MELAKA REFINERY PSR-2 REVAMP PROJECT LMS FOR PIPING FIELD FABRICATION AND ‘©C-3080-008-FF-020 INSTALLATION ‘JMS FOR PIPING FIELD FABRICATION AND INSTALLATION Cc-3080-009-FFI-020 FOR c¢-2080-009 MECHANICAL AND MAINTENANCE WORKS (PACKAGE A2) t aera a= Pick eae eed a a Le [as 2 [eae [vero [wun - fe ageea i | eaiecieommtnteteeee eee “TSFOR PPG FELD HISTORICAL REVISION SHEET Revo Rov-t | Change Tile ‘Comment from CONSULTANT and shall be revised Revised as per comment CONSULTANT. Rev Rev2 |conmerttomconsuiranT | eved specu ease conse BRICATION AND NSTALLATION| TOUGH FFTOLOara HANICAL AND MAINTENANCE WORK (AREA AZ) "DNS FOR PIPING FIELD FABRGATION AND INSTALLATION ‘TABLE OF CONTENTS 4. SCOPE 2, REFFERANCE 3. DEFINISION 10. PREPARATION [Link] Receipt and Storing 4.2Matorial Traceability [Link] Tolerances [Link] Roquiromont FABRICATION INSTALLATION REPAIR PROCEDURE (FOR WELDING DEFECT) 7.4. General 7.2, Ropalring for Stainless Stoo! 7.3. Repairing for Dissimilar Material 7.4. Base Metal Defect PAINTING WORK INSPECTION AND TESTING 9.1, WELD INSPECTION 9.2, PRESSURE TEST, CLEANING & DRYING FOR PIPING. DOCUMENTATION TOSS DOSFFT OIDCHANICAL AND MAINTENANCE WORK (AREA A2) a {WS FOR PING FELD FABRICATION AND INSTALLATION 1. SCOPE This procedure describes the method for field piping fabrication and installation work tobe applied for PSR2 REVAMP PROJECT. This method covers the following steps: > Preparation > Fabrication > Installation > Repair Procedure > Painting > Inspection and testing > Documentation 2. REFERENCE ‘All works shall be carried out in accordance wth the procedures, Spectcation and /\, Document Contract n Part B ofthe Contract Requisition including but no ited othe following: > APIRP 582 Welding Guitolnes or the Chemica, Ot and Gas industries, > ASME 831.3, Process Piping > ASME SEC. IX Welding and Brazing Qualifications > ASME SEC. V Non Destructive Examination > ASME 8165 Pipe Flanges and Flanged Fiting > ASME B109 Factory Made Wrought Steel Butt Welding Fiting > PTS31.38.01. 11 Piping General Requirements > PTS 30.1060. 18 ‘Welding of Metals > PTS31.38.01.91 ‘Shop and Field Fabrication of Piping > CC-8080-008:WCP-001 Welder Control Procedure For Construction > CC-3080-008:WRP-002 Welding Consumable Controt Procedure > [Link].003 Welding Procedure Specification > CC-8080.000-PHT-004 PWT Procedure For Piping > CC-3080-009-PEP.008 Project Execution Plan > CC-3080-008-SCP-017 Site Construction Plan > CC-8080-009-0A6-005 Project Quality Plan ‘CC-3080-009-PIP-018 Piping Spool Receiving Inspection Procedure TOOT VOT FFTOLToS SR? MECHANCAL AND MANTENANCE WOR (AREA A2) D FABRIOATION AND INSTALLATION aa WS FOR PING > CC-3080-008-+HST-012 Hydrostatic Test Procedure For Piping installation > 3080-8280-00-SP-0007 Piping Material Specification > P1S61.1006.11 Field Inspection Pir To Commissioning of Mechanical Equipment > 3080-8440.00-SP.0003 PM of Aloy Materia > 3080-8440-00-SP.0004 Shep and Field Fabrication of Pipe Work A > 3080-8710-00-PR-0001 Construction HSE Plan 3080-8710-00-PR-0012 Lift Classification Procedure DEFINITIONS. (OWNER shail mean Malaysia Refining Company Sdn Bhd. (MRC) CONSULTANT Foster Wheeler E&C [Link]. (FWM) in the role of Engineering Procurement and Construction Management CONSULTANT CONTRACTOR shall mean Pre Engineering Sdn. Bhd, SUBCONTRACTOR shall moan a fim which is carrying out on behalf of the CONTRACTOR but under CONTRACTOR Management and Contrl PREPARATION 44. Material receipt and storing 1) CONTRACTOR and SUBCONTRACTOR shall inspect all material upon receipt and ensure that identification, dimensions, material quality and preparations are in accordance with the approved piping spool drawing, and receiving material report shall be submitted to CONSULTANT including back up evidence. Material damaged or incorrectly marked, shall be immediately brought to the attention of CONSULTANT and subsequently placed in storage area separate quarantined area from acceptance material with sufficient safeguard to 2 preclude its being used 3) Physical separation of different material placed into storage shall be enforced and each batch of material shall be marked in such @ manner that it can be related to the original specification of material and advice