BAB 04 Pipe Manufacturing & Fabrication

Bab 4 Pipe Manufacturing & FabricationBab 4 Pipe Manufacturing & Fabrication

BAB 4PIPE MANUFACTURING

BAB 4PIPE MANUFACTURING

Desain, Fabrikasi, dan inspeksi Sistem PerpipaanDesain, Fabrikasi, dan inspeksi Sistem Perpipaan1

ELECTRIC WELD PROCESSES:A. ELECTRIC RESISTANCE WELD (ERW)B. ARC WELDING PROCESSES (SMAW/MMA; SAW;

FCAW)FCAW).

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B. SEAMLESS PROCESS

I. PIERCING PROCESSES: ROLL AND DISC PIERCINGARE USED TO MAKE PIPES AND TUBES UP TO 26INCHES IN DIAMETERINCHES IN DIAMETER.A. HOT FINISHED (TO 26” OD)B. COLD DRAWN (ANY SIZE UP TO 10 ¾” OD)C. COLD EXPANDING (SIZES 16” TO 26” OD)

II. VERTICAL PIERCING PROCESS

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TO MAKE TUBES AND CYLINDERS, 3 TO 20” ODHOT DRAWN (FINISH).

III. EXTRUSION PROCESS (SMALL SIZES ONLY)

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PENGENDALIAN KUALITAS YANG DILAKUKAN:

1. PEMERIKSAAN PELAT BAHAN PIPA DENGAN METODA ULTRASONIK

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2. PEMERIKSAAN LAS-LASAN PADA PIPA UOE DAN ERW.

METODA PEMERIKSAAN: UT DAN X-RAY

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3. PEMERIKSAAN KUALITAS PIPA SEAMLESS DENGAN METODA EDDY CURRENT, ELECTROMAGNETIC; MAGNETIC DAN UT

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PENERAPAN COATING;

1. EXTERNAL COATING:

BAHAN: POLYETHYLENE UNTUK PIPA DENGANBAHAN: POLYETHYLENE UNTUK PIPA DENGAN DIAMETER YANG KECIL DAN MEDIUM

* GENERAL UNDERGROUND SERVICE

* HIGHLY CORROSIVE SOIL SERVICE

* UNDERWATER SERVICE

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NOMINAL DIAMETER: ½ - 24 IN.

PIPE LENGTH: 20 – 40 FT

STANDARD COATING THICKNESS: 0.06 – 0.1 IN

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UNTUK DIAMETER PIPA YANG BESAR COATING DILAKUKAN DENGAN CARA: HELICALLY WRAPPED.

NOMINAL DIAMETER: 16 – 64 IN.

PIPE LENGTH: 20-62 FT

STANDARD COATING THICKNESS: 0.1 – 0.12 IN

BAHAN PELAPIS LAIN YANG DIGUNAKAN ADALAH:

FUSION BONDED EPOXY POWDER. LAZIM DITERAPKAN PADA PIPA DENGAN DIAMETER YANG BESAR

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PADA PIPA DENGAN DIAMETER YANG BESAR.

STANDARD COATING THICKNESS: 14 MIL (350 MIKRON)

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UNTUK MEMELIHARA UJUNG PIPA (PIPE END); TERUTAMA UNTUK DIAMETER PIPA YANG BESAR, DILAKUKAN PEMASANGAN “BEVEL PROTECTOR”

20UNTUK PIPA YANG KECIL DIPASANG VINYL SHEET COVER

2. INTERNAL COATING:

LAZIMNYA DITUJUKAN UNTUK MENURUNKAN GESEKAN ANTARA FLUIDA DAN DINDING PIPA BAGIAN DALAM

BAHAN YANG DIGUNAKAN: EPOXY RESIN, PHENOLIC DAN ATAU BAKED URETHANE

DIAMETER NOMINAL YANG LAZIM ADALAH: ½ - 56 IN.

PANJANG PIPA: 20-45 FT.

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C. CENTRIFUGAL CASTING:

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D. PROSES PEMBUATAN PIPA YANG LAIN:

I. UOE PIPE (U-ING; O-ING AND EXPAND-ING)II. ERW PIPEIII SPIRAL WELD (SP) PIPEIII. SPIRAL WELD (SP) PIPEIV. ROLL AND PRESS BENDING (RP) PIPE

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FABRICATION and

INSPECTION

FABRICATION

• Fabrication in pipeline system is design