 Qualification
2.1.1 Persons involved in welding work must pass a qualification test.
2.1.2 People involved in alignment, assembly, installation, etc. will be an
experience.
2.2 Material
2.2.1 All piping materials must comply with applicable codes and standads.
2.2.2 Temporary supports must not be welded to the pipe walls. If this cannot
be avoided, then the tactical area must be improved.
2.2.3 All selection of welding consumables must be in accordance with the
drawings and approved welding prosedures. Consumables should be
separated by type and stored according to the manufacturer's
recommendations. The welding electrode manufacturer certificate must
be archived and documented.
2.3 Drawing And Document
2.3.1 All drawings and documents covering pipe construction work must be
listed, published and controlled in accordance with the “Drawings and
Documents Control Procedure”.
2.3.2 Piping work must be carried out in accordance with drawings and
documents as “For Fabrication” or “For Construction”, unless otherwise
instructed.

3 FABRICATION
3.1 General
3.1.1 All materials for fabrication must be stored and protected from rain,
especially stainless steel.
3.1.2 Stainless steel should be kept separate from carbon steel fabrication
work.

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 3.1.3 Tools and equipment used in stainless steel fabrication must be coated
with a suitable stainless steel material (not affecting its properties) and
not used in other than stainless steel fabrication.
3.1.4 Bolt holes on the flange should be located symmetrically from the
vertical center line on the horizontal pipe line, and from the installation
to the north on the vertical pipe line unless otherwise specified on the
drawings.
3.1.5 Marking of piping materials must be in accordance with project
procedures or specifications.
3.2 Cutting
3.2.1 The piping cutting must be marked accurately according to the
isometric drawing.
3.2.2 Heat schedules and numbers must be trabsferred to all cuts (if
required).
3.2.3 In the case of gas cutting, the cutting surface mus be rounded to
remove edges and roughness and made flat and smooth so as not to
compromise the quality of the weld. The preparation angle must be
within code tolerances or welding procedure spesifications. If the
thickness is not to same, there should be no deviation in the corners
around the cut.
3.2.4 If pipe is cut using oxyacetylene process (for carbon steel pipe), all cut
edges must be rounded bact to eliminate draw lines or imperfections.
3.2.5 Abrasive discs used for cutting and grinding austenitic stainless stell or
other high Cr-Ni steels must be iron free.

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3.3 End Preparation
3.3.1 Final preparation for groove welding specified in the welding procedure
is acceptable.
3.3.2 If the ends of pipe components are drilled, the drilling must not result in
the final wall thickness after welding being less than the minimum
design thickness.
3.3.3 If the ends of piping components are damaged, the ends of the
components can be drilled to allow the support ring to be completely
recessed, provided that the remaining net thickness of the finished end
is not less than the minimum design thickness.
3.3.4 Preparation of branch connections follow the image below.

3.4 Cleaning
The welding surface must be clean and free from paint, oil, rust, scale or other
materials that interfere with welding.

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3.5 Alignment And Trimming
3.5.1 The inside diameter of pipe components to be welded must be aligned
as accurately as possible according to existing commercial tolerances
regarding diameter, wall thickness, and outside roundness. Alignment
must be maintained during welding. Internal misalignment of the ends to
be joined must comply with the approved WPS.
3.5.2 If internal misalignment exceeds the permissible limits, it is
recommended that components with internal longitudinal walls be
trimmed internally at a ratio of 4:1.
3.6 Spacing
Joint end openings shall be provided in the wealding procedure specifications.

3.7 Socket Weld Assembly

In assembling the joint prior to welding, the pipe should be inserted into the
socket to the maximum depth and then withdrawn approximately 1/16 inch (1.6
mm) from the contact between the end of the pipe and the shoulder of the
socket. In sleeve type connections without an inner shoulder, there should be a
distance of approximately 1.6 mm (1.6 mm) between the ends of the pipe.

3.8 Seam Welding Distance

If pipes having longitudinal weld seams are used in horizontal lines, the pipes
must be installed in such a way that the longitudinal weld seams are not at the
bottom or top of the pipe. The allocation and relationship between circular
welds, longitudinal welds and other welds (branches, supports, etc.) must be as
shown in the following figure :

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 3.8.1 Circular and longitudinal weld seams
The minimum distance must be five (5) times the pipe thickness or
more.
3.8.2 Branch pipes and welded lines on pipes
The minimum distance is six (6) mm or three (3) times the pipe
thickness, whichever is the smallest.
3.8.3 Suports / shoes and weld seams on main pipe seams.

3.9 Pre Heating

3.9.1 Preheating, if required shall be in accordance with the approved WPS.
3.9.2 The preheating temperature shall be controlled using a temperature
crayon or digital thermometer.