note. “SOEODOSFPTOTTsea! {NS FOR PING FELD FABRIGATION AND INSTALLATION sas 4) Carbon steel, ow temperature steel, stainless steel, piping materials shall not be transported or stored in such a way as to cause cross contamination ofthe materials, 5) All Pipe flanges require careful {ull face protection at all times, 6) Allmaterial, whether loose or prefabricated, shall be stored at minimum 30 om iandiing and storage and shall be fited wit above ground on flat surfaces, platform type skids or other similar approved ‘supports in a manner that can prevent deterioration. Materials shall be kept free from dit, grease, paint spray, and other foreign matter. Intemals of pipe fitings and water senstive components of other material stored outdoors shall be protected with plastic cover. 4.2. Material Tracoability 1) The identification and marking requirements and techniques for all materials shall be in accordance with applicable specification of identification for piping material. Heat number transfer of identification of this information shall be cartied out before sections of material are removed for use, 2 IF at any time during installation or. fabrication, any piece of material is not readily identifiable, it shall be segregated and subject reported to ‘CONSULTANT. Fabricated spools shall be clearly and permanently marked with the spoo! ‘dentifcation. Markings shall be located and repested, it necessary, in such a ‘manner thatthe spool can be identified without lifting oF turning The spool identification shal include individual spool sequence number, Care shall be taken to ensure that these marks do not obliterate other identification marks, and CONTRACTOR should consider Tracking Register for Traceability and material matching 3 4.3. Dimensional Tolerances In addition to the tolerances specified in the referenced codes and standards, the folowing shall apply TOTO DUST FTOMTsz | T “JS FOR PING FIELD FABRIGATION AND INSTALLATION eats Linear dimensions for the relative position of branches, bosses, instrument tapings, flanged or but-welded ends and changes in direction, each to other, shail not exceed +3.0 mm and tolerances shall not be cumulative. 2) Flange bolt holes shall straddle the vertical centerine of the pipe end. Rotation of the flange from the true centerline pesiton shall nt exceed 1.8 ‘mm measured at the outside edge of the flange. 83) The gasket contact surfaces of flanges shall be flat and true within 0.8 mm measure across any diameter. If warping occurs in the fabrication proces, the flange shall be re-faced to the original surface finish with accuracy Provided thatthe flange thickness is not reduced below the minimum allowed by the flange manufacturing specication. This shall be checked after re- facing. 4.4 Welding Work Requirement 1) Welding Procedure Specification (WPS) and welder performance {ualifcation test to be applied for constuction shall be qualified in accordance with ASME section IK and shall be approved by CONSULTANT. Before starting to work Contractor shal submit those documents to CONSULTANT for review. 2) No welding works shall be carried until welding procedure specification and the welder are qualified in accordance with project specification and approved by Consultant. 3) __Allweiging material shall be stored in their orginal packets or cartoons in a dry place and working welding material shall be Kept in dkyer equipment land adequate protected fom weather effects. Low hydrogen (ype electrodes shall be baked in accordance with the welding materials ‘manufacturer recommendation. 4) All welding joints to be executed shall have supporting steel work or ‘wooden, for anticipated of deflection, 5) Socket weld valves must be in the open position during welding. The weld ‘hall be alowed to cool between runs to provent overheating, ©) Where valves are butt-welded, consideration shall be given to the removal ‘of internals to avoid damage to seats and seal SOFsre LANA AND MAINTENANCE WORK (A » |W “TAS FOR PIPING FELD FABRICATION AND INSTALLATION To 7) For pipe sizeof 12 inch and targer, two welders shall be employed working ‘on the opposite sides of the pip. 8) Before installation, CONTRACTOR shall ensure all welding joints and Painting shall be inspected 