Piping Inspection Procedure [PDF]

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DOCUMENT NO. : XXX-P-PR-001

DOCUMENT TITLE :

PIPING INSPECTION PROCEDURE

REV.

0

EFFECTIVE DATE 05/09/2009

CONTENTS 1. Purpose

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2. Scope

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3. Responsibility

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4. Applicable Document and References

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5. Definition

3/9

6. Piping Inspection Work

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6.1. Piping Material Receiving and Storage

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6.2. Piping Spool Shop Fabrication

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6.3. Field Installation of Shop Fabricated Piping Spool

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6.4. Piping System Flushing and Cleaning

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7. Piping as Built Data

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8. Inspection Record Form

9/9

REVISION RECORDS REV.

DATE

DESCRIPTION

Originator by

0

Original

Issued for Approval

DISTRIBUTION 1. 2. 3. 4.

All Manager Department Project Manager Site Manager File ( DCC )

OWNER

CONTRACTOR

CHECKED

REVIEWED APPROVED BY BY

ARS

REMARKS

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PIPING INSPECTION PROCEDURE

1

PURPOSE This procedure provide guidelines for the inspection works that shall be performed by QA / QC Inspector for piping work on Building Piping Process as such to achieve the final product conforming to Owner requirement. 2.1.1.1.1.1.1.1.1.

SCOPE

This guide covers quality assurance and control of piping work activity from receiving of material, storage, shop fabrication / testing and field installation / testing. 2.1.1.1.1.1.1.1.2.

RESPONSIB ILITY

The QA / QC – Mechanical & Piping shall be responsible for the performance of quality assurance in piping work. 2.1.1.1.1.1.1.1.3.

APLICABL E DOCUMEN TS

and

REFERENC ES The following documents / references out lines the inspection requirements for piping and shall be implemented as applicable to the project work: -

ASME B 31.1.

Power Piping

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ASME B31.3

Process Piping

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ASME Sec. IX

Welding and Brazing Qualification

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ASME B31.9

Building Piping

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ASME/ANSI B1.20.1 Pipe Threads, General Purpose (Inch)

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ASME/ANSI B 16.5. Pipe Flange and Flange Fittings

The inspector shall ensure the above corresponding references are available / handy anytime during the performance of the piping work, including this procedure.

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PIPING INSPECTION PROCEDURE

2.1.1.1.1.1.1.1.4.

DEFINITIO N

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Contractor Owner MIGAS

: : : 2.1.1.1.1.1.1.1.5.

PIPING INSPECTIO N WORK

The following paragraph outlines inspection works / items that shall be done by the inspector for piping works as a minimum. 2.2. Piping Material Receiving and Storage 2.2.1. Piping material receiving. Prior to material arrival at site, the inspector shall carry out the following work. -

Obtain pipe material Purchase Order (P.O.), packing list and shop inspection mill certificates. The inspector shall identify the quantity, type and size of the piping as a reference to inspect the storage area to be provided and the storage method / requirement.

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Prepare the receiving inspection record forms. Project specific forms are recommended.

Upon arrival of the piping material at site the following inspection shall be done: -

Inspect the pipe material for damages that may occur during shipping / handling. Damage report shall be prepared and submitted to Contractor/Owner. The damage report shall contain damage type and identification of rejected and accepted material. The damage report of rejected material shall quote the appropriate specification as reason for rejection.

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Identify the material of pipe shall conform to the purchase order.

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Check sizes, type of pipe fittings, flanges etc. to conform to P.O. 02/01/17lh\

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PIPING INSPECTION PROCEDURE

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Verify the mill certificates :

Ladle analysis (chemical composition) shall conform to tabulated composition in the standards & specification. Tensile strength and ultimate strength value shall conform to strengths as tabulated in the standards & specification. Other specific certificates (valves, flame arrestors etc.). Any discrepancy shall be reported in non- – conformance report and be submitted to Contractor/Owner and copied to the vendor and purchaser. 2.2.2.

