LARSEN & TOUBRO LIMITED - ECC DIVISION Procedure no

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QUALITY MANAGEMENT

PROCEDURE FOR AG PIPING FABRICATION & ERECTION

PROCEDURE NO. L&T/ KKRO / MECH / WP 05

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PROCEDURE FOR AG PIPING FABRICATION & ERECTION

CONTENTS:

1. PURPOSE

2. SCOPE

3. CONTROLLING SPECIFICATIONS

4. PROCEDURE

5. PAINTING

6. CHEMICAL CLEANING

7. INSPECTION

8. DOCUMENTATION

9. HEALTH, SAFETY & ENVIRONMENT (HSE)

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1.0 PURPOSE:
The purpose of this procedure is to provide guidelines to carry out the piping fabrication and
erection activity with proper Manner, Quality & Safety in schedule time.

2.0 SCOPE:
This procedure covers execution, inspection, testing and method of record keeping for
fabrication & erection of all Above Ground piping systems at site.

3.0 CONTROLLING SPECIFICATIONS:

 Process and instrument diagram.

 Piping materials specification.

 Piping support standards.

 Line list.

 Job specification of non-destructive testing of piping.

 Job specification of welding.

 Job specification for pressure testing of erected piping system.

 Welding specification for fabrication of piping.

 Job specification for fabrication & erection of piping.

 Job specification for shop & field painting.

 Specification for inspection, flushing & testing of piping systems.

 ASME B 31.3 process piping, ASME Sec.VIII, IBR, NACE MR-01-75.

4.0 PROCEDURE:

4.1 FABRICATION / ERECTION:

4.1.1 The complete piping work shall be carried out as per Approved For Construction drawings and
sketches. For piping falling under IBR, necessary approval of boiler inspector on the drawings

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shall be obtained prior to start of fabrication and all works shall be carried out as per the
requirement of IBR.

4.1.2 Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system
shall be strictly as per the BOQ for the pipe class specified for the system.

4.1.3 After receipt of approved drawings, detailed fabrication schedule shall be worked out by
Planning Engineer / Piping Engineer based on availability of drawings and material.

The approved ISO drgs. shall be marked with all the welded joints (shop & field) prior to
fabrication from following flow direction or left to right with a number to identify each weld in
sequence, VIZ 1,2,3…. and each line shall have the joint nos. in sequence, no joint nos. shall
be repeated in same line no. The marked up copy of the isometric will be made available for
planning / site personnel & QC dept. for co-ordination. Any addition joint in between two
joints if arises due to modifications of line, this joint will bear next continuation joint number
of previous joint like J 01.01, J 01.02, …-like this.
For butt joints, joint type will be "BW"
For branch joints, joint type will be '' BR".
For socket joint, joint type will be " SW".

4.1.4 Sequence of fabrication of piping spools shall be decided by the Planning Engineer / Piping
Engineer based on availability of erection front. Any change from the sequence can be made
by discussions and approval from Project In charge.

4.1.5 Only accepted material (inspected before issuing as per ITP) will be issued for fabrication,
however, in case of urgency material with positive identification shall be issued for fabrication
in absence of MTC. MTC shall be subsequently reviewed and accepted.

4.1.5 Material will be marked as per requirement of sizes and transfer the control no. On each piece
Dimensional tolerances for piping fabrication shall be as per standard. Site QAQC of PMC are
there take care of minor variations in the actual location (at site) of equipments, inserts,
structures etc.

4.1.7 Field welding of weld joint near the pumps shall be done only after pump and connected
piping have been truly aligned.

4.1.8 Welding of flange connection to pumps, turbines, compressors, cold boxes, air coolers etc.
shall be carried out only after the proper alignment of terminal equipment.

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4.1.9 Pipe material like C.S., Low Alloy steels shall cut to size by gas cutting or grinding machines
and stainless steel shall be cut by grinding or plasma arc cutting machine. The grinding wheel
used for SS works shall be identified separately.

4.1.10 Finished flame cut edges shall be smooth with no cutting oxides, slag or other cutting marks
such as drag grooves.

4.1.11 Root, face landings on flame cut bevel joints shall be ground axially square to the axis of the
pipe.

4.1.12 The cutting tolerance is based on the “Out of Roundness”. The tolerance in internal can be
adjusted.

4.1.13 Pipe joints type shall be as per approved drawing.

4.1.14 Fit up shall be done as per approved WPS / drg. For pipes of wall thickness 05mm and above
couplers, yokes or C clamps shall be used to maintain perfect alignment. For pipes of wall
thickness below 05mm edge tacking shall be done by a qualified welder because the tack welds
become part of the final weldment and shall be free from defects.

