Flowchart work piping in shop

and site area

By: Ir Agus Priyo Wibowo

WORK FLOW CHART FABRICATION PROCEDURE (Spool Shop) CHECK LIST
CARBON STEEL PIPING

ISO-DRAWING 1) Acquisition of iso drawing

2) Check & confirm the fleld weld point
3) (1) Correct material (color code)
MATERIAL 3) Collection of materials from material controller (2) S.No
REQUISITION (3) Quantity
(4) Size

4) (1) Surface prepapartion 4) (1) Check the surfase cleanness

PRIMER PAINT (2) Primer paint (2) Paint material
(3) Dry film thickness
(4) Protection original color mark of stamp

5) (1) From cutting plan. Mark the required length 5) (1) Dimention
CUTTING
(2) Mark the line no, Drawing no, and party no on (2) Size
the spool piesce (3) Material code
(3) Cut

6) a) Butt Joint 6) (1) Material code and size

1) Gap of 1 < to 3.2 mm (2) Edge: preparation, agle root gap
FIT UP 2) Bridge bracket Alignment dimension
3) Tack weld by qualified welder (3) Confirm the Jig material
(4) Cleaning of the welding parts
b) Socket joint (5) Cleaning of werding pats
1) Expansion gap 1.6 mm (6) Confirm the Jig material
2) Direct tack weld
3) Tack weld by qualified welder
WORK FLOW CHART FABRICATION PROCEDURE (Spool Shop) CHECK LIST
CARBON STEEL PIPING

7) 1) Butt Joint root pass welding 7) (1) Qualification ofwelders

WELDING
*GTAW-EK70S-G or Equivalent (2) Welding rod, material drying, size
Cover pass (3) Root pass
SMAW-7016 or Equivalent * Penetration , inner cut, pinholes,
2) Socket joint 2” cracks, inner bead
*GTAW-EK70S-G or Equivalent (4) Cover pass
3) Remove tack works, spatter and finish clean * Under cut, bead, overlap, pinhole
All welding are done by qualifiY welders only. * Hight of reinforcement of weld and
4) Write weld joint number and welders numbers welded leg of filled weld.
next to weld seam (5) Finishing
* Spatter
* Cleanliness

NDT 8) Radiography 8) Judgement of X Ray film

(1) Identity by contractor * Submit to CLIENT
(2) Mark location
(3) Welding joint detail

TEST 9) Test 9) Leak check by soap liquid

(1) Pneumatic test of reinforceng pad of branch

10) (1) Marking of parts 10) 1) Internal clean iness

PACKING (2) Internal cleaness 2) Dimension
(3) Seal both ends 3) Part identification
(4) Update progress record sheet 4) Get CLIENT approval
5) Provide cover for packing

TRANSPORT 11) Final inspection before delivery 11) Confirm the spool No, and piece No.
TO SITE
12) Transportation to site for Installation
WORK FLOW SITE INSTALATION CARBON STEEL SITE INSTALATION ALLOY STEEL CHECK LIST
CHART

