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Design-Engineering-Construction-Testing & Commissioning of piping

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Procedure

Welding Procedure

Based on ASME (American Society of Mechanical Engineers) standards which involves outlining the necessary steps to ensure that welding is performed safely and effectively while maintaining high quality and integrity. Below is a comprehensive general welding procedure that can be adapted for various applications.

General Welding Procedure Based on ASME

1. Purpose and Scope

  • Purpose: Define the goals of the welding process, including structural integrity, safety, and performance requirements.
  • Scope: Specify the materials, types of joints, and applications covered by the procedure, such as carbon steel, stainless steel, and alloy steel welding.

2. References

  • ASME Section IX: Welding and Brazing Qualifications
  • American Welding Society (AWS) specifications and standards
  • Material specifications (ASME B31.3, ASME B31.1, etc.)
  • Manufacturer’s data sheets for filler materials

3. Welding Processes

Specify the welding processes to be used, such as:

  • SMAW: Shielded Metal Arc Welding (Stick Welding)
  • GMAW: Gas Metal Arc Welding (MIG Welding)
  • FCAW: Flux-Cored Arc Welding
  • TIG: Gas Tungsten Arc Welding
  • SAW: Submerged Arc Welding

4. Welding Materials

  • Base Metals: Identify the materials to be welded, including their specifications (e.g., ASTM).
  • Filler Materials: Specify the type and classification of filler metals per AWS/ASME standards.
  • Shielding Gases: Identify the type of shielding gas used for processes like GMAW or TIG welding (e.g., Argon, CO2, Helium).

5. Welding Joint Design

  • Outline the joint configurations, including:
  • Butt Joints
  • Fillet Joints
  • Edge Joints
  • Define the joint design based on the required strength and service conditions, ensuring it is compliant with relevant ASME codes.

6. Preparation of Base Metals

  • Cleaning: Remove contaminants such as rust, oil, dust, and other impurities from the surfaces to be welded.
  • Fit-Up: Ensure proper fit-up of the joint with tolerances as specified in the applicable standards.
  • Preheating: If necessary, preheat the base materials to reduce the risk of cracking based on material type and thickness.

7. Welding Parameters

Specify the following parameters:

  • Voltage (V): Set appropriate arc voltage for the welding process.
  • Current (I): Set the welding current according to the process and joint thickness.
  • Travel Speed: Determine the appropriate welding speed to ensure proper bead appearance and penetration.
  • Heat Input: Calculate or control the heat input to minimize distortion and prevent material degradation.

8. Welding Technique

Provide details on the technique to be used, including:

  • Electrode Angle: Specify the angle of the electrode or torch relative to the workpiece.
  • Weaving: Include details on weaving patterns for different joint configurations (if applicable).
  • Pass Sequence: Define the sequence of weld passes (e.g., root pass, fill passes, final cap pass).

9. Inspection and Testing

  • Visual Inspection: Conduct a visual examination of the welds to check for defects such as undercuts, porosity, and cracks.
  • Non-Destructive Testing (NDT): Specify NDT methods (e.g., RT, UT, MT, PT) to be implemented based on service requirements to ensure weld integrity.
  • Destructive Testing: Outline any requirements for tensile, impact, or bend tests if necessary according to applicable codes.

10. Post-Weld Heat Treatment (PWHT)

If required by the material or design specifications, specify post-weld heat treatment details, including:

  • Temperature and duration
  • Cooling rate and method

11. Safety Considerations

  • Implement safety measures throughout the welding process, including:
  • Personal Protective Equipment (PPE) such as helmets, gloves, and protective clothing.
  • Ventilation to avoid exposure to harmful fumes.
  • Equipment safety checks before operation.

12. Documentation and Records

  • Maintain records of:
  • Welder qualifications (per ASME Section IX)
  • Welding procedure specifications (WPS)
  • Inspection and testing results
  • Material and filler metal certifications

13. Training and Qualification

  • Ensure that personnel performing the welding are trained and qualified in the applicable welding processes, techniques, and safety practices.

Conclusion

This general welding procedure based on ASME provides a structured approach to welding operations, covering all necessary steps from planning and material selection to final inspections and documentation. Adhering to these guidelines facilitates quality assurance and compliance with industry standards, ensuring that welded structures meet performance and safety requirements. Always refer to current codes and standards for specific applications.