4.1.15 All piping spools shall be marked / stamped for proper identification like as line no., joint no.,
welder no., spool no.

4.1.16 Bending of pipe shall be done as per ASME B31.3. Cold bend for lines 1½ and below, with a
bend radius of 5 times the nominal diameter shall be used as required in place of elbows
wherever allowed by piping specifications.

4.1.17 Mitre bends and fabricated reducers shall be governed by the piping material specifications.
Generally all 90º mitres shall be 4-piece 3-weld type and 45º mitres shall be 3-piece 2-weld
type unless otherwise specified.

4.1.18 After completion of fabrication of spools, spools will be stored as per their grade and quality,
line no./ ISO no. at a dry place. Handling of spools shall be done in such a fashion that there
should not be any excessive stress and any damage to pipe.

4.1.19 After completion of NDT, SR, Hardness checks, the spools will be surface cleaned & primer
painted wherever applicable, and shifted to erection site. All joints after SR shall be identified
with a SR band.

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4.1.20 The erection of piping will be planned in such a way that the Minimum No. Of field welds
are encountered.

4.1.21 Slopes specified for various lines in the drawings/P&ID shall be maintained during erection
of piping spools.

4.1.22 Check the documents of the piping spools and identify the spools ready for erection by
suitable identification marks (isometric no, spool no to be painted and punched on the spool).

4.1.23 After erecting / placing of piping spools in position, it will be aligned to meet the
requirements and its orientation, levels, slopes, supports location, cold pool, expansion will
be checked.

4.1.24 PMI of piping system shall be carried out as per approved procedure.

4.1.25 Vents and drains, instruments and line mounted equipments / items shall be erected in
position as per approved lay out drgs. / P&ID and shall be checked for their tag no., flow
direction, orientation, location, etc.

4.1.26 Pipe supports will be provided at the location as per isometrics / pipe support index and
standard.

4.1.27 After hydro test pipeline shall be final painted or insulated whichever is applicable.

4.2 PREHEATING:

4.2.1 Minimum preheat temperature shall be 10 C.

4.2.2 Preheat will be applied with minimum as specified in welding chart or in 330.1.1 of ANSI
B 31.3 CHEMICAL & PETROLEUM REFINERY PIPING or as per established welding
procedure.
4.2.3 Higher pre-heat temperature can be used for particular fabrication procedures. These
temperatures will be depending on the carbon equivalent of the joint, welding process and
consideration for the control of distortion. Preheating will be applied to weldments by hand
held gas heating torch (for less dia & low thickness) or electrical resistance heating coils or
straps.

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4.2.4 All welding consumable such as electrodes, filler wires, flux and gas shall be stored,
baked , handled and used in accordance with the manufacturers instructions.

4.3 FILLER MATERIALS.

4.3.1 The welding electrodes and filler wires used shall be as per approved WPS / welding
specification chart and B.T.C. of electrode / filler wire shall be submitted to QAQC.

4.3.2 Electrodes will be baked in a master oven at manufacturers recommended temperature.

Electrodes issued for fabrication should be transferred to portable heating ovens in the
working areas. After a maximum working period, welders shall return all unused electrodes
from working areas into the main baking oven. Each welder will be provided with one
portable oven.

4.3.3 All welding filler wires issued to welding operators shall be handled in strict accordance with
the manufacturer’s recommendations. Particular attention should be made to wire used in
working areas, welding filler wires shall be kept covered at all times while in the fabrication
shop to avoid contamination by oil and grease or allow moisture to form rust on the wire. All
filler wires shall be identified by a colour coding system at both ends to avoid mixing of
wires at the time of welding.

4.4 SHIELDING & PURGING GAS:

4.4.1 Welding gases shall be supplied with analysis sheets showing the purity of the gas and
manufacturer shall certify it.

4.4.2 Purging shall be used as per approved WPS and be maintained during the root pass and for
the first filling pass to minimize oxidation on the inner side of the pipe, unless otherwise
specified in welding specification chart.

4.4.3
Initial purging shall be maintained for sufficient period of time so that at least 4-5 times the
volume between the dams is displaced in order to completely remove the entrapped air.
4.5 WELDING:

4.5.1 All welding shall be carried out by qualified welders as per approved WPS, welding
specification chart and approved drgs.

