FABRICATION PROCEDURE

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

PIPE BENDING 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 procedure is intended to provide a detailed Types of Bending Processes and Equipment Used description of
shop cold bending operations of 1’” piping line:25-SA-4200-70621-1C127DA-N Sulphur Acid at unit 4200 UF 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 V, 2015 Ed. Non Destructive Examination
3.3 PTS 12.30.05 Shop & Field Fabrication Of Piping
3.4 SA-4200M00450-70621-03 Isometric 1
3.5 SA-4200M00450-70621-04 Isometric 2

4. Types of Bending & Equipment

4.1 Types bending - Cold Bending Method
4.2 Equipment Bending - 3 Roll Bending

5. Preparation
5.1 Bend 90ºdegree
5.2 Bend 45ºdegree

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

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

5.3 Safety
5.3.1 Before each use, inspect the Pipe Bender for bent or damaged components.
5.3.2 Check that bending die is correctly seated on ram and that the roller shafts are fully engaged in the frame
and pinned before operating hydraulic unit.
5.3.3 Regularly wipe down and clean the tool to keep it in best condition.
5.3.4 Keep hands away from die and rollers when bending pipe.
5.3.5 Use a qualified person to lubricate and maintain the hydraulic unit. Confirm that the recommended
hydraulic oil is used during maintenance.
5.3.6 DO NOT top up system with brake fluid. Use hydraulic oil only.
5.3.7 DO NOT operate the pipe bender if damaged. \
5.3.8 DO NOT exceed the rated capacity of the hydraulic unit
5.3.9 DO NOT use the pipe bender for purposes other than that for which it is intended.
5.3.10 DO NOT alter the settings of the pressure control valve. When not in use, store the tool in a clean, dry,
safe location out of reach of children and other unauthorized persons.
5.3.11 Ensure that you read, understand safety instructions before operating the pipe bender.With the hydraulic
unit release valve open and the ram fully retracted, fit the appropriate sized die to the ram.

5.3.12 Move pipe rollers and shafts to appropriate holes in frame and ensure that shafts are properly fitted and
secured using hitch pins. Stand-by fire extinguishers, fire water and a signage at the area of works.
5.3.13 Use proper tools, barricaded area, fire blanket and wear a proper PPE especially face shield and glove.

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

5.4 Record & Documentation

5.4.1 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.
5.4.1.1.1 Fabrication Procedure
5.4.1.1.2 Inspection Test Plan
5.4.1.1.3 Material & Consumable Certificate
5.4.1.1.4 Welding Inspection Control Sheet (WICS)
5.4.1.1.5 Inspection Report
5.4.1.1.6 Welding Procedure Specification (WPS)
5.4.1.1.7 NDT Report inspection
5.4.1.1.8 Pressure Test Report Inspection
5.4.1.1.9 Pressure Test Calibration Certificate
5.4.1.1.10 Isometric

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

STS/CLIENT2020/TP001/WP01