Bekerja pada construksi oil and gas terutama dibutuhkan beberapa panduan yg disebut dengan prosedur , dibawah ini saya sharing satu contoh prosedur untuk PIPING FABRICATION pada sebuah plate form. Semoga bermanfaat
REVISION
TABLE............................................................................................................................ 2
TABLE OF CONTENTS................................................................................................................... 3
1. PURPOSE................................................................................................................................ 5
2. SCOPE..................................................................................................................................... 5
3. REference
documentS.................................................................................................. 5
3.1. Company SPECIFICATION.................................................................................................. 5
3.2. STANDARD DOCUMENTS..................................................................................................... 5
3.3. PROJECT Documents........................................................................................................ 5
4. RESPONSIBILITIES................................................................................................................ 5
4.1. CONSTRUCTION Manager................................................................................................ 5
4.2. PROJECT ENGINEER............................................................................................................. 6
4.3. yard and fabrication manager................................................................................. 6
4.4. PRODUCTION LEAD ENGINEER.......................................................................................... 6
4.5. yard / construction superintendent.................................................................... 6
4.6. yard Facilities superintendent................................................................................ 7
4.7. CONSTRUCTION SUPERVISOR........................................................................................... 7
4.8. SUPERVISOR.......................................................................................................................... 7
4.9. HSE yard coordinator.................................................................................................. 7
4.10. QC Inspector...................................................................................................................... 7
5. RESOURCES........................................................................................................................... 7
5.1. Equipment............................................................................................................................. 7
5.2. Personnel............................................................................................................................ 8
6. DRAWING
ISSUE.................................................................................................................... 8
7. MATERIAL
REQUISITION..................................................................................................... 8
8. fabrication........................................................................................................................ 9
9. INSPECTION......................................................................................................................... 11
9.1. WELDER QUALIFICATION................................................................................................... 11
9.2. NDT REQUIREMENT............................................................................................................ 12
9.3. Weld inspection.............................................................................................................. 13
9.4. IMPLEMENTATION OF painting RELEASE NOTE FOR BLASTING............................ 13
10. PACKING,
TRANSPORT..................................................................................................... 13
This procedure covers primarily the
requirements for controlling the shop fabrication of steel piping for......
Applicable to all steel piping fabrication processes, which the
fabrication will be carried out in safety manner and the quality of the product
fabricated and installed within specification and to be completed within
planning schedule.
· Piping Material
Class
· Steel Piping
Fabrication
· Welding of
Pressure Containing Piping and Equipment
· External Protection of Offshore and Coastal Structures and
Equipment by Painting
· External Protection
of Onshore Structures and Equipment by Painting
·
ASME
Section V Non-Destructive
Examination
·
ASME
Section IX Welding and
Brazing Qualification
·
ASME
B 31.3 Process
Piping
·
ASME
B 31.8 Gas
Transmission and Distribution Piping System
· Material
Control Procedure
· Dimensional
Control Procedure
· ITP
Fabrication/Erection Piping
· Inspection
and Test Plan Blasting Painting
· Routine
Lifting Procedure on Yard
· Non
Destructive Test (NDT)
· SPEC
– Piping Material Classes
The Construction Manager, reports to the Project
Manager. He is responsible to manage the overall fabrication yard activity. He
shall ensure and over see that the fabrication works is conducted within the
construction sequence and plan as per approved procedures, company
specifications and HSE requirements. He will also attend daily construction
coordination meetings between site installation, construction engineers, yard
fabrication and Quality Control; ensure that the equipment used to assist the
fabrication is fit condition, certified and ensure that tool box meetings are
performed as required.
He shall be an engineer with minimum five years
in construction work, knows about construction engineering and hazard of
construction. His duty is to handle a dedicated area or platform and
associated piping fabrication, off site piping, structure and piles. He acts as
the coordinator between engineering, material, yard, QA/QC, man power
resources, document control, production progress and safety. Ensure that the
work is carried out using the latest construction approved drawings, specifications
and standards, attend fabrication meetings and tool box meetings, communicate
with company inspectors, supervisors. He reports to the Construction Manager.
The Yard & Fabrication Manager will be authorized to all Yard &
Fabrication activities and is responsible for ensuring that all safety and
quality requirements are met.