Piping Material Storage Inspection. Inspection to ensure the piping material is placed in the storage area properly: -

Pipe or fitting stainless steel shall be separated with carbon steel / galvanized material

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Protected against weather or corrosion, refer to project specific requirement.

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Each piping component or group shall have material identification tag.

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Surface of plunges shall be protected with wood or rubber / plastic.

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Rejected material shall be stored separately to avoid misuse and shall have special identification (e.g. rejected, do not use etc.).

2.3. Piping Spool Shop Fabrication. a) Construction Drawings -

The inspector shall check the isometric drawings had been checked and approved for construction.

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The isometric drawings to be used for fabrication were marked at shop for spool number, welds number and WPS number.

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Spool drawings were checked by Piping Construction Group (by project engineer) for correct dimension, identification of pipe cutting length, fittings and flanges. Selection of the correct fittings and flange (shall be in accordance with isometric drawings) will be by the Construction Group but the inspector shall inspect and notify them if any discrepancy occur.

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PIPING INSPECTION PROCEDURE

b.

Check Welders certifications -

The welder’s certification of the welders shall be checked that they have certificate copy handy. Identify the certificates corresponds to which WPS. This avoids misuse of welder.

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Ensure that the welders use welder badge identifying their qualification.

c. Welding Facility. -

Inspect to ensure the welding machines have proper amperage capacity (WPS requirement), stable voltage etc.

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Inspect that welding holder in good order.

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Inspect space for welding to ensure welder free movement as required during welding. This will avoid weld defects.

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Inspect whether welding tents is needed to avoid winds during welding. Strong wind may cause blowhole or porosity on welds.

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Inspect the welding electrode heater for storage and heating of welding electrode for immediate use. Heating temperature as per manufacturer recommendation shall be checked.

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Inspect size of grinder and grinding wheel to match the need for weld joints.

d. Welding of Pipe Spools -

Inspect to ensure fit – ups work utilizes proper method as usually in construction practice (use of angle, level, clamp etc.).

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Inspect to ensue that fit – up tack welding is done by qualified welder. Check the welding electrodes used conform to WPS.

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Inspect randomly that weld bevel angle and gap are correct in accordance with WPS.

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Inspect to ensure that each welded spool is marked to identify the isometric drawing & mark number, each weld with welder number, welding date and radiography number / date shot.

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Refer to project specification procedure for further requirements of inspection.

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PIPING INSPECTION PROCEDURE

e.

Radiography of welds. -

Inspect the Radiography ray equipment must have the valid permit; proper radiation power, etc. refer to Project (Specific) requirements.

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Interpretation of Radiography film shall be done by inspector having Contractor/Owner acceptance of interpretation is required.

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The inspector shall prepare the weld Defect Report indicating type of defect, location etc., refer to Project Specific requirement. The report should clearly indicate the acceptability (rejected or accepted) of the weld. The rejection must indicate type of repair (local or overall cut and re weld).

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The welds on the spool shall be marked with Radiography result (accepted, rejected / repair or cut / re weld. The Radiography film of weld to be repaired shall be given to the welding Supervisor. The repaired weld shall be marked and radiographed.

f. Pressure Test of shop fabricated Spools : -

The inspector shall review the project (specific) requirements for pressure testing of the shop-fabricated spools which normally should be pressure tested at shop yard. The pressure test circuit design shall be prepared by the chief project engineer. Typical test circuit is displayed in the exhibit 1. The isometric drawing shall be reviewed to identify pressure test type (hydro test with pressurized water or by pneumatic / air pressure or by hydraulic oil), test pressure, test temperature etc.

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The Inspector shall ensure all radiography films of weld joint at the spool were interpreted, inspected acceptable to Contractor/Owner prior to hydrotest.

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The spools shall be checked against P & ID prior to test.

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The inspector shall ensure the pressure test is carried out in accordance with the project (specific) procedure.

