STSSB/PCE/TA14/PF002

PIPING FABRICATION Rev : 2

PROCEDURE Date : 22/03/2014
Page : 1 of 7

PIPING FABRICATION
PROCEDURE

DEFECT RECTIFICATION WORKS

FOR PCESB TA 2014

2 22/3/14 ZULFADLI SHAHARUDDIN

1 16/3/14 FAIZUL ZULFADLI
0 25/2/14 JEFF ZULFADLI
PREPARED REVIEWED APPROVED
REV DATE CHECKED BY
BY BY BY
 STSSB/PCE/TA14/PF002
PIPING FABRICATION Rev : 2
PROCEDURE Date : 22/03/2014
Page : 2 of 7

TABLE OF CONTENTS

1.0 SCOPE
2.0 MATERIALS INSPECTION
3.0 REFERENCES
4.0 LAYOUT AND CUTTING
5.0 EDGE PREPARATION
6.0 FIT UP
7.0 WELDING
8.0 FINAL INSPECTION
9.0 SANDBLASTING AND PAINTING
10.0 DISPOSITION OF NONCONFORMITIES
 STSSB/PCE/TA14/PF002
PIPING FABRICATION Rev : 2
PROCEDURE Date : 22/03/2014
Page : 3 of 7

1.0 SCOPE
Piping fabrication shall be done in accordance with the provisions of the general specifications,
relevant codes, standards and customer’s specifications for the project.

2.0 MATERIALS INSPECTION

Material for fabrication was supply by owner.

3.0 REFERENCES

2.1 ASME section IX

2.2 ASME B31.3

2.3 ASME II

2.4 ASME VIII

2.5 PTS 31.38.01.31

4.0 LAYOUT AND CUTTING

4.1 Inspectors or supervisors shall ensure that site measurement must be taken prior
fabrication.
4.2 Allowance must be provided for cutting and grinding.
4.3 Fitter/foremen shall be mark out on the pipe to the dimension required before cutting.
4.4 Transfer the heat number of the material prior cutting.
4.5 Special requirement when working with stainless steel, used only iron free tool for
cutting, grinding, brushing, ect. Flaming cutting was prohibited to cut stainless steel.

5.0 EDGE PREPARATION

5.1 Checks that edge preparation for welding are of the correct shape and dimensions as
indicated in the approved client technical spec. or, Welding Procedure Specification
(WPS) id client spec. is not available.

5.2 All cutting, coping, beveling and shaping carried out by flame cutting equipment shall be
performed accurately using mechanical guidance system whenever possible. Where
location or position prevents the use of such system, all possible care shall be taken to
achieve an accurate and smooth edge.

5.3 All cutting used flame, plasma or grinding disc, edges are to be ground after cutting to
remove any irregularity.

5.4 Any edge create using flaming cutting shall be removed out oxide layer between 2 to 5
mm thickness
5.4 All sharp edges must round off except those where welding work to be carried out.
 STSSB/PCE/TA14/PF002
PIPING FABRICATION Rev : 2
PROCEDURE Date : 22/03/2014
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6.0 FIT UP

6.1 An accurate alignment and fit-up shall be achieved prior to welding and in all cases shall
be within the tolerance specified in the client tech. Spec. or Welding Procedure
Specification (WPS) if client spec. is none exist.

6.2 The use of weld attachments to aid fit-up shall be kept to a minimum. Where such
attachments are used, they shall be welded neatly. All such aids are to be removed after
use without damage to the parent metal and the profile restored by grinding without
undue delay. Insert filler rods to reduce root gaps or penetration weld are not allowed.

6.3 Use correct welding consumable during fit up activities as per approved WPS>

6.4 All structure connections/erection shall be held to plan and elevation dimensions site
measurement. ISO drawing in Joback just to aid fabrication and installation process/flow.

6.5 Weld matrix shall be provided at every joint. Only for pipe NPS 2 and above. (refer
attachment 1)

7.0 WELDING

7.1 All welding is to be carried out in accordance with B31.3 and approved WPS expect as
modified by the customer’s specifications.

