5.a. Piping Fabrication Plan
5.a. Piping Fabrication Plan
5.a. Piping Fabrication Plan
GBARAN PHASE 3B - UZU WITH CPF UPGRADE- PKG 1 PIPELINES SCOPE TENDER No. CW348814
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Restricted
ECCN: EAR 99 Deminimus
This document is made available subject to the condition that the recipient will neither use nor
disclose the contents except as agreed in writing with the copyright owner. Copyright is vested
in Shell Petroleum Development Company Ltd. © All rights reserved.
Neither the whole nor any part of this document may be reproduced or distributed in any form or by
any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written
consent of the copyright owner
Revision
Philosophy:
a. All FEED documents for review shall be issued at R01, with subsequent R02, R03,
etc as required.
b. All documents approved for issue, or approved for design shall be issued at A01 with
subsequent A02, A03, etc. as required. (Management of Change is required for
A02, A03, etc.)
c. All Detailed Design documents for review shall be issued at D01, with subsequent D02,
D03, etc. as required.
d. All documents approved for construction shall be issued at C01 with subsequent C02,
C03, etc. as required. (Management of Change is required for C02, C03, etc.)
e. All approved “As Built” documents shall be issued at Z01, with subsequent Z02, Z03, etc. as
required. (Management of Change is required for Z02, Z03, etc.)
Revision History
Rev No Date of issue Reason for Issue / Change
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TABLE OF CONTENTS
1.0 INTRODUCTION 4
2.0 SCOPE OF WORK 4
3.0 REFERENCE DOCUMENTS 5
3.1 CODE AND STANDARDS 5
4.0 DEFINITION AND ABBREVIATIONS 5
5.0 FABRICATION ORGANIZATION STRUCTURE 6
5.1 PRODUCTION ENGINEERING AND METHOD (PEMT) 6
5.2 WORKSHOP SUPERINTENDENT 6
5.3 QUALITY CONTROL 6
5.4 HSE OFFICER 6
6.0 PIPING FABRICATION PROCEDURE 7
6.1 GENERAL 7
6.2 MATERIAL PREPARATION 7
6.3 CUTTING AND MARKING 7
6.4 MACHINING (BEVELING, TRIMMING, THREADING, DRILLING) 8
6.5 FIT UP/ASSEMBLY 8
6.6 DIMENSIONAL CONTROL/FIT UP INSPECTION 8
6.7 WELDING AND VISUAL WELD CONTROL 9
7.0 NON DESTRUCTIVE TESTING (X-RAY) 9
7.1 POST WELD HEAT TREATMENT (IF REQUIRED) 9
7.2 HARDNESS TEST (IF REQUIRED) 10
7.3 HYDROSTATIC TEST 10
7.4 PIPELINE EXTERNAL COATING 10
7.5 OTHER TREATMENT (IF REQUIRED) 10
7.5.1.1 MECHANICAL CLEANING 10
7.6 STORAGE OF FABRICATED PIPE 11
7.7 HANDLING OF PIPE PIPES 11
7.8 HSE REQUIREMENT FOR FABRICATION PHASE. 11
7.9 WORKSHOP PREPARATION, STORAGE AND HANDLING 13
7.10 CUTTING, MARKING, MACHINING AND ASSEMBLY 13
7.11 DIMENSIONAL CONTROL, WELDING, VISUAL WELD CONTROL 14
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7.12 NON DESTRUCTIVE TESTING (X-RAY) 14
7.13 PWHT AND HARDNESS TEST 14
7.14 HYDROSTATIC TEST 14
7.15 PRESERVATION 14
1.0 INTRODUCTION
This detailed Fabrication Plan is written to minimize on-site fabrication, testing and commissioning
of piping pipe for Gbaran Phase 3B – Uzu with CPF Upgrade Project.
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6. Design, procurement and installation of all junction boxes and termination and splicing materials
for the FOC.
This plan covers the basis for material traceability and fabrication work for pipes prefabricated
in the workshop provided with pipe drawing. The plan is to provide guidelines on general
working procedure and operative method for conducting piping fabrication work.
ISO Drawing A drawing used for pipes fabrication, detailed with all information
necessary or all fabrication works.
GBARAN PHASE 3B - UZU WITH CPF UPGRADE- PKG 1 PIPELINES SCOPE TENDER No. CW348814
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WPS Welding Procedure Specification
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Assists in investigation and reports.