He authorize to coordinate all fabrication aspects of the project and
interface with other project discipline (i.e. Engineering, Procurement &
Offshore) as required, coordinate establishment and management of the
fabrication planning, ensure integration of the activities of partners and/or
associates and subcontractors in the overall fabrication planning, and coordinate,
supervise preparatory activities for fabrication of the elements constituting
the works.
The Yard and Fabrication Manager also shall define the minimum stock of
consumable goods, tooling, welding accessories, etc., Ensure Maintenance and
periodic inspections of equipment, as defined by the equipment division, and monitor
the activities at fabrication yard,
Production lead engineer reports to
Construction Manager.
He is responsible to overall production
engineering activities on Yard and Site, and he shall ensure that all safety and quality
requirements are met.
He shall be an experienced person in
fabrication or field construction. His duty is to collect new work instructions
and dispatch the work to the fabrication supervisors, arrange fabrication
material from the warehouse, arrange the fabrication tools and equipment,
arrange the man power to its work location and report the work progress to
contractor’s planners. Perform daily coordination meetings with his
supervisor’s, coordinate with the fabrication yard safety officers on safety
issues and QA/QC inspectors as well. Close look to worker capabilities,
issuance of warning letters and push the work forward. Follow up immediately
any outstanding issue related to fabrication activities so that that to smooth
fabrication completion. He reports to the yard fabrication Manager.
Yard Facilities Superintendent is responsible
to supply activities and accomplishment of requirement on yard and site.
Yard Facilities Superintendent has authorize to
coordinate allocation of man power and equipment requirements on yard and site.
He shall ensure that all distribution of
equipment and facilities on yard and site has performed as required. He also
makes coordination with other department to ascertain availability of
inspection team, survey team, rigging team, scaffolding team as required on
yard and site.
Yard Facilities Superintendent shall make
coordination with Production Engineering to conform of availability of
materials, work schedule and any technical problems.
Construction supervisor is in charge of the
complete operation and responsible for the equipment and personnel. Perform the
fabrication work as per approved construction shop drawings, fabrication
procedures, specifications, and HSE requirement. He shall also be responsible
to run the overall HSE plan implementation at the fabrication yard. He reports
to the Construction Manager.
He shall be a steel piping fitter with more
than five years experience in steel piping fabrication. His duty is to collect
new work instructions and dispatch the work to steel piping fitters, arrange
fabrication material from the warehouse, arrange the fabrication tools and
equipment, arrange the man power to its work location and report the work
progress to contractor’s planners. Perform daily coordination meetings with his
piping fitters and welders; coordinate with the fabrication yard safety
officers on safety issues and QA/QC inspectors as well. Close look to worker
capabilities, issuance of warning letters and push the work forward. He reports
to the Construction Superintendent.
HSE Yard Coordinator is responsible for
monitoring compliance of overall HSE plan on yard, see contractors safety
management plan. He reports to the HSE Manager.
QC Inspector is responsible to carry out the
quality of the fabrication work as per ITP and approved procedures, company
specifications, and standard requirement see QC procedure. He shall control the
piping fit up, dimensional, welding visual check, NDE and to advise the piping
supervisor for any repairs necessary.
During execution of the work the minimum
equipment shall be in conformance with HSE requirement and Company
specifications.
The equipments to be used would be as follows:
·
Crane
·
Stagger capacity 3 T c/w chain block.
·
Cutting plate torch. (as required)
·
Welding machine or DC welding rectifier 400 /
600 Amp ( 5 ea )
·
Welding holders, cables, and other welding
accessories (as required).
·
Burners for preheating and temple stick up to
120° C.
·
Grinding machine (as required).
·
Welding gauges.
·
Special dog plate, steel triangle, metering
tape, etc (as required).
·
Sufficient sets of scaffoldings pipes, clamps and
planks for working on height.
Minimum personnel for each working shift as following:
·
Supervisor
·
Foreman
·
Quality Control Inspector
·
HSE Inspector
·
Fitter
·
Welder
·
Labor /Helper
Engineering issue approved construction drawing
(isometric drawing, general arrangement drawing and spool drawing) to Document
Control and Fabrication Yard Manager shall on receipt of the drawing register
from document control check that the fabrication drawings (isometrics, general
arrangement and spool drawing etc.) are the latest AFC issues.