7.2 Edges shall be smooth, clean and are free of rust, oil, grease and other organic materials

73. Only qualified welders for a particular welding procedure are allowed to perform
welding.

7.4 Welding variables such as type, size and conditions of electrodes, current, voltage,
polarity, temperatures, speed of travel, etc shall be in accordance with the approved WPS.

7.5 Use only correct welding consumable as per approved WPS. If process GTAW was used,
ensure the filler was free from contamination and WST.

7.6 Visual inspection shall be conducted on all welds for possible surface undercuts, pinholes
or shrinkage cavities, cracks, etc.

7.7 Visual inspection shall be performance by welder on the root pass after cleaning prior
going to the subsequent pass.

7.8 When coping are used to achieve full penetration, such coping shall be filled or blanked
prior to blasting and painting.

7.9 Storage, issue and handling of welding consumable shall be in accordance with approved
practice.

7.10 All welds shall be clean. Weld spatter, rough edges, slag and arc strikes shall be removed.
 STSSB/PCE/TA14/PF002
PIPING FABRICATION Rev : 2
PROCEDURE Date : 22/03/2014
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8.0 FINAL INSPECTION

8.1 After complete fabricated, pipe spool shall be dimensionally checked as a reference for
redline drawing in final documentation.

8.2 Inspect appearance and workmanship of the finished items.

8.3 As surface defect during visual inspection shall be repair accordanly to meet ASME
B31.3 and client specification.

8.4 Complicated Components that are to be installed/connected in the field, shot trial fit is
highly recommended prior to sending out to site.

8.5 NDT to be carried out if necessary, and all defect form NDT result shall be repair.

8.6 Some of pipe spool to be hydrotest after all documentation and NDT requirement are
completed.

8.7 Fabricated product is allow to leaved fabrication shop for delivery to site only after
inspected by QC inspector or production supervisor and meets the quality requirements.

9.0 SAND BLASTING AND PAINTING

9.1 All surfaces to be blasted shall be free of oil and grease.

9.2 After blasting, surfaces shall be kept free of all oil, grease, dirt and moisture until the
application of the protective coating. The same care shall also be taken prior to be
application of succeeding coatings.

9.3 Areas to be welded after the application of the coating shall be masked a distance of three
inches form weld area prior to coating.

9.4 All damage coating shall be repaired to the satisfaction of the in-house or, customer’s
inspector.

9.5 All sharp edges must be rounded off by filling or grinding prior to blasting.
 STSSB/PCE/TA14/PF002
PIPING FABRICATION Rev : 2
PROCEDURE Date : 22/03/2014
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10.0 DISPOSITION OF NONCONFORMITIES

10.1 Piping inspectors shall put a mark “OK” by either QC or production supervisor using a
chalk or permanent marker, items accepted after each stage of operation i.e., layout, fit-
up, full welding or assembly.

10.2 Non conformities shall be marked “HOLD” and a Non conformance Report (NCR)
prepared / issue to contractor / foreman immediately.

10.3 Copies if the Nonconformance Report shall be furnished to Customer’s Authorized

Representative, Project Manager and Workshop Manager for proper disposition.

10.4 If the disposition of the NCR is “Use AS Is”, the inspector shall change his markings
from QC “HOLD” to QC “OK”

10.5 If the disposition of the NCR is “REPAIR”, the inspector shall change his markings from
QC “HOLD” to “REPAIR”

10.6 If the disposition of the NCR is “REJECT”, the inspector shall immediately stamp a
“REJECTED” sticker and request Production Dept. to segregate the item(s) to an area
designated for rejects.

10.7 Repair procedure shall be prepared by Production Dept, and, shall be reviewed by QC
inspector and customer inspector. No repair work shall start until the repair procedure is
approved.

10.8 Repair items shall be inspected in the same manner as the original fabricated work.
 STSSB/PCE/TA14/PF002
PIPING FABRICATION Rev : 2
PROCEDURE Date : 22/03/2014
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Attachment 1

Weld Matrix

No DESCRIPTION

1 Joint No

2 Welder No

3 Fit up Date and Sign

4 Visual inspection date and sign

5 NDT date and result (RT/DPI/MPT)