PROCEDURE FOR PIPING WORKS

Revision Document Number Page

IFI

PROJECT : CSTSR BIOGAS PLANT REPAIR AT KEDIPI MILL at PT MAYA AGRO

INVESTAMA (CARGILL)

LOCATION : AIR DEKAKAH , MANIS MATA , KABUPATEN KETAPANG , KALIMANTAN BARAT 78864

PURPOSED FOR : KEDIPI MILL ( PT MAYA AGRO INVESTAMA CARGILL GROUP )

 PROCEDURE FOR PIPING WORKS

Revision Document Number Page

IFI 1

TABLE OF CONTENTS

1 PURPOSE AND OBJECTIVES................................................................................................. 2

2 PIPE MATERIAL ..................................................................................................................... 2
3 PIPING ARRANGEMENT ........................................................................................................ 2
4 PIPE INSTALLATION ............................................................................................................... 2
5 STAINLESS STELL PIPE........................................................................................................... 3
6 TESTING PIPE ....................................................................................................................... 4
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1 PURPOSE AND OBJECTIVES

The design and installation of pipes used at the Biogas Plant as a medium for transport of
POME, Biogas and water. POME use HDPE pipe (PE100) and stainless steel pipe (SS304) for
Biogas. Transport of water utilize PVC pipes.

2 PIPE MATERIAL
The HDPE pipes for POME at the Biogas Plant are used particularly within the area of the Raw
POME Treatment System, Recirculation Pump and Sludge Effluent System. Biogas pipes are
used within the area of the Reactor Gas Ring, Venting Gas, Reactor Outlet, Scrubber, Heat
Exchanger, Blower, Gas Engine and Flare Unit. The pipes that are used to transport Raw POME
from the Palm Oil Mill to the cooling pond is placed underground, and flange is installed to be
used when the underground pipe rises to ground elevation. The selection of HDPE pipes for
POME fluids, and HDPE and Stainless Steel pipes for biogas is so that it can handle the
corrosive properties of POME and biogas. With the fluid pressure at the Biogas Plant reaching
a pressure of around 4 bars, HDPE (PE100) pipes has a maximum design stress of 80 bar to 100
bar and whereas Stainless Steel SCH10 is sufficient to handle the pressure stress.

3 PIPING ARRANGEMENT
Installation of pipes at the Biogas Plant must be arranged in a neat and orderly manner so to
avoid clash between pipes with pipes or pipes with cables. Pipeline arrangements made by
contractors must follow the drawings made by the Piping Designer and reviewed by the
Piping Engineer.
2D and 3D Drawing required includes:

 General Layout for Piping Plant

 Sectional Drawing for Ponds and Pumps
 Layout for Pipe Support
 Isometric Drawing.

4 PIPE INSTALLATION

The activity that follows after the engineering design are the procurement of materials and
installation of pipes. In order for all pipes, fittings and valves to be purchased to meet technical
specifications, such as type, material, size, dimension and quantity, a material take-out (MTO)
document is used as a document of reference to act as an offer to be made for Vendors.
At the stage of pipe installation, things that must be considered are:
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a. All required pipes, fittings and valves must match the data on the MTO
b. Pipe spool work can be done at workshops using an isometric drawing as reference
c. Determination of the type, size, location of pipe support must follow the Piping Support
Layout and Pipe Support Detail Drawing provided by the Engineering Team.
d. Installation of penetrate pipes at concrete pond must be carried out simultaneously
when casting concrete by ensuring the correct leveling of position and elevation of the
pipe / nozzle.
e. To ensure that a pipeline is installed correctly and accordingly, each coordinate points
and elevation must be checked using a guideline based on the 3D drawing and
isometric provided by the Engineering Team.