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The pressure test assembly shall be inspected for:

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PIPING INSPECTION PROCEDURE

a. The facilities for pressuring water/other medium inlet, depressurizing after hydrotest, air bubble vent with valve, calibrated pressure gauge or recorder, etc. b. The appurtenance piping for the pressure test (vent valves, supply block valve depressurizing block valves etc.) shall have line class pressure rating as the spool being hydrotested, as a minimum. c. Ensure the pressure test assembly sketch and pressure testing procedure (prepared by chief project engineer) is approved by Contractor/Owner. d. Ensure Contractor/Owner and / or third party agent witnesses, as required. -

The hydrostatic tested and acceptable spools shall be marked accordingly and stored properly.

g. Storage of shop fabricated piping. Inspector shall check that the fabricated spool is laid in the storage area in the proper way as follows: 

Open-end pipe shall be covered with wood or steel / plate.



Spools area laid with wooden support or equivalent, no contact to earth soil (avoid corrosion).



Spools are separated in line class group or line size group, refer to project (specific) requirement.



Stainless steel spools shall be laid in location separated form carbon steel / spools.

2.4. Field installation of shop fabricated piping spools. -

Prior to field welding, the inspector has to carry out similar inspection as outlined in paragraph 6.2. (As applicable).

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Inspect that field welds are marked with welding number, welder identification and welding date.

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The inspector shall carry out the work similar to paragraph 6.2.e.

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Where field pressure test is required, the inspector shall carry out inspection works similar with paragraph 6.2.f.

Special notes for piping field installation / test: a) Valves

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PIPING INSPECTION PROCEDURE

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All valves installed in the piping system and included in the hydrotest circuit shall be opened (inspector shall check).

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The inspector shall check against project or manufacturer’s specification if the valve is to be included in hydrotest (as reference inspector should check the standard used in manufacturing the valve).

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The inspector shall check that the valves are installed in correct flow direction, and orientation in accordance with construction drawing (hand wheel position, angle of incline etc.)

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During testing, the valves that are not to be included in hydrotest shall be isolated or replace by flange spool. Control valves, flow orifices, relief valves, strainers / filters shall not be included in pressure testing. Inspector shall further verify with project specification all limitation and requirement.

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All instruments shall be isolated during pressure testing.

b) Blind Flanges The blind flanges or spades installed to isolate valves and instrument shall not be dismantled, as they are required for protection during flushing. Blind list shall be prepared to easily control during removal for re-commissioning of the piping system. c) Bolts / Studs and Gaskets -

Prior to field pressure testing, all bolting of flanges shall be inspected for correct size / dimension, material and well tightened. The inspector shall check and record.

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Similar for gaskets shall be inspected

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All dismantled gaskets used for pressure testing spools / flanges shall not be re used for permanent installation. Similar with spades.

d) Spring Supports and Temporary Supports -

Prior to pressure testing, the inspector shall inspect the required temporary additional supports for pressure testing due to additional weight of piping due water or gases fill of the piping system. 02/01/17lh\

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PIPING INSPECTION PROCEDURE

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Spring support normally shall be in “stop’ position during testing to avoid overload of the spring or affect the pipe alignment to the equipment it connected to. Spring support status list shall be prepared, needed for precommissioning.

2.5. Piping System Flushing and Cleaning -

After pressure testing, the piping system shall be cleaned with air blowing. Hydraulic oil piping and tubing shall not be flushed with water but with air or hydraulic coil.

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The inspector shall witness the air outlet to verify that piping system is clean already. Contractor/Owner witness is required.

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The inspector shall verify and perform other flushing requirement in the project (specific) procedure. 2.5.1.1.1.1.1.1.1.

PIPING

AS

BUILT DATA The inspector shall ensure that the as built data were marked by the project engineer in the isometric drawings, P & ID and piping plan drawings. This will facilitate next preparation of back – up documents of mechanical completion acceptance request to the Contractor/Owner. 2.5.1.1.1.1.1.1.2.

INSPECTIO N RECORD FORM

The inspection from samples in the appendix I are recommended formats to be used to record the result of inspection. Other format may be utilized, provided that the inspection item shall completely cover the inspection requirements.

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