FABRICATION PROCEDURE

Document No:STS/CLIENT2020/TP001/WP01 Revision: 01 Date: 5 February 2020

FABRICATION PROCEDURE
PIPING LINE NO.25-SA-4200-70622-1G101DA-N

PETRONAS REFINERY & PETRO CHEMICAL CORPORATION SDN.BHD.

FOR APPROVAL √

Name / Designation Signature Date Rev

Originator Mohd As Shahiddin Jafri
QAQC
Reviewed Mohd Farid Abu Bakar
00
Project Manager

Approved

FOR REVIEW

FOR CONTRUCTION
 FABRICATION PROCEDURE

Document No:STS/CLIENT2020/TP001/WP01 Revision: 01 Date: 5 February 2020

TABLE OF CONTENTS

1. INTRODUCTION

2. SCOPE

3. REFERENCE

4. SPECIFICATION

5. WELD SUMMARY

6. PREPARATION

7. FABRICATION PROCEDURE

8. RECORD & DOCUMENTATION

9. SAFETY

10. ATTACHMENT

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Document No:STS/CLIENT2020/TP001/WP01 Revision: 01 Date: 5 February 2020

1. Introduction
This document covers the sequence of activities for Fabrication, Erection and Installation Piping line: 25-SA-4200-70621-
1C127DA-N procedure Carbon Steels systems and to ensure the compliance to the above activities with the contractual
applications and HSE requirements in RAPID Project.

2. Scope
This procedure covers erection of piping work for Unit 4200 installation of piping for Acid Sulphur including preparations
work, lifting of pipe spools and pipe supports, fit-up and welding work, non destructive testing, radiography test, line check
and pressure test.This document also covers general HSE requirements while working inside live plant areas.

3. Reference
3.1 ASME B 31.1 Power Plant Piping
3.2 ASME B 16.5 Pipe Flanges and Flange Fittings.
3.3 ASME IX, 2015 Ed Welding and Brazing Qualification
3.4 ASME V, 2015 Ed. Non Destructive Examination
3.5 PTS 12.30.05 Shop & Field Fabrication Of Piping
3.6 PTS 15.12.01 Welding For Chemical Oil And Gas Industries
3.7 SA-4200M00450-70621-03 Isometric 1
3.8 SA-4200M00450-70621-04 Isometric 2

4. Specification
4.1 Piping Line No : 25-SA-4200-70621-1C127DA-N
4.2 Piping Specification : ASME B31.3
4.3 Operating Pressure : 5 BARG
4.4 Operating Temperature : 20.00ºC
4.5 Design Pressure : 8 BARG
4.6 Design Temperature : 80.00ºC
4.7 Material Specification : CARBON STEEL A106-B SCH 160

5. Preparation
5.1 Site visit prior to confirming dimension
5.2 Prior to start work at site, STS shall apply Permit to Work (PTW) from Area Owner for scaffolding, lifting and pipe
installation.
5.3 Submit Welding Inspection Control Sheet (WICS) together with WPS,WQT & Specific Repair Procedure to SRAIM
UF for review and approval.
5.4 Remove the existing pipe and cut using Air grinding to send at STS EDAC Workshop for fabrication
5.5 The pipe spools shall be erected as per isometric and AFC drawings. Horizontal position and alignments shall be
checked during cutting activities.
5.6 Supervisor to ensure proper housekeeping during and after completion of daily work activity at work place.

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Document No:STS/CLIENT2020/TP001/WP01 Revision: 01 Date: 5 February 2020

6. Fabrication Procedures
6.1 Material Inspection
6.1.1 All inspection activities shall be fully monitored by STS EDAC QC and witness by SRAIM UF / Third party
6.1.2 Perform material inspection as per below with SRAIM UF inspection team to ensure materials are free
from damage & in good condition check heat number & Material certificate.
NO DESCRIPTION MATERIAL GRED SIZE TYPE THK QTY
1 Pipe Sch160 SMLS A-106 Sch160 A-106 25 Carbon Steel 6.35mm 4
2 Pipe Sch160 SMLS A-106 Sch160 A-106 15 Carbon Steel 4.78mm 1
3 Reducer Ecc Sch 160 A 234 25 x 15 Carbon Steel 3.38mm / 4.78mm 2
4 Pipe Bend 90ºDeg 5D Tan Sch160 A-106 25 Carbon Steel 6.35mm 1
5 Flange WN #150 RF Sch160 A-105 25 Carbon Steel 6.35mm 1
6 Flange WN #150 RF Sch160 A-105 15 Carbon Steel 4.78mm 2