Procedure

Painting Procedure

Based on ASME (American Society of Mechanical Engineers) guidelines involves a systematic approach to ensure that the painting process meets safety, performance, and quality standards. Below is a detailed procedure for painting piping systems, including surface preparation, material selection, application, and inspection.

Piping Painting Procedure Based on ASME

1. Purpose and Scope

  • Purpose: Define the rationale for painting the piping, such as corrosion protection, aesthetics, and identification.
  • Scope: Specify the types of piping systems covered by this procedure (e.g., process piping, HVAC, utility lines).

2. References

  • ASME B31.3 Code for Process Piping
  • NACE International Standards
  • Manufacturer’s recommendations for coating materials
  • Safety Data Sheets (SDS) for all chemicals used

3. Materials and Equipment

  • Coatings: Select appropriate coatings based on service conditions, including:
  • Primers (anti-corrosive)
  • Intermediate and Topcoats (epoxy, polyurethane)
  • Application Equipment:
  • Brushes, rollers, or spray guns
  • Airless spray equipment if applicable
  • Surface Preparation Tools:
  • Abrasive blast equipment
  • Power tools (grinders, sanders)
  • Cleaning solvents and rags

4. Surface Preparation

  • Cleaning:
  • Remove dirt, oil, grease, and contaminants from the surface using solvents (e.g., mineral spirits) and cleaning rags.
  • Abrasive Blasting:
  • Use abrasive blasting (sand or shot) to achieve a surface cleanliness level of NACE No. 2 (near-white metal) or higher, according to applicable standards.
  • Power Tool Cleaning:
  • For areas that cannot be blasted, power tool cleaning may be done following NACE requirements to remove loose rust and old paint.
  • Inspection:
  • Inspect the prepared surface for any contaminants or areas missed during cleaning.

5. Application of Coating

  • Environmental Conditions:
  • Ensure ambient temperature and humidity conditions meet coating manufacturer recommendations (typical range: 40°F to 90°F and relative humidity < 85%).
  • Priming:
  • Apply a suitable primer as per the manufacturer’s specifications.
  • Ensure the primer is compatible with the topcoat.
  • Topcoat Application:
  • Apply the topcoat using the selected application method (brush, roller, spray).
  • Follow the manufacturer’s recommendations for wet film thickness.
  • For critical areas, a second coat may be warranted based on the design requirements.

6. Curing and Drying

  • Ensure proper curing conditions as per manufacturer recommendations (e.g., drying time between coats, full curing timelines).
  • Monitor ambient conditions during curing to prevent issues related to humidity or temperature fluctuations.

7. Inspection and Testing

  • Visual Inspection: After application, visually inspect for:
  • Uniform coverage
  • Absence of runs, sags, or defects
  • Adhesion and surface integrity
  • Dry Film Thickness Measurement: Use a dry film thickness gauge to measure the thickness of applied coatings and ensure compliance with specified requirements.
  • Adhesion Testing: Conduct adhesion tests (e.g., cross-hatch adhesion test) if required by the specifications to ensure coating bonds properly.

8. Safety and Environmental Considerations

  • Develop and implement safety procedures including:
  • Personal Protective Equipment (PPE): gloves, goggles, respirators.
  • Ventilation: Ensure proper ventilation during spray application.
  • Waste Disposal: Follow local regulations for disposal of paint waste and cleaning solvents.

9. Documentation

  • Maintain records of:
  • Material Safety Data Sheets (MSDS) for all coatings used.
  • Surface preparation and painting dates.
  • Inspection reports and thickness measurements.
  • Conduct a final review of the inspection and testing results before full operational use.

10. Training and Qualifications

  • Ensure personnel conducting the painting are trained and qualified in:
  • Surface preparation techniques
  • Coating application processes
  • Safety procedures related to painting

Conclusion

This procedure serves as a guideline for painting piping systems, ensuring compliance with ASME and best practices for surface protection and aesthetics. Adhering to these practices will enhance the longevity of piping systems while promoting safety and operational efficiency in industrial settings.