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3.10 Welding
3.10.1 General Requirement
3.10.1.1 Circular butt welding must be carried out without using a support ring.
Back protection with argon gas is required according to the WPS.
3.10.1.2 The maximum inter-pass temperature must comply with the approved
WPS/PQR.
3.10.1.3 Welding shall not be carried out in adverse weather conditions where
there is impingement of rain, sleet storm or excessive wind at the
working area, unless appropriate and adequate protection is
provided.
3.10.1.4 The bevel must be completely cleaned so that there is no remaining
rust, oil, paint, grit, moisture, etc. Care must be taken that stainless
steel does not come into contact with zinc-based materials of any
kind. If the bevel is not welded immediately, it must be protected to
prevent contamination.
3.10.1.5 Sparks, slag, etc. on welds or in areas affected by heat must be
removed completely from the metal surface.
3.10.1.6 Electric arc strikes on the base metal should be avoided at all times.
If an arc attack occurs, a ground flush and a penetrant test must be
carried out.
3.10.1.7 Welding and heat treatment (preheating, PWHT) for welded end
valves must be carried out with the seat open to prevent thermal
entrapment.
3.10.1.8 The inner protrusion of the weld at the weld neck joint of the hole
flange should be removed evenly and smoothly with a grinder. Any
depressions in the roots should be repaired and then leveled with
soil.
3.10.1.9 Socket welding must be carried out in a minimum of 2 layers of
welding and the end points of each layer must not overlap.

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3.10.2 Welding Requirement
3.10.2.1 All welding work must be performed by a qualified welder and
in accordance with the approved Welding Procedure
Specifications.
3.10.2.2 All welders must be identified by assigning a badge system
according to range qualifications.
3.10.2.3 Tack welding should be carried out as follows :
3.10.2.3.1 Either root or bridge welding methods can be
applied.
3.10.2.3.2 Avoid improper installation which will cause residual
stress.
3.10.2.3.3 Maintain proper root gaps as per WPS.
3.10.2.3.4 Provide adequate external pipe clamps or internal
spiders for installation.
3.10.2.3.5 Connecting pieces must not be hammered and must
be removed by grinding. The connecting material
must have the same P number as the parent
material.
3.10.2.3.6 Tack welding musk be performed by a qualified
welder.
3.10.2.4 Welding of butt joints on pipe must be carried out in
accordance with the WPS.
3.10.2.5 Branch joints must be welded in accordance with drawing s or
project specifications, standards and codes.
3.10.2.6 Shall be provided with marking welder identification as a
confirmation symbol.
3.10.2.7 The roll cut number must be clearly marked on the
manufacturer and must be welded on. Pipe filling into slip-on or
socket weld flanges must be done in accordance with
specifications, standards and codes.

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 3.10.2.8 All piping components have been welded, checked for
clearance and heat treated (if applicable) before installation on
site.

3.10.3 Heat Treatment

If preheating and PWHT work is required by the WPS, then the heat
treatment method must follow project procedures or specifications.

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 3.10.4 Storing
3.10.4.1 Inside of fabricated components shall be cleaned.
3.10.4.2 Opening shall be covered to prevent foreign mater such as
sand and dust etc. from entering into piping components.
Bevel and flange faces and threaded ends, shall be protected
to prevent damage due to cleaning work and handling of
storing.
3.10.4.3 Zinc contamination of stainless steel and high Ni-Cr Steaks
should be avoided.
3.10.4.4 Pipe spool should be stored neatly and stacked on top of each
other.
3.10.4.5 Pipe spooling is to be kept unit segregated.
3.10.4.6 Pipe is to be kept off the ground and stacked according to the
type of Dunn life.
3.10.4.7 Flange faces are to be protected at all the times.

4 ASSEMBLING AND ERECTION

4.1 General
4.1.1 Installation tolerances shall be maintained as per WPS or project
specifications. If hot work is carried out around electrical instruments or
controls.
4.1.2 Cable duct, adequate protective cover must be provided in advance to
avoid damage to the cable

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4.1.3 When work is carried out around pipes made of, or lined with special
materials such as plastic, rubber, glasss, etc., care must be taken not
to damage them.
4.1.4 The valve must be installed in a clean condition, it must not be opened
during pipe installation except welding and heat treatment or welded
valve joints must be carried out with the valve open.
4.1.5 Pipes shall be cleaned spool by spool after fabrication.
4.1.6 The following requirements shall be observed for pipe supports.
4.1.6.1 Pipe support shall be fabricated and installed in accordance
with pipe support details
4.1.6.2 As a rule the location of pipe supports shall be in accordance
with the piping arrangement drawing and hook up drawing
4.1.6.3 In case of spring hanger, travel stops are to be removed after
all hydro testing and flushing completed.
4.1.6.4 A shoe support shall be attached to pipe in accordance with
the drawing. Any tack weld shall not remain between shoe.
4.1.6.5 Support and bracket or pipe rack, unless shoe supports are
permanently fixed as anchor point.
4.1.7 Thermal straightening of pipe supports may be applied in accordance
with the following manner.
4.1.7.1 Torch heating or electric heating coils shall perform heating.
4.1.7.2 Using surface thermometer, temperature-indicating crayon,
etc., shall control heat input.
4.1.7.3 Only mechanical aids such as chain block, hydraulic jacks,
etc. shall be used, Shock loading by such as hammering shall
not allow.
4.1.7.4 Working temperature shall be determined depending on
material.

