Piping Installation & Fabrication

 

Piping Installation

1.      Piping installation or erection refers to the laying of the piping system and its related accessories to make for fluid transfer.

2.      Popper piping Installation following code and standard are the key to safety and good operation.

3.      The next step to piping fabrication where pipe spool made in the fabrication shop by cutting of the pipe as per accurate length and requirements.

Documents for Reference

·        Contract Documents

·        Standards Specification for Fabrication and erection of piping

·        Standards Specification for non-destructive examination requirements of piping.

·        Piping Materials specification.

·        Specification for Positive Materials Identification at site

·        Construction Drawing Latest Revision

·        Materials Specification

·        ASME code Pressure Piping -ASME-B31.3

·        Materials Specification: Welding Rods, Electrode & Filler Metal

Input required for Piping Installation

The main Input during refer during Piping Installation

1.      Structure Drawing

2.      P & ID

3.      Piping GA Drawing

4.      Piping Isometric Drawing

5.      Piping Support Drawing

P & ID is considered to be the heart of piping, they include, Pipe Line Number, Size of pipe, Materials and Insulation. Process Condition and Physical Data. Operation Condition, Stream Flow details, Equipment’s Number etc.

Piping isometric drawings with exact dimensions represents, line number, piping fittings, valves, flange, specials components and including a list of all fittings in the drawing etc.

Piping GA includes the main equipment of the plant, main piping items, fittings and valve Nozzle Orientation etc.

Procedure of Piping Installation

Piping Installation normally start after civil supports are Erected and   major type of equipment are placed on construction site.  Installation piping can we group into the following’s parts.

• 1.      Pipe work Erection.
• 2.      Installing Piping Flange & Support.
• 3.      Insulation and Painting.
• 4.      Marking and Identification.
• 5.      Installation Expansion joint.
• 6.      Vent and Drains.
• 7.      Underground Pipe Installation.

 

WPS/PQR & Welder Qualification

·        Proposed Welding Procedure Specification (PWPS) shall be submitted before star the work.

·        Client Inspector Will review and check and approve the Welding Procedure Submitted And shall release the Procedure for Qualification tests.

·        Procedure Qualification Record (PQR) & respective welding Procedure Specification (WPS) shall be prepared on the basis of test result and submitted to client for approval and then Production welding joint at site.

Welder Qualification.

·        Welder shall be qualified in accordance with the ASME Sec-IX code.

·        Only those welders who have been approved by the client inspector shall be deployed for welding.

·        The welders need to always have welder identification card.

·        If welder found to perform a wrong position and type of welding then client disqualified that welder.

Electrode & Filler

·        All electrode must be sealed containers and stored, after removing from seal containers shall be kept in oven holding at suitable temp.

·        The Electrode and filler wires used shall be free from rust, oil, grease which affect the quality of welding. 

·        Welding Consumable shall be controlled as per approval procedure.

PIPING Fabrication:

• 1.      Piping Materials
• 2.      Dimensional Tolerance
• 3.      Pipe Joints
• 4.      But Welded and Socket welded piping.
• 5.      Screw Piping
• 6.      Flange connection
• 7.      Branch Connection
• 8.      Miter Bend and Fabricated Reducer
• 9.      Cutting And Trimming of Standard Fittings & Pipe.
• 10.   Galvanized Piping
• 11.   Shop Fabrication.

1. Piping Materials:

·        All incoming materials shall be inspected as per approved ITP

·        Pipe, Pipe Fittings, Flange, Valve, Gasket, Stud Bolts etc all are check strictly as per PMS.

·        Materials Traceability shall be maintained for A.S, S.S, NACE, LTCS & transferring heat number.

·        Must be Colour Coadding for all piping materials as per procedure.

2.Dimensional Tolerance:

·        Dimension tolerance for piping fabrication shall be as per client standard. In order to adjust the variation in Dimension shown in AFC drawings & actual site, “Field Weld” shall be provided during fabrication.

·        Whenever error occur in drawings and bill of materials it shall be supervisor responsibility to notify the client.

3.Pipe Joints

·        Joining of line 2” and above in process and utility piping shall be pererered by butt weld.

·        Joining of line 1-1/2” and below shall be by socket welding/ Butt welding/ Threaded joints as specified in piping materials specification.

4. But Welded and Socket welded piping.

·        End preparation, Alignments and Fit-up of piece to be welded, Welding, Pre-heating and heat treatment (PWHT)shall be followed as describe in the welding specification chart.

·        NDT specification as along with tender documents

5.Screwed Piping

·        Galvanized Piping shall have thread as per ANSI B2.1.

·        Pipe thread shall be clean cut, without any burrs.

·        Threading of Pipe shall be done after bending or Heat treatment Operation.

·        During assembly of threaded joints, all threaded of pipe or fittings shall be cleaned.

·        The male threads shall be coated with thread sealant and the joint tightened sufficiently for leak proof joint.

6. Flange connection.

·        All Flange Facing shall be true and perpendicular to the Axis of the pipe to which they are attached.

·       Clean pipe flange, without forcing to bear uniform bolt tension and gasket compression & flange hole as per drawing.

·       Line item like orifice flanges, Spectacle blind, Strainer etc. shall be installed Following proper orientation.

·       A flange connection for the equipment’s shall be check for misassignment excessive gaps etc.

·       Extra care is to be exercised for flange connection to pump, turbines, cold boxes, air cooler.

·         Whenever a sceptical blind is to provided, Drilling and taping Jack screws in the flange shall be done before welding.

7. Branch connection: -

·        Branch connection with or without reinforcing pads shall be as indicates in the PMS.

·        For End preparation, Alignments, spacing, fit-up and welding and any of branch connection client guideline to be referred.

8. Cutting and Trimming of Standard fittings & pipe.

·        Component like pipe, elbow, Couplings, half couplings etc. shall be cut / trimmed edge preparation whenever required to meet fabrication and erection requirements as per drawings or as per client standard.

9. Shop Fabrication/ Prefabrication

·        The purpose of shop fabrication or pre-fabrication is to minimize work during the Erection.

·        Piping spool after fabrication stacked with proper identification marker on each spool.

·        During this period all flange raise face and threaded nee to be extra care and to avoid physical damage also.

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