Construction Manager shall then ensure
isometrics are itemized within the sequence according to the schedule and given
to the Engineering Dept. to produce shop drawing, spool production drawings and
other drawing such as weld maps and NDE plan drawings shall be ready before
cutting and fit up commencement.
Supervisor shall
issue material demand form to warehouse with approval of Construction Manager.
Upon received
the material, Supervisor shall verify the heat number or cast number
availability, visual check and dimensional of the material. He should transfer
the heat number on the surface of pipe/material where it may visible.
When there is a
shortage of quantity, clarification or feed back to engineering shall be
reported.
After the first
stage inspection completed, the receipt note shall be signed and all material
listed released for fabrication. Non compliance material or rejected material will
be hold in accordance with Material Control Procedur.
With respect to
welding electrodes a separate requisition shall be made to the Material
Controller to issue in accordance with the approved relevant WPSs by the
Welding Supervisor.
The respective drawings shall be issued to the
shop and pipe cut lengths shall be quoted.
When marking for cutting the heat/cast number
and MVR shall be transferred accordingly to each section of pipe prior to
cutting and witnessed by the QC Inspector or as required by the ITP. QC Inspector
will issue MVR and reviewed by CPY.
The weld preparations shall be made in line
with the appropriate WPS. The weld preparation shall be grinded or power
brushed to ensure the pipe or fitting and flanges weld bevels are clean from
any foreign materials, dirt, oil or grease etc. The QA/QC inspector shall check
the fit-up before welding, control during welding and verify the visual welding
and indicate of NDE requirement. In the case of Stainless Steel only special
discs for grinding and Stainless steel brushes shall be used or a pipe beveling
machine.
When setting up, if material is Stainless steel
then any carbon steel support frames shall be covered by wood/plywood so no
cross contamination contact can be made between the two materials.
Upon fabrication of Stainless steel spool, this
product will be stored to special place or covered by wood/plywood/canvas to
prevent contamination with carbon steel material. If the contamination is
happened, pickling will be performed. QA/QC inspector has to work closely with
Construction Supervisors for the record of the spools and proper tagging should
be done on every spools.
On setting up the butt weld clamps shall be
used to centre the pipe to fitting. Any excess misalignment shall be brought to
the attention of the Fabrication shop Supervisor and also the QC Inspector
before proceeding. If it is found to be out of tolerance then both pipe and
fitting will be checked again to the job specification. Whichever is found to
be incorrect then that item will be moved back to the stores and quarantined
while further checks are carried out.
If more than one item is received from the
supplier then the remaining items shall be given a further dimension check any
found to out of specification shall be segregated from the stock and put into
quarantine till the supplier sends a representative to review and clarify.
If at the weld alignment setup stage has finished,
the root gap which in accordance with the WPS is accepted by the QC inspector,
an approved welder shall be allowed to tack weld the joint. If welding is finished,
tack weld shall be removed by grinding and NDT checked. No report required for
NDT checked on tack weld (Tack weld cannot be perform on bevels and it is shut be
on pipe). QA/QC inspector should be the person to give the approval to commence
the welding and he will control during welding and after welding.
Dimensional tolerance shall be in accordance to spec
Welding shall be
carried out in line with the parameters as shown on the appropriate WPS and
particular notes made to any preheat requirements. WPS shall be approved by CPY
and in accordance with GS EP PVV 611.
Once the fit up is done the fitter shall be
made box by paint marker and the joint number to be indicate.
Supervisor/foreman to make sure the identification box mark beside each joint
and in the box should be mentioned joint number, fit up, root welder number,
capping welder number, NDT. Sample box as below:
Joint No.
|
|
Fit Up
|
|
Root No.
|
|
Capping No.
|
|
NDT
|
|
The QC inspector will follow up by fit up
inspection with client, write the fit up date and sign at the fit up box. Only
QC Inspector or client supervisor can fill the fit up date sign approved then only
fabricator can proceed with welding work. Welder or welding foreman will fill
the root/capping welder number box and NDT box will fill in by NDT Inspector
after NDT completion works. Fabricator to prepare fit up report with up date
required information and sign by all parties during inspection.
On completion of welding, the QC inspector
shall carry out a visual inspection, fabricator will prepare welding visual
report and sign by all parties during inspection. The spool shall be identified
by using steel tags with spool ID stamped and tied to the spool with wire.
