LIST OF CONTENTS

1. TITLE 3
2. SCOPE OF WORK 3
3. OBJECTIVE 3
4. REFERENCE 3
5. RESPONSIBILITY 3
6. WORK PROCEDURE 3
6.1. GENERAL 4
6.2. RECEIVING, HANDLING, STORAGE AND DELIVERY 5
6.3. INSTRUMENT CALIBRATION 6
6.4. INSTRUMENT INSTALLATION 7
6.5. LOOP CHECK 10
7. BASIC COMMUNICATION 11
8. SAFETY 12
9. ATTACHMENT 13
1. TITLE
Procedure for Piping Installation Works

2. SCOPE OF WORK
This procedure is to describe the minimum requirements for the piping materials
receiving, storing, installation, testing, inspection, and pre-commissioning.
The specifications given are adequate for the majority of applications. However, for
unusual situation, such as very high temperatures and/or pressure, corrosive
conditions etc., alternate procedure may be required.

3. OBJECTIVES
This is to assure that the installation of piping is done as per the specification
requirements, drawings and applicable codes. To make sure that all the works are
satisfactorily done, tested and accepted according to contract specifications.

4. REFERENCES
4.1. Applicable Manufacturers Manuals
4.2. Contract Specifications and Construction Drawings
4.3. Standard, codes and recommended practices

5. RESPONSIBILITY
5.1 The Engineer at site shall be responsible for the planning scheduling and
coordination, record and monitor progress of installation works, to guide the
supervisors in the field in terms of engineering and technical problems.

5.2. The Mechanical Superintendent shall be responsible for the daily construction
activities to coordinate with Area Supervisors and support The Supervisors in terms of
technical matters.
5.3. The Mechanical Supervisors shall be responsible to the respective superintendent
and carry out the direct field activities through the skilled and unskilled workers
according to the installation procedures and drawings.
6. WORK PROCEDURE
6.1 General

6.1.1. Field Engineers will ensure that they are in possession of the following
documents, prior to the commencement of construction activities:
 Applicable Engineer's specifications (Data Sheets)
 Applicable Owner specifications
 Vendor's/Manufacturer's installation instructions
 Applicable Engineer's installation drawings/construction drawing
 Applicable purchase orders

6.1.2. The work shall be done according to good workmanship by using the suitable
tools and material as stated in the construction drawing and procedures and it should
be studied before carry out any mechanical works.

6.1.3. Form reports which will be in the possession of Field Engineers and which will
be completed during the major construction activities.

6.1.4. Safety and Sanitation

Full care and pre-caution shall be given by the field management for the safety and
sanitation of workman in the field to prevent accidents during execution of the works.

6.2. Receiving, Handling, Storage, and Delivery

6.2.1. When receiving the piping materials and before delivered to the field it will be
subjected to the following inspections by warehousing:
a) Piping received will be uncrated and checked against the packing slip. Piping must
be categorized from dimension and material. Non ferrous piping must be placed at
shelter and avoid from UV radiation.
b) Piping will be visually inspected for any signs of damage as they are uncrated or
unpacked.
c) The quantity of piping shipped will be checked to confirm that it corresponds to
the quantity indicated in the purchase order.
d) The model, style or type of piping received will be checked to confirm that it
corresponds to the exact model, style or type of piping stated in the purchase order
and instrument specification sheet.
6.2.2. Piping materials shall be handled with care to ensure against mechanical and
moisture damage.

6.2.3. If the packing must be stored outdoors for a longer period of time it is very
important that the covering is kept unbroken. It is of course best to store the packing
indoors until it is time for installation.

6.3 Installation Method

6.3.1 Cutting
6.3.1.1 Cutting surface shall be ground off to remove any edge and roughness and be
made flush and smooth so as not to harm welding quality.

6.3.1.2 The angles of preparations shall be within the code tolerances.

6.3.1.3 If pipe is cut using the oxy acetylene process all cut edges is to be ground back
to remove any dragline or imperfections.
6.3.1.4 Plasma arc cutting may be applied for stainless steel. Plasma cut edge is to be
ground back to remove burnt areas and imperfections.