9) The classification and size of electrode or filer wie, are length, voltage, ‘and amperage shall be in accordance with the applicable welding procedure and shall be suited to the thickness of material, type of grove, ‘welding position, and other circumstance at tending the work 10) Welding consumables that have been removed from the original package shall be protected and stored so that the welding properties are not affected 11) Allow hydrogen type electrodes shall be In hermetically sealed containers or shall be backed by the user in conformance with AWS AS.1 and A5.S prior to use, 12) Contractor shall fumish certification that the electrode of filer wire conforms tothe requirements of the classification, 18) Surface on which weld metal is to be deposited shall be dry, smooth, uniform, and free from fins, tears, crack, lamination, paint, and other discontinuities which would be adversely affect the quality of strength of the weld. And also shall be free from loose or thick scale, slag, rust, moisture, grease, and other material that would be prevent proper welding, 14) Weld cleaning by brushing of other suitable means shall be applied not nly on the finish weld surface but also to successive beads and the crater area when welding on over previously deposited weld metal, Al slag shall be removed. 15) Are stikes outside the area of permanent welds shall be avoided on any base metal 16) Welds shail not be allowed to cool down until at least half the wall thickness has been welded, 47) The root, fil, and cap of all pipe materials with diameter equal to or less than DN 50 shall be welded using GTAW processes. 18) All GTAW machines shall be equipped with are starting devices (high frequency, lft are). SOBEL“INS FOR PING FELD FABRCGATION AND INSTALLATION 8013 19) The preheat temperature (if required) shall be applied throughout the entire thickness ofthe weld and atleast 3 in on each side ofthe wel, 20) The preheat and inter pass temperature shall be checked by temperature ingicating crayons, pyrometers or by other suitable method 21) All welding will be carried out and accordance with approved Weld Procedures. 5. FABRICATION 1) Fabrication area Fabrication of diferent materials, carbon steel, low temperature carbon steel, stainless steel and support material shall be done on survey & marking of location based on AFC drawing of piping arrangement drawing, isometric rawing and spool drawing before execution work, segregated from each other ‘materia to prevent cross contamination during cutting & welding, 2) Proper storage and handling of piping material shall be observed to minimize lost and damage, any damage shall be rectified and repaired before use for fabrication & installation. 3) Cutter / blade of abrasive cutting machine for cutting austenitic stainless steel shall be used only for austenitic stainless steel or free from ion content. 4) Thermal cutting can be used for un-alloyed or low-alloyed materials. If thermal cutting is desired for stainless stee! (high alloy) only plasma flames cutting is allowed. Thermally-cut surface edges shall be dressed back approximately 2 ‘mm by machining or grinding to remove notch and scale. 5) If plasma gas cutting is used, bevel ends shall also be flame cut or by beveling machine to make no deep grooves and teeth marks are visible, 6) Beveled end of pine to be welded shall be thoroughly cleaned from rust, dust, oil tc, edge of the beveled pipe shall not be re-prepared unless the edge damage lor the angle of bevel is diferent from as required, 7) Edge preparation (Vor flat end pipe or other) shall be done as required in ‘epproved drawing and can be proceed by grinding machine, or flame cut and surface shall be ground smoothly and stag shall be removed from the surface 8) Tack weld shall be carried out by qualified welder, and shall be in such a way that tacks welding must not touch the root gap or root face of the joint to be SOOOPSR2 MECHANECAL AND MA JIMS FOR PIPNG FELD FABRIOATION AND STALLATION oa, ‘welded. Temporary tack welds shall be smoothly removed by grinding or chipping without reduction of wall thickness, folowed by MT or PT inspection to confirm the linior of indication 10) Fit up shall be given with dimensions (root gap, root face etc.) as mentioned in approved Welding Procedure Specification 11) Alljoints during fi-up shall be given at least three tack welds separated equally ‘around the diameter. 