6.2 Bending
6.2.1 Pipe bending shall comply with ASME B31.3
6.3 Cutting & Beveling
6.3.1 Butt weld of pipe & Fitting shall be in accordance with ASME B.16.25 & ASME B31.3
6.4 Fit Up inspection
6.4.1 Ensure the alignment, gap, rating, type of material and sufficient tack weld are accordance to acceptance
criteria, ASME B31.3.
6.4.2 Tack weld shall be performed by qualified welder.
6.4.3 Refer to PTS 12.30.02 for flange misalignment acceptance criteria
6.5 Welding
6.5.1 Welding to be carried out as per approved repair procedure by qualified welder.
6.5.2 Acceptance criteria ASME B31.3.
6.5.3 Process : GTAW .Filler : ER70S-G
6.5.4 WPS No: STS/WPS/(M)001
6.5.5 Production welding shall comply to all essential & supplementary variables as per approved WPS.
6.6 Visual Inspection
6.6.1 Shall be perform after completed welding work.
6.6.2 See Table 341.3.2, ASME B31.3 for visual inspection acceptance criteria.
6.6.3 Machining or grinding methods shall be used. After cutting, cut surface shall be machined or ground
smooth.

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6.7 Weld Summary

DWG NO:SA-4200M00450-70621-01 SHT:01 REV:00
SW01 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW02 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW03 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW04 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW05 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW06 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW07 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW08 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW09 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW10 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW11 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW12 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW13 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
DWG NO:SA-4200M00450-70621-03 SHT:01 REV:00
SW01 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW02 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW03 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW04 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW05 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW06 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW07 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI
SW08 Butt Joint / Single V GTAW STS/WPS/(M)001 RT / DPI

6.8 Non Destructive Testing

6.8.1 Inspection and testing shall be carried out according to Inspection Test Plan (ITP).
6.8.2 Radiography Testing (RT) by PRPC third party.
6.8.3 Acceptance criteria as per Table 341.3.2, ASME B31.3.
6.8.4 100% visual examination on butt welded connection.
6.8.5 100% volumetric examination (RT/UT) on butt welded connection.
6.8.6 10% surface examination (DPI/MPI) on butt welded connection
6.8.7 If the result of NDT is unacceptable, remove the defect by grinding, repair and carry out NDT again.
6.9 Pressure Testing
6.9.1 Pressure testing shall be done at times 1.5 design pressure 12barg.
6.9.2 Hydrotesting is to be perform at STS workshop.
6.9.3 Pressure Test Form by SRAIM shall be used
6.9.4 Pressure test shall follow the approved procedure in accordance PTS 12.30.02
6.9.5 Pressure Testing Flow shall be holding 1st Step at 10min at 12barg / 2nd Step at holding shall be done at
pressure 24.00barg and hold for 1hour.

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6.10 Safety
6.10.1 Safe Operating Procedure For Grinding work
6.10.2 Stand-by fire extinguishers, fire water and a signage at the area of works.
6.10.3 Use proper tools, barricaded area, fire blanket and wear a proper PPE especially face shield and glove.
6.10.4 Supervisor / foreman must ensure that the work can only be started when no more hazardous gases
detected around the work and covered by approved permit.
6.10.5 Welding machine, gen-set, electrical power hand tools, torches, hoses and other electrical & fire producing
equipment must be checked and safe to use.
6.10.6 Welders and his assistant must wear a complete PPE.
6.10.7 Welders and his assistant must handle carefully the compressed gas cylinders.
6.10.8 When leaving the work area, turn-off the gas and all other electrical equipment.
6.10.9 Avoid jarring, dumping or dropping them and always secure it by tied it up to a stable structure and in the
position.

6.11 Record & Documentation

6.11.1 After completion fabrication & final acceptance of the repair work an inspection shall be made. The
Contractor's QAQC inspectors and the third party inspector / SRAIM UF representative shall both be
represented and they shall sign an agreed inspection report.
6.11.1.1.1 Fabrication Procedure
6.11.1.1.2 Inspection Test Plan
6.11.1.1.3 Material & Consumable Certificate
6.11.1.1.4 Welding Inspection Control Sheet (WICS)
6.11.1.1.5 Inspection Report
6.11.1.1.6 Welding Procedure Specification (WPS)
6.11.1.1.7 NDT Report inspection
6.11.1.1.8 Pressure Test Report Inspection
6.11.1.1.9 Pressure Test Calibration Certificate
6.11.1.1.10 Isometric

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Document No:STS/CLIENT2020/TP001/WP01 Revision: 01 Date: 5 February 2020

FIGURE: PIPING TOLERANCE

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 FABRICATION PROCEDURE

Document No:STS/CLIENT2020/TP001/WP01 Revision: 01 Date: 5 February 2020

FIGURE: PIPING FLOW

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