6.3.2 Alignment and Trimming

6.3.2.1 Root gap for butt weld shall be in accordance with the WPS.

6.3.2.2 In the case of butt-welding pipe and/or fitting having unequal wall thickness,
of which the difference is more than 3 mm at outer surface and /or 1.5 mm at inner
surface, the end of thicker pipe shall be trimmed by grinding or machining as show
bellow. The gradient of this trimming shall be less than 30 between worked and
unworked parts shown as bellow (refer to ASME B31.3. – para 328.4.3)

6.3.2.3 Alignment shall be to the pipe ID in all cases.

6.3.2.4 Stainless steel pipe shall not be torch heated to achieve alignment.

Max. 30
3.0 Or over

 Tm

(a)

 Tm

1.5 Or over
Max. 30

(b)
  tm

(c) Max. 30

Note: tm is required minimum wall thickness of pipe.

Refer to ASME B31.3 – para 328.4.3 and Fig 328.4.3 (Trimming and permitted
misalignment)
6.3.3 Preheating

6.3.3.1 Preheating, if required shall be in accordance with approved WPS.

6.3.3.2 Preheating temperatures are to be controlled using temperature crayons.

6.3.4 General Requirement for Welding

Requirement for welding shall be as follows, unless otherwise specified in the

drawings:

6.3.4.1 Circumferential butt-welding shall be performed without the use of a backing

ring. Back shielding with Argon Gas shall be required according to the WPS.

6.3.4.2 The maximum inter-pass temperature shall be in accordance with the approved
WPS/PQR.

6.3.4.3 Welding shall not be carried out in adverse weather conditions where there is
impingement of rain, snow, sleet storm or excessive wind at the working area, unless
appropriate and adequate protection is provided.

6.3.4.4 The bevel shall be fully cleaned so that there is no rust, oil, paint, sand,
moisture, etc. remaining. Care shall be taken that the stainless steel does not come into
contact with any form of zinc-based material. Where a bevel is not be welded
immediately it shall be protected to prevent contamination.

6.3.4.5 Spatter, slag, etc. on the weld or in the heat affected zone, shall be thoroughly
removed from the metal surface.

6.3.4.6 Arc strike on base metal shall be avoided at all time. Arc strike, if any, shall be
ground flush and liquid penetrant test shall be provided. Any defect shall be ground
out or repaired.

6.3.4.7 Welding and heat treatment (preheating, post heating and post weld heat
treatment) for a welding end valve shall be carried out with the seat opened to prevent
seizing by thermal affect.
6.3.4.8 Weld internal protrusion at the weld neck joint of an orifice flange, shall be
removed flush and smooth with grinder. Any concavity in the root shall be weld
repaired and ground flush and smooth.

6.3.4.9 Socket welding shall be performed at least 2 layers weld and end point of
respective layer shall not be over lapped.

6.3.4.10 Welding work shall be continuous. If welding must be interrupted, welding

groove shall be filled at least 1/3 of the wall thickness. Liquid penetrant examination
shall be performed prior to start the welding again. The continuation of welding shall
be according to the WPS.

6.3.5 Welding Consumable

6.3.5.1 Welding consumables shall be as stipulated on approved Welding Procedures.

6.3.5.2 Consumables are to be segregated as to type and to be stirred as the

manufacturer recommends.

6.4 Welding

6.4.1 Tack welding shall be carried out as follows:

6.4.1.1 Either root or bridge tack welding method may be applied.

6.4.1.2 Avoid improper fit-up which would cause residual stress.

6.4.1.3 Keep the correct root gap according to the WPS.

6.4.1.4 Welding condition of tack welding shall be in accordance with the WPS.

6.4.1.5 Provide sufficient external pipe clamps or internal spiders for setting up.

6.4.1.6 Ensure the contact surface of the clamps or spiders are made of the same base
metal or an inert compound.

6.4.1.7 Bridging pieces shall never be hammered of. Bridge pieces shall be removed
by grinding.

6.4.1.8 Bridging pieces if used are to be the same number as the parent material.

Tack welds shall be performed by qualified welders.

The alignment of butt joints and branch piping is to be done using pipe clamps on
tools in all cases.

6.4.2 Butt joint welding of pipes shall be performed as follows:

6.4.2.1 Welding shall be performed in accordance with WPS.

6.4.2.2 In case root tack welding before welding of root, both ends of the root tack
weld bead shall be prepared with a grinder as shown in the illustration below in order
to make complete fusion.