12) All field weld shall be identified by application of a box adjacent to the weld containing: Date of welding, Joint no, Welder Stamp, Weld Procedure used, Final inspector name, 13) For large diameter pipes and small thickness pipes, jigs used for ft up shall nat bbe removed unless atleast 1/3 ofthe root bead has been welded, 8. INSTALLATION 1) CONTRACTOR shall inspect all prefabricated pipe work, valves, piping specials, tc, before instalation to ensure that protective packing, covers and wrappings are removed and intemal protective such as siica gel bags, pallets, and other foreign matter and removed, Protective covers of pipe and equipment shall not bbe removed until immediately prior to installation, 2) Piping shall be supported as indicated on the piping drawings. Where supports required to faciitate installation, they shall be of the removable type, Temporary supports shall not transfer detrimental reactions to piping, structural members or equipment. Welding to pipe as a temporary support measure during installation is not permite. 3) Where pipe support attachments are to be permanenty welded tothe pipe work, other than those shown on the piping drawings are the welding shall be in accordance with applicable specication, employing only Welder qualified in accordance with that specification. Galvanized material shall not be welded to stainless stee! under any circumstances, 4) CONTRACTOR shall check all closing dimensions to equipment and make field adjustments as necessary to assomble pipe work. All modifications other than OBIT OO—_|__ 8) ” 3 9 10) 1) 12) 13) “TiS FOR PIPINS FELD FABRIGATION AND INSTALLATION oH the “Field ft weld” designated on piping drawing shall be notified to CONSULTANT as proposal for rectification before work is commenced, Pipe work shall be carefully and accurately fabricated and installed without the use of force to connect closing pieces. Connections to pumps, vessels, ‘compressors, ec., shall not be made until the foundation bolting is completed. When connecting pipe work to equipment, CONTRACTOR shall ensure that equipment manufacturers instructions are carefully observed as to removal of ‘external and internal protective devices and that the opening is clean and free ‘rom obstruction and foreign matter. Flange faces shall be cleaned of protective coatings, ete, and checked for ‘mechanical or corrosion damage to the gasket contact surfaces. Flange bolts shall be tightened evenly and sequentially to impose even pressure cn gaskets and to avoid distorton or overstressing of equipment, The use of bolt tensioning torque equipment shall be used where specified in the procedure documents, Flange bolting shall be made up such that the minimum required bott stresses to achieve the desired joint requirements are met, CONTRACTOR shall ensure that gaskets or foreign materials do net protrude inside pipe bore, Spiral wound gaskets shall not be re-used. Ifa flanged joint must be opened, ©.g for system pressure testing, line flushing, removal of temporary binds or strainers, etc., the joint shall be re-made with new gaskets and with the bolt lubricant replenished Flanged joints at equipment of valves employing tapped holes shall have the thread depth checked prior to assembly to ensure that cap screws of the correct length are used. Flange connections to pumps, compressor and other equipment shall be the final connection in the line minimize the period in which the equipment covers are removed before commissioning and to enable the final closure to be made Without subsequent force or moment from the rest of the line. Temporary strainers (where specified) shal be included when connections are frst made up and cleaned and should be assembled under clean conditions, in all cases TOTO OUTFIT14) 18) 16) ore HANICAL AND MAINTENAW NORK (AREA Aa) {INS FOR PIPING FELD FABROGATION AND INSTALLATION extreme care shall be taken to ensure no foreign matter, dt, etc, enters the equipment. Valve in horizontal piping shall be installed with the actuator in the upright Position unless