Stops any unsafe or environmentally non-compliant act observed
Have the right to intervene and stop any unsafe work condition and disseminate information to
Site HSE Supervisor or HSE Manager when required.
6.1 GENERAL
The pipe fabrication drawing may be used to record all QA/QC requirements (eg material traceability,
heat number, NDT, Weld Map, welder/fitter identification etc) and accompany the pipe along the
entire fabrication process.
Method for workshop progress tracking and material traceability other than above can be used, such
as using a Work Progress Sheet and/or Welding Follow Up Sheet. Final record of workshop progress
reporting has to be compiled using a dedicated software.
Carbon Steel piping material will be fabricated in dedicated piping workshop. The installed concrete
coating
shall meet the specifications in the DEP on Concrete Coating.
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7. The ISO drawing shall follow these material to the next step of fabrication.
8. Pipe fitters fill the workshop progress sheet.
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7. Pipe fitters fill the workshop progress sheet.
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1. Pipe from NDT Bunker or temporary storage area will be send to PWHT area using forklift.
2. Arrange pipe for PWHT preparation.
3. Prepare the PWHT equipment.
4. Conduct PWHT as per required by WPS/PWHT Procedure.
5. Remove the PWHT equipment.
6. Fill up the workshop progress sheet.
7. Let the pipe on PWHT area for hardness test.
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7.5 OTHER TREATMENT (IF REQUIRED)
Other treatment mentioned in here are passivation and acid cleaning of CS pipe materials. These
activities will only be conducted if required by design/code/spec.
Ensure that the electrical system is in line with the international standards and inspected by
competent electrician;
Ensure adequate HSE personnel are being mobilized to manage all activities to reduce all risk
factors to acceptable limits.
Ensure adequate risk assessment is developed to cover all activities during the fabrication.
Prepare structural protection to separate areas where grinding and cutting operation is ongoing
from the walkway.
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Ascertain the type of steel quality/ electrode and welding procedure is appropriate (via work
sheets, drawings, etc.);
Ensure that all combustible material are cleared away from the workshop area before hot work
is commenced;
Ensure that a valid Permit to Work has been issued for activities to be performed.
Ensure that all welding equipment/hand power tools and machines are correctly used and
properly maintained in good working condition. This includes all personal protective
equipment.
Ensure proper housekeeping around the work location, before, during and after the activity.
Welding trailing cables shall be adequately arranged and managed to avoid tripping hazard.
Adequate cable hanger and trays shall be used respectively.
All welding equipment must have undergone and passed company pre-mob inspection (PA
test) and the validity shall be well maintained
Fire blankets shall be used to contain all welding sparks while working at height.
Ensure that all MSDS and Shock card of Dangerous Material is present at site;
The minimum PPE requirement for the welders and welders mate, pipefitters (helpers) are listed
below.
Rain boot
Hard Hat
Rain coat
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Dark Safety Glass
Welding Glove
Welder’s sleeves
Ear muff
Rain boot
Hard Hat
Rain coat
Ear muff
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Storage area of equipment and tools shall be segregated. An identification code system shall
be established for above segregation.
Each pipe, pipe fittings, assembled pipe, welded pipe shall not be storaged directly on the
ground. These items shall be stored on wooden bar at least 150 mm from the ground or on a
surface fully covered with wood.
Walking, stepping or placing any item on CS piping items are strictly prohibited.
Before starting any new work in CS pipes shop, inspection will be conducted to ensure the
carbon decontamination.
7.13 PRESERVATION
To maintain the quality of anticorrosion properties of CS pipes material and to prevent the
deterioration of pipes surface finish, a special care shall be given during pipe storage and handling
after fabrication.
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1. All the pipes opening shall be sealed with air tight closures after passivation process.
2. End closures shall be durables and securely attached to the pipes such they will remain intact
and in position during transfer, handling and storage.
3. Pipe end connection can be sealed by blinds secured using wire. Unflanged pipe end
connection can be sealed by end cap from plastic (or similar) and wrapped with protecting
tape 50mm around the pipe-cap joint. Threaded end connection, whenever possible, shall be
sealed by means of threaded plastic (or similar materials) so that the pipe thread will be
protected.
4. Pipe to be stored on wooden supports and not on the ground
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