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4.1.8 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 reserved against the flow
direction of pipeline.
4.1.9 For all erection scaffolding shall be provided to permit safe work
condition. Especially for the worn on high elevation refer to safety
regulation.
4.1.10 All material for fabricate should be storage and protected from rain,
especially stainless steel.
4.1.11 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.
4.1.12 The flange mating to rotating equipment shall be concentric with and
not more than 1.5mm (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 1.5mm (1/16 inch)
4.1.13 Gasket in flanges 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.
4.1.14 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.
4.1.14.1 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

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 20 bolt flange 1,11,6,16,4,14,19,9,2,12,17,7,20,10,
5,15,3,13,18,8
4.1.14.2 The bearing surface of the bolt/nut is in good condition and
the bearing surface of the bolt and nut threads must be
coated with lubricant thinly and evenly so that is does not
become standed.
4.2 Flange Joints
4.2.1 Flange joints shall be bolted up, after checking the alignment of the
flange centers and the parallel ness of flange faces, to ensure that bolt
tension is spread uniformly around the flange
4.2.2 Cast iron flanges of equipment such as pumps shall be tightened
carefully so that the flange does to break
4.2.3 The flange clearance for the connections of pums, compressor, shall
be measured by the use of a clearance gauge (filler gauge). The
parallelism check and then the bolts tightened evently.
4.2.4 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 joint of a pump,
compressor, etc., shall be kep covered with thin metal plate or other
solid blinds with handle to prevent dust and/or foreign material from
entering into the machine.
4.2.5 Particular care shall be exercised to insure that all bolt, nut and gasket
are correctly installed in accordance with procedure or project
specification.

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4.3 Threaded Joints
4.3.1 The standard to be applied to all threads shall be ANSI/ASME B1.20.1
Pipe Threads (NPT).
4.3.2 Lubricant shall be removed completely from the thread and inside of
pipe after threading.
4.3.3 In a thread joint between pipe and flange, the length of thread on the
pipe shall be such that the end of the pipe is short of the gasket
surface on the flange by 1.5 to 3.0 mm when screwed in.
4.3.4 Threaded joint shall be sealed as per project specification.
4.3.5 High point vent used for hydrostatic testing only in process, flare and
fuel gas lines are to be seal welded after hydrostatic test. Seal welded
tow passes as a minimum are applied.
4.4 Mechanical Joint
4.4.1 Mechanical joint other than flanged joint and threaded joint shall be in
accordance with manufacturer’s instruction or drawing.
4.4.2 Care shall be taken to avoid distorting the sheet when incorporating
such joint into piping assemblies by welding.
4.5 Tubing Joint
The sealing surface of the flare shall be visually checked before assembly
and any flare having damage or imperfections ahll be rejected for flare tubing
joint.

4.6 Erection Of Pipe Support

Prior to pipe installation, supports can be installed and welded if possible. For
the U-Bolt type, it is best to install it during pipe erection, tightening the bolts
will be done after completion of the pipe route. Welding work directly on the
pipe (example, saddle,etc), shall be done before hydrostatic test. Installation
of spring support and adjustable support shall follow vendor spec/procedure.

4.7 Erection Of Under Ground Pipe

The erection of underground pipe is as follows:

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  Make sure dimensional and depth of ground excavation as per drawing
and check the surface refer the spec include the material will be applied
on the ground inside.
 Check document of spool piece have completed include inspection
report.
 Wrapping of coat for carbon steel pipe to be finish and inspection.
 Put the spool piece on the base and field weld joint to be located on the
upper ground level.
 Pilling upper by sand before back fill soil.

5 INSPECTION AND TESTING

Before, during and after completion of piping system work, inspections and tests
must be carried out in accordance with procedures, quality inspection scope lists or
project specifications.

6 CLEANING OF PIPING SYSTEM

Piping systems shall be cleaned by one of the following methods:

6.1 Water Flushing

This is generally used on most lines, except for:

6.1.1 Steam lines

6.1.2 Air lines
6.1.3 Large diameter lines where a water velocity of 1.5 m/sec (5ft/sec)
6.1.4 Piping systems where water is not permitted
6.2 Air Blowing
Generally used for air lines and other systems where water flushing is not
feasible.

6.3 Hand Cleaning

Used for large diameter lines that can be manually.

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 6.4 Chemical cleaning
Used for cleaning of positive displacement compressor piping and certain
other system requiring a high level of cleanliness.

All flushing works (water, air blowing, hand cleaning, chemical cleaning) shall be
follow to procedure or project specification.

7 PAINTING AND INSULATION

All painting and insulation works shall be performed as per procedure or project
specification.

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