6.4.3 Fillet welding of pipe to slip-on or socket weld flanges shall be performed as
shown as bellow:

Notes:

1. Any excess weld protrusion into the bore of the pipe shall be removed by grinding
of filling to make it flush with the inside diameter, normal penetration weld bead is
allowable and can be left as weld
2. Front and back welds shall be applied. Face welds shall not be applied.
REMARKS: 1. T : nominal wall thickness of pipe
: nominal wall thickness of flange hub
2. Xmin shall be the lesser of 1.4 T or t
3. Ymin shall be the lesser of 6.4 mm

6.4.4 Socket welding of pipe components other than flanges shall be performed as
shown as bellow:
All socket welds will be completed with a minimum of 2 noses weld passes.
 Unit : mm

7. ASSEMBLING AND ERECTION

7.1. General

7.1.1. If hot work to be performed in the vicinity of instrument control or power

cable duct, an adequate protective cover shall be provided in advance so as not
to damage the cables.

7.1.2. When work is carried out in the vicinity of piping made of, or lined with
special materials such as plastics, rubber, glass, etc, care shall be taken so as
not to damage them.

7.1.3. Valve shall be assembled in clean condition, they shall not be opened during
piping erection except that welding and heat treatment or a welded valve joint
shall be carried out with valve opened.

7.1.4. Pipe shall be cleaned out spool by spool after fabrication.

7.1.5. The following requirement shall be observed for piping support.

7.1.5.1. Pipe support shall be fabricated and installed in accordance

with Pipe Hanging Details.

7.1.5.2. As a rule the location of pipe-supports shall be in

accordance with the piping arrangement drawing and hook-up drawing.
7.1.5.3. In case of spring hanger, travel stops are to be removed
after all hydro testing and flushing completed.

7.1.5.4. A shoe support shall be attached to pipe in accordance with

the drawing. Any tack-weld shall not remain between shoe support and
bracket or pipe rack, unless shoe supports is permanently fixed as
anchor point.

7.1.6. Thermal straightening of pipe supports may be applied in accordance with the
following manner.

7.1.6.1. Heating shall be performed by torch heating or electric

heating coils.
 7.1.6.2. Heat input shall be controlled by using surface
thermometer, temperature indicating crayon, etc.

7.1.6.3. Only mechanical aids such as chain block, hydraulic jacks,

etc. shall be used. Shock loading by such as hammering shall not
allowed.

7.1.6.4. Working temperature shall be determined depending on

material.

7.1.7. Valves having flow direction shall be installed to conform the flow direction in
accordance with piping drawings. Care shall be taken to the valves in case
valve flow direction is reversed against the flow direction of pipeline.

7.2. Flange Joints

7.2.1. Flanged joints shall be bolted up, after checking the alignment of the flange
centres and the parallel ness of flange faces, to ensure that the contact faces
bear uniformally on the gasket. Bolting-up shall ensure that bolt tension is
spread uniformly around the flange.

7.2.2. Excessive stress shall not be allowed to the nozzles of rotating machine when
the flange of fabricated component is connected, such work shall be carried
out in the presence person in charge of the mechanical work. And openings
such as flanged joints of a pump, compressor, etc. shall be kept covered with
thin metal plate or other solid blinds with handle to prevent dust and/or foreign
material from entering into the machine.

7.2.3. Openings such as flanged joints of equipment shall be kept covered with thin
metal plate or other solid blinds with a handle to prevent dust and / or foreign
material from entering into the machine.

7.2.4. The flange mating to rotating equipment shall be concentric with and not more
than 1.5 mm (1/16 inch) from being parallel to the equipment flange, measured
across any diameter. Also, before any flange bolt-up, the axial clearance
between mating flanges shall equal to the initial gasket thickness  1.5 mm
(=1/16 inch)

7.2.5. Gasket in flanged connections that must be opened after testing or cleaning
shall not be reused. A new gasket must be installed and any damaged bolting
also replaced.

7.2.6. When installing spiral wound gasket, ensure that all flange faces are
completely clean. Do not use grease or gasket compound on either gasket of
flange faces.

8. BASIC COMMUNICATION ON SITE

Basic communication if any installation and construction is not same with approval
document, CONTRACTOR shall be submitted document information to
EMPLOYER. The information letter shall be with:
 a. Information letter from CONTRACTOR to EMPLOYER with transmittal letter
completed with remarks, sign and stamp.
b. Recommended letter from vendor or manufacture
c. If any calculation sheets from vendor or manufacture
d. Actual picture take from site location
e. CONTRACTOR give information to EMPLOYER about change installation and
construction, this information still keep and for final result for “ AS-BUILT
DRAWING”

9. SAFETY
The CONTRACTOR shall only use competent and experienced personal to carry out
the Installation, construction, Inspection and testing activity.
Before commencement of any testing and check activity it must be established that
the equipment not energizes and all necessary safety precaution have been taken.
The CONTRACTOR shall comply with all safety regulations and from safety
induction.