shown otherwise on the drawings Wafer type check valves in horizontal piping shall be installed withthe hinge pin in a vertical positon, AA intine instruments and equipment shall be installed in strict conformance with the manufacturer's instruction and recommendation. Pipe Support installation (@) Al supports shall be installed and accordance with the project support | standard and shall be completed with the coating in accordance with the painting specification. ‘Spring support shall be installed withthe stop in pasttion prominently flagged towarn ofthe necessity for emoval ater completion of testing of the line (©) Temporary support shal be limited to the unavoidable minimum. They shall bbe designed and manufactured to take all loadings that they wil be subjected to, They shall be painted a suitable color to warn of the necessity of removal before plant start up. (@) Temporary support shall not be attached to equipment or steel work unless. shown on drawing ) 7. REPAIR PROCEDURE (for DEFECT WELDING) 7 GENERAL Weld repairs! rework shall be made before any required PWHT (Post Weld Heat Treatment) it specified Unacceptable discontinuities shall be completely removed by chipping gouging, grinding or other authorized method. The excavated area shall be examined as a minimum visually to assure the discontinuity is removed compietely TO BOST OTF POLOPSR2 MECHANICAL AND MANTENANCE WORK (AREA A} “JS FOR PIPING FELD FABRIGATION AND INSTALLATION. Wold repairs shail be made using the same as with original the qualified WPS (Welding Procedure Specification) and shall be in accordance in accordance with ASME Ix ‘After welding, the repaired areas shall be re-examined using the same inspection method which detected the original defect. 7.2 REPAIRING FOR STAINLESS STEEL 4) Special grind disc type and stainless steel brush shall be used to avoid carbon inclusion and contamination. ) Are gouging shall be prohibited 7.3 REPAIRING FOR DISSIMILAR METAL 4} Special grind disc type shall be used for grinding on stainless stee! surface. 8) Grind alse for stainless stool area shall be different from grind dise for ‘carbon steel area. ©) Stainless stee! brush shall be used for brushing on stainless steel surface, 4) Brush for stainless stee! shall be different from brush for carbon stee! area, 7.4 BASE METAL DEFECT 2) Ifdefects on the base material are found, they shall be removed by flame or are gouging, grinding, chipping or machining 0) The excavated area shall be examined by penetrant test to make sure all the defect is removed completely. ©) The excavated area shall be welded using the qualified WPS and the qualified welder. 4) Weld surface defect will be visually examined, and for defect through inside material and the root area wil be examined by Radiography, ©} The inspector shall make sure that the repairing is completed, accepted and recorded. 8. PAINTING WORK Painting work shall be cartied out in accordance with PTS 30.48,00.31 P. ! TOROS DOSFPTOETG 9. INS FOR PIPING INSPECTION AND TESTING 9a 92 10, WELD INSPECTION Inspection of welds shall be carried out after final heat treatment in accordance with the inspection casses shown in see PWHT Procedure, Doc. No. ‘€C-3080-008-PHT-004 (Appendix B). The methods to be employed for inspection, the aoceptance criteria for welds, and the progressive examination shall all be in accordance with ASME B31.3, And Project Specification Standard, PRESSURE TEST, CLEANING & DRYING FOR PIPING. Pressure testing, cleaning and drying shall be carried out in accordance with ITP for Fabrication and Pre-Commissioning and System Turnover Procedures and documentation. DOCUMENTATION ‘All QC documentation shall be complied In line with Project Quality Documents and approved Inspection and Test Plans. CONTRACTOR shall allocate sufficient personnel to compile populate and handover QC documentation Packages for Pipe work and equipment. ‘All documents and reports shall be prepared and compiled in the Final Quality Dossier including but not limited to: ‘Material traceabilly report ‘bWelding summary report ©. NDE report [Link] report 2 Prossure Test report {Painting report [Link] Cleaning report hAs-buit drawing others DFABRGATION AND INSTALLATION Bal SORT DOS FROST