4.5.2 Welding technique / process (es) followed during welding shall be as per approved WPS.

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4.5.3 All root passes must be completed by one or more welders as a continuous operation.

4.5.4 Each layer of deposited weld shall be thoroughly cleaned before further deposits of weld
metal are commenced. When necessary the deposited metal shall be ground free of profile
irregularities. Particular attention shall be given to the toe of each layer of welding at the
junction to the fusion face of the joint to avoid slag traps or lack of fusion in subsequent
welding deposits.

4.5.5 All weld joints are defined as full penetration welds with a minimum of two passes.

4.5.6 A minimum of two passes shall be made in multi layer joints before welding stopped for any
reason.

4.5.7 Fillet joints shall be welded with a proper weld profile as per codes & Standards.

4.5.8 Peening shall not be used.

4.6 VISUAL INSPECTION OF WELDS:

4.6.1 During final examination, all temporary bridge attachments and welds located on the parent
metal shall be removed. Oxy-acetylene cutting and grinding can remove temporary
attachments. Any damage to parent material shall be repaired by welding and grinding.

4.6.2 All piping spools shall be checked for proper identification / stamping like as line no., joint
no., welder no., spool no.

4.6.3 Visual inspection of weldments shall include location and distance between all welds.

4.6.4 Finished weld joints must not have any surface porosity, spatters, under cuts etc…

4.6.5 Finished weld joints must have proper reinforcement, if fillet proper leg length and throat and
thickness shall be maintained.

4.7 HEAT TREATMENT OF WELD JOINTS:

4.7.1 PWHT, wherever required for weld joints shall be carried out as per the welding
specification chart/ codes.
4.7.2 PWHT procedure shall be submitted for approval.

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4.7.3 No welding / hot work shall be permitted after Post Weld Heat treatment (PWHT / SR).

4.8 INSPECTION, TESTING AND REPAIR OF WELD:

4.8.1 All NDT works like as RT, DPT, MPT, UT, PMI examination shall be carried out by
experienced / qualified personnel as per approved job procedures.

4.8.2 The application of above NDT for welding shall be as per inspection class mentioned in job
specification.

4.8.3 For spot or random Non – Destructive examination, the selection of joints shall be by Client /
L&T QC department if required. No repair of the joint is permitted without the knowledge of
Client/L&T QC department.

4.8.4 All repair work shall be carried out as per established welding procedure followed during
actual welding. Repair area of the weld can be removed by grinding according to the size,
depth, and location of the weldment.

4.8.5 The complete repair will have a specified appearance, which will meet the established
welding procedure specification and code inspection standards.

4.8.6 Welding repairs are unavoidable made on PWHT, and then complete PWHT cycle must be
repeated with a second heat chart.

4.8.7 After PWHT the hardness value on the weld, HAZ and parent metal shall be measured either
using Poldi type or portable digital hardness instrument wherever PWHT is applicable and
hardness requirement shall be as per welding specification chart.

4.8.8 All loops will be marked piping identification/flow direction / service by Execution engineer.
Execution Engineer will make Loop files. Execution engineer will do mechanical clearance
QC engineer will do NDT, PMI clearance.

4.8.9 The Hydro-testing of the loop shall be carried out as per the specification, class of piping.
The test pressure and holding time will be as specified in Isometrics / line schedule. After
Hydro-testing is complete the water will be vented first & drained off safely and pipelines
will be demarcated by painting “HYDRO TESTED” on the pipelines.
4.8.10 After draining lines/ systems shall be dried by air.

5.0 PAINTING:

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Painting of pipeline shall be carried out by approved procedure.

6.0 CHEMICAL CLEANING:

Generally chemical cleaning is recommended for stainless steel (SS) materials. The chemical
cleaning solution viz. degreasing, pickling and passivation shall be carried out as per
approved procedure. While handling the above solution care shall be taken to avoid any
mishap/accident and only specialised agencies shall be employed.

7.0 INSPECTION
The stage wise inspection shall be carried out as per approved ITP.

8.0 DOCUMENTATION:

Reports and documentation shall be maintained as per approved ITP & in the approved format
only.

9. HEALTH, SAFETY & ENVIRONMENT (HSE)

1> All necessary PPEs shall be available with all workmen.

2> Only trained & experienced workmen shall be deployed for this job.
3> Provide sufficient safety protection (like warning signs, barricading etc) around the working
zone.
4> Sufficient width of working platform & hand railing should be provided as per safety plan
when working at height

Note: Any conflict between the job procedure & contract documents, the later shall be followed.

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