Procedure

Procedure for piping material receiving inspection based on ASME B31.3

I. Purpose

  •    To ensure that all piping materials received at the job site conform to the specified requirements of the project and ASME B31.3
  •    To establish a system for verifying material identity, quality, and documentation
  •    To prevent the use of non-conforming materials in the piping system

II. Scope

   This procedure applies to all piping materials, including pipes, fittings, flanges, valves, gaskets, bolts, and other components used in the construction of piping systems

III. References

  •    ASME B31.3, Process Piping
  •    ASME Section II, Materials
  •    Project Piping Material Specification
  •    Approved Piping Drawings and Material Take-Offs (MTOs)
  •    Purchase Orders
  •    ASTM Standards (as applicable to specific materials)
  •    Company Quality Control Manual

IV. Responsibilities

  •    Procurement Department: Responsible for ensuring that purchase orders accurately reflect the project’s material requirements
  •    Receiving Inspector: Responsible for performing the receiving inspection in accordance with this procedure
  •    Quality Control (QC) Engineer: Responsible for overseeing the receiving inspection process and resolving any non-conformance issues
  •    Material Controller: Responsible for maintaining material traceability and storage

V. Procedure

A. Pre-Receiving Activities

  • 1.  Review Documentation: Before material arrives, the Receiving Inspector shall review the Purchase Order, Material Requisition, Piping Material Specification, and approved drawings to understand the material
  • 2.  Prepare Inspection Area: Ensure a designated receiving area is available with adequate lighting, measuring tools, and access to relevant specifications
  • 3.  Obtain Approved Vendor List: Verify that the material supplier is an approved vendor per the project’s quality control requirements.

B. Receiving Inspection Steps

1.  Visual Inspection:

  •        Verify Packing List: Check the packing list against the purchase order to confirm the correct quantity and description of materials received
  •        Inspect for Damage: Carefully examine all materials for any signs of damage during shipping, such as dents, bends, corrosion, or broken packaging.
  • Document any damage on the receiving report and notify the supplier        
  • Check for Proper Marking: Verify that each item is clearly and legibly marked with the correct material grade, size, schedule, and heat number.
  • Markings should comply with applicable standards (e.g., ASME, ASTM)

2.  Material Verification:

  •        Review Material Test Reports (MTRs): Obtain and review the MTRs (also known as Certified Material Test Reports or CMTRs) for each material lot
  •        Compare MTRs to Specifications: Verify that the chemical composition, mechanical properties (tensile strength, yield strength, elongation), and heat treatment listed on the MTRs meet the requirements of the applicable material specification (e.g., ASTM A106 Grade B, ASTM A105) and the project piping material specification
  •        Verify Traceability: Ensure that the heat number on the MTR matches the heat number marked on the material
  • This confirms traceability of the material back to its origin
  •        Positive Material Identification (PMI): For critical applications or materials susceptible to mix-ups (e.g., alloy steels), perform PMI using a portable spectrometer to verify the material’s chemical Document PMI results

3.  Dimensional Verification:

  •        Check Dimensions: Using calibrated measuring tools (e.g., calipers, tape measure), verify that the dimensions of the received materials (pipe diameter, wall thickness, flange dimensions, fitting dimensions) conform to the specified standards and the project drawings
  •        Verify Wall Thickness: Use ultrasonic thickness testing to verify the wall thickness of pipes and fittings, especially for corrosion-resistant alloys.

4.  Specific Component Checks:

  •        Pipes: Check for straightness, ovality, and surface defects
  •        Fittings: Verify the angle, radius, and end preparation (e.g., bevel angle for welding
  •        Flanges: Check flange face finish, bolt hole alignment, and dimensions
  •        Valves: Verify valve type, pressure rating, end connections, and operator type. Check for smooth valve operation
  •        Bolting: Verify bolt diameter, length, material grade, and thread
  •        Gaskets: Check gasket type, size, and material compatibility with the intended

5.  Documentation:

  •        Complete Receiving Inspection Report: Document all inspection results on a receiving inspection report, including the purchase order number, material description, quantity inspected, inspection date, inspector’s name, and any discrepancies or non-conformances
  •        Attach MTRs: Attach copies of the MTRs to the receiving inspection
  •        Maintain Records: Maintain a file of all receiving inspection reports, MTRs, and related documentation for future