5 STAINLESS STELL PIPE

A. PREPARATION
a. The welding point will be determined by the appointed Engineer (in the form of the Isometric
spool Drawing) and will be submitted for approval.
b. The minimum inter-edge distance of two adjacent butt welds on the outer rings must be at least
25 mm or 4 times greater than the thickness of the pipe.
c. Before fit-up for welding, all pipes and fittings must be cleaned out on the inside to remove dust
and rust and other foreign contaminants (the ends of the pipes should be closed after cleaning).
d. Before welding work, the contractor must submit WPS & PQR for review and approval

B. CUTTING

Pipe cutting must follow the following direction:

1. Pipes must be accurately marked and then cut according to the dimensions shown in the
piping drawing or dimensions that are most suitable for field installation conditions.
2. If special deductions must be made for branch connections for either one or more, the
curved and miter part, the cut must then be done using a template (standard example /
guideline).
3. Preparation for the end of the pipe must be done by cutting work and forming the bevel
followed by grinding it out. Cutting using oxy-fuel welding is allowed only for non-
pigging line piping and continued with fine grinding process.
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4. Pipes with a large diameter cannot use high speed pipe cutters, so an alternated method
to be used is as follow:
Carbon pipes can be cut automatically or manually be done by acetylene oxygen gas
welding

C. FINAL PREPARATION WORK

1. The form of Grooves for welding must be in accordance with the welding process to be
carried out, and the contours formed must be able to accommodate the formation of
a perfect connection. In principle, all grooves must be produced in accordance with
the Welding Procedure Specification (WPS).
2. Carbon steel pipes and low alloy steel that have a wall thickness of less than 4 mm
must have a little chamfer at the ends.
3 . The ends of the piping components to be connected must be parallel and to be as
straight as possible with tolerances of pipe diameter and thickness according to Table
2 and ASME B16.9
Table 1: Factory-Made Wrought Buttwelding Fittings, and appropriate root face and root
gap tolerances made with the WPS and PQR Procedure specifications. If the end of the
piping component has an internal misalignment of more than 1.6 mm, the excess
thickness must then be cured at an angle of 30°, as shown in figure 5.1. The trimming
process must be done as smooth as possible, and the minimum thickness requested
must be maintained even though the trimming process has been done.

Figure 5.1 : Internal Misalignment

6 PIPE TESTING

In order for the pre-commissioning of the Biogas Plant to run accordingly, the installed piping
must first be tested. Testing may either be done by hydrotest or flushing method.
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The reference code used in the hydrotest follows ASME Section VIII Div. 1 Latest Edition (Rules for
Construction of Pressure Vessels) and ASME V Latest Edition (Non Destructive Examination). This
pressure test uses water to determine if any leakage is present within the pipe.

A. PREPARATION OF PIPE CLEANING

• Using cleaning fluids available on site, usually water and compressed air
• Prepare the tissue to be cleaned, this determines the volume of water used and the time
needed.
• According to the process function in the system, the POME piping network is cleaned
using water, while the biogas piping network will be cleaned using air.
• If possible the cleaning fluid must flow from top to bottom.
• The main header must be cleaned off before connection of piping network.
• Dead end must be avoided, if it is not possible to clean it separately
• Cleaning fluids may not pass through piping inside a heat transfer instrument unless it has
been cleaned off.
• Cleaning fluids must not pass through pumps and blowers. The network must be
separated first.
• To withstand the weight of a large diameter pipe, a piping support must be installed to
anticipate removal of it from the main line.

B. PIPE CLEANING PROCEDURE

• The area to be cleaned is determined depending on the progress of the construction
and the function of the area.
• The appropriate flow rate is first calculated. Select the appropriate speed between 3 m
/ s and 1.3 times the maximum speed of the process.
• Make a diagram of the designated area to be cleaned. To simplify reading during
implementation, color codes are utilized to indicate the cleaning process needed: blue
for the network to be cleaned, green for the removed network, red for the flange that
is removed, and any for the isolated area.
• Determined the site of source and disposal of water. This is related to the type and
location of the pump, or if any additional piping is needed.
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• Provide materials and tools needed, such as gaskets, flanges, pipes.

• The duration of the cleaning process is determined by the quality of the output water. The quality of
the water output must be of the same quality with the incoming water.

C. ACTIVITIES AFTER CLEANING

• After piping is reinstalled, valve orientation including ball, globe, butterfly and any valves
within the system must be checked.
• In-line instruments such as flow meters must be reinstalled.
• A new gasket must be placed at the site of the flange.
• Valve must be checked and replaced when and if necessary.