SITE 1) Site Inspection & confirmation Check & confirm 1) Daily Hot Work Permit
INFIRMATION a) Equipment Instalation & Alignment
b) Nozzle location and orientation
c) Support location, type, guide, etc 2) Line number and spool part
d) Alignment no.
e) Valve location, material, size 3) Vehiicle entry permit
f) Bolt length, material, size
g) Hot Work Permit
4)Dimension on site condition
2) Collecttion of fabricated spool pieces
COLLECTION * Fitting etc
SPOOL PIECES 3) Shifting & Unloading on site 5) Edge preparation & fit-up
4) Installation of piping * Angles, foot gap
* Mis allignment
FIT-UP
Carbon Steel fit-up Alloy fit-up * Fitting valve, etc
* Pre heating temp & area
5) But Joint Socket 5) Socket But Joint * Material check
PRE-HEAT * Gap 1,6 mm-3.2 mm * Expansion gap 1.6 mm * Expansion gap 1.6 mm * Gap 1,6mm-3,2mm * Cleanness of edge
* Bridge bracket * Direct tack weld by qualified * Preheat 150-300 C * Bridge bracket * Joint No
* Tack weld by qualifed welder * Direct tack weld by * Preheat 150-300 C
welder qualified welder * 18” & over heater coil or 2” 6) Welding
by propane torch * Qualification of welder
* Below 18” by propane burner * Welding rod material
*Tack weld by qualified welder * Electrode (Amp & Volt)
* Preheating Temp & area
6) Root pass 6) Root pass * Root pass
WELDING
* GTAW – ER70SG or equiv * GTAW – ER70SG or Equiv * GTAW–ER 80SG or Equiv * SMAW – 7016 B2 or Equiv a) Penetration
* SMAW – E7016 or Equiv * SMAW–E8016 or Equiv * Post heat 594 C – 15 min b) Crack, Inner cut
* Liquid penetrant check c) Beed
* Preheat 150 – 300 C d) Pin hole etc
* Post weld temp & area
Cover pass Cover pass * PT check
* SMAW - E8016 B2 or equivalent * SMAW – E8016 B2 or Equiv Cover pass
a) Nunder cut
While weld joint number & welder
b) Beed overlap
nomber to weld seam c) Pin holes
d) Crack
FINISHNG
7) Finishing
* Spatter, tack weld work etc 7) Finishing cleaneses of joint
WORK FLOW CHART SITE INSTALATION CARBON STEEL SITE INSTALATION ALLOY STEEL CHECK LIST

8) Installation 8) All connecting bolting, support ,

INSTALLATION
* All Pipe supports * Valve boxing blind etc
* Flange bolting * Temporary support
* Temporary test blind * Gasket 9) Judgement of film
*Temporary piping test/flush
10) Judgement of temp control
RADIOGRAPHY 9) Radiography sheet
5 % (Identify Contractor) 100 % (Identify Contractor)
* Mark location * Mark location 11) Judgement of PT
* Weld joint detail * Weld joint detail 12) Judgement of Hardness
STRESS RELIEVE 13) Check progress record
10) Post Weald Heat Treatment 705 – 745 C * Radiograph reshoot
11) Liquid penetrant test *Additional line records
NDT 12) Brinnel Hardness test (max 225) * Full endorsement
13) Updated progress record 13) Updated progress record
14) All completion of
14) Line check 14) Line check * Supports & Acces & Operation
LINE CHECK Confirm all connection completed all supports. Finishing * Welding joints
all welding joint, bolt tigthteness for flange connection temporary * Bolfing joint
test blind, temporaryl ine and support for tested
* Temporary blade
* Fitting for prssure test
15) Pressure test * Isolation of instrument
* Determine pressure test joint, drain point, air trap outlet , * Equip & Rotary machined
Pressure gauge location.
* Confirm testing fluid N2 or H2O . 15) Check test pressure
PRESSURE TEST
* Inspect for leak. * Range of pressure gauge.
* Be pressure * Test press
* Location of press, rise & drain out
16) Flushing * Location of pressure gauge
* Determine air inlet point andconfirm flushing point . * Leak check of all connectedjoints.
* Flush wit air or water.
15) Check flushing clean liness.
FLUSHING
17) Reinstallation * Blow point and flushing press.
* Remove temporary support, blind etc. * Isolation from equipment.
* Restoration of values ordils plates ring etc.
* Final check. 17) Final check lines an follows
REINSTALLATION
* Set spring support at cold post..
Before operation
* Flow direction on ctrl valve etc.
of facilities
* Bolt tighteness.
* Gasket, bolt material.
* Item Tag No, instrument equipt.
* Piping alignt to rotary machine.
* Gasket surface cleanliness.
* Removed temporary blind & etc.
Beberapa tipe penyambungan
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