Steel tags shall be removed during punch list and line check conformity. De pendant on the specific contract requirements welds will be submitted
for NDE examination. If any repairs required they shall be carried out in line
with the appropriate WPS and NDE procedure.
Upon finish fabrication of spools and
inspection release approved by both QC CTR and CPY, the spools will be moved
out to spool lay down area and under spool controller monitoring.
When all
inspections clear, spool controller will deliver for painting in line with the
contract requirements. See Procedure Surface Preparation and Painting Application,
On completion of
the Painting and clearance are given by QC, the piping(s) can be sent to the
packing, shipping and transport for installation area.
All reference
detailed shop drawings shall be submitted to Engineering for compilation of “As
fabricated” information in contract dossier.
Welder qualification shall be valid for one
year from last qualification performance date, beyond which re-qualification is
required. A validity period of two years may be considered if sufficient
evidences are shown that the related welder has regularly used the same welding
process and materials with no interruption exceeding six months.
Welding
inspection will be carry out as per .......... The extent of NDT
requirements other than visual inspection is defined in the table hereafter.
Table 1 - NDT Requirements
Service
Conditions
|
Hydrocarbons
(liquid or gas)
|
Utilities
lines
|
Pressure Class
|
≤300
|
≥600
|
≤600
|
≥ 900
|
Longitudinal Welds
|
C
|
C
|
C
|
C
|
Girth Welds
|
B(1) E
|
C F
|
A
|
C E
|
Socket Welds
|
E
|
F
|
None
|
E
|
Pressure- containing tee Welds such as pipe-to- pipe
conn as lateral tee is subject to 100% RT, slip-On flange welds, pipe
couplings, etc.
|
E
|
F
|
D
|
E
|
Non pressure-containing filet welds (attachments
welds to pressure containing parts)
|
D
|
E
|
None
|
D
|
General Notes for Table 1
A = Minimum 10% of random RT. Penalty 2
joints for every rejection affected for every isometric per diameter.
B = Minimum 10% of random RT. Penalty 2
joints for every rejection affected for every isometric per diameter.
C = 100% RT.
D = 5%
Magnetic Particle (MPI) or Dye Penetrant (DPI) Inspection.
E = 10%
Magnetic Particle (MPI) or Dye Penetrant (DPI) Inspection, RT 10% for gab checking
and can be lieu by alert gab metal during fit up witness by CPY.
F = 100%
Magnetic Particle (MPI) or Dye Penetrant (DPI) Inspection.
·
RT may be applied to check branch connection
such as “pipe-to-socket welding fitting” gap, with acceptance range is 1 ~ 3 mm
or ¾ depth pipe insertion in the socket weld fitting. Fit up shall be witnessed
by CPY when the gap clearance is not possible to be assessed by RT.
·
Extend of NDT :
Minimum 10% of random RT. Penalty 2 joints for
every rejection affected for every isometric per diameter up to 100% of the
percentage of repair.
·
A and B
= If the weld repair rate per welder exceed 5%, RT shall increase to 100% and
shall stay at 100% until the repair rate per welder drops below 5% and stays
there during 5 consecutive working days.
All basic
inspection tolerances shall be in line with those set out in the following
codes ASME Section V, ASME Section IX, ASME B 31.3, ASME B 31.8, and GS EP PVV 171
and also any project specific requirements.
Radiography joint
selection will be chosen by inspector based on percentage (refer to
Table-1) of total joint in the same isometric drawing number and sheet and the
total joints on all isometric should be equal to percentage agreed in contract.
Numbering of
additional joint in approved isometric drawing will be called following to the
number in between and take the small adjacent number as prefix and alphabet as
a suffix, e.g. : additional number between joint 2 and joint 3 will be numbered
as 2a, 2b, etc.
The release of
the spool for sandblasting/painting will only be done after applying with the
full requirements of NDE and plate/marking identification and will be issued
officially to COMPANY for review (implementation of Release Note for Blasting /
Painting).
Packing for
transport shall be done by ensuring all flange faces are properly protected with
Dioxide Aluminates and strong ply wood, weld preparations also have adequate
protection (plastic caps) and threaded connections plugged or taped. Any client
specific requirements shall also be carried out. Material to be secured accordingly
during transportation.