C. Non-Conformance Handling

  • 1.  Identify Non-Conformances: Any material that does not meet the specified requirements shall be identified as non-conforming
  •  2.  Segregation: Segregate non-conforming materials from conforming materials to prevent accidental use
  • 3.  Notification: Notify the QC Engineer and Procurement Department of the non-conformance
  • 4.  Disposition: The QC Engineer will determine the appropriate disposition of the non-conforming material, which may include:
  •        Return to Supplier: Return the material to the supplier for replacement or credit
  •        Repair: Repair the material, if possible, and re-inspect to verify conformance
  •        Use-as-is: Accept the material “as-is” with a deviation, if it is determined that the non-conformance does not affect the safety or functionality of the piping system. This requires approval from the Engineering Department and the client, if
  • 5.  Documentation: Document the non-conformance and the resolution on a Non-Conformance Report (NCR)

D. Material Storage and Handling

  • Proper Storage: Store materials in a clean, dry, and secure area to prevent damage or deterioration
  • Material Identification: Maintain material identification throughout storage and handling
  • Handling Procedures: Use proper lifting and handling equipment to prevent damage to materials
  • Inventory Control: Implement an inventory control system to track the location and status of all piping materials

VI. Acceptance Criteria

  •    Materials are accepted if they meet all the requirements of this procedure, the applicable material specifications, and the project piping material
  •    All documentation is complete and accurate
  •    There are no unresolved non-conformances

VII. Training

   All personnel involved in the receiving inspection process shall be trained on this procedure and the relevant material specifications

VIII. Records

  •    Receiving Inspection Reports
  •    Material Test Reports (MTRs)
  •    Non-Conformance Reports (NCRs)
  •    Purchase Orders
  •    Material Requisitions
  •    Calibration Records for Measuring Equipment
  •    PMI Reports

This comprehensive procedure ensures that all piping materials are thoroughly inspected upon arrival at the job site, minimizing the risk of using non-conforming materials and ensuring the integrity of the piping system

Remember to adapt this procedure to your specific project requirements and company standards.

Procedure

Basic procedure for conducting piping pressure tests based on ASME B31.3

I. Purpose

  • To verify the integrity and leak-tightness of the constructed piping system before it is put into service
  • To ensure compliance with ASME B31.3 code requirements

II. Scope

  • This procedure applies to all new piping systems and modified piping systems within the specified facility or project
  • It covers hydrostatic and pneumatic testing methods

III. References

  • ASME B31.3, Process Piping
  • Project Piping Specifications
  • Approved Piping Drawings and Isometrics

IV. Responsibilities

  • Piping Engineer: Responsible for determining the test pressure, test medium, and any special testing requirements
  • Construction Supervisor: Responsible for ensuring that the piping system is properly prepared for testing, including adequate supports and restraints
  • Quality Control Inspector: Responsible for witnessing and documenting the pressure test
  • Test Personnel: Responsible for performing the pressure test in accordance with this procedure

V. Prerequisites

  • All piping fabrication and installation must be complete and inspected
  • All welds must be visually inspected
  • Piping system should be supported per the design requirements
  • Temporary supports may be needed to accommodate the weight of the test fluid
  • All components, including valves, fittings, and specialty items, must be properly installed and tightened
  • The piping system must be clean and free from debris
  • All connections not subject to the pressure test must be disconnected or isolated using blinds or other suitable methods
  • Pressure gauges must be calibrated and certified
  • Safety relief devices must be installed or provisions made to prevent over pressurization
  • All personnel involved in the test must be trained and familiar with this procedure and potential hazards

VI. Test Medium

  • Hydrostatic Test: Potable water is the preferred test medium. If water could damage the system or cannot be used due to freezing, a suitable non-toxic liquid with a flash point above 120°F (49°C) may be used
  • Pneumatic Test: Clean, dry compressed air or nitrogen is used

VII. Test Pressure

  • Hydrostatic Test Pressure: Calculated per ASME B31.3, para. 345.4.2
    The test pressure shall be 1.5 times the design pressure multiplied by the ratio of the allowable stress at the test temperature to the allowable stress at the design

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