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

1. PURPOSE

This procedure covers primarily the requirements for controlling the shop fabrication of steel piping for......

2. SCOPE

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.

3. Reference

3.1. Company SPECIFICATION

· 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

3.2. STANDARD DOCUMENTS

· 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

3.3. PROJECT Documents

· 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

4. RESPONSIBILITIES

4.1. CONSTRUCTION Manager

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.

4.2. PROJECT ENGINEER

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.

4.3. yard and fabrication 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,

4.4. PRODUCTION LEAD ENGINEER

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.

4.5. Yard / construction superintendent

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.

4.6. Yard Facilities superintendent

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.

4.7. CONSTRUCTION SUPERVISOR

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.

4.8. SUPERVISOR

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.

4.9. HSE

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.

4.10. QC Inspector

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.

5. RESOURCES

5.1. Equipment

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.

5.2. Personnel

Minimum personnel for each working shift as following:

· Supervisor

· Foreman

· Quality Control Inspector

· HSE Inspector

· Fitter

· Welder

· Labor /Helper

6. DRAWING ISSUE

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.

7. MATERIAL

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.

8. Fabrication

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.

9. INSPECTION

9.1. WELDER QUALIFICATION

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.

9.2. NDT REQUIREMENT

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.

9.3. Weld inspection

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.

9.4. IMPLEMENTATION OF painting RELEASE NOTE FOR BLASTING

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).

10. PACKING, TRANSPORT

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.

Saung Chipoet

Minggu, 06 Januari 2013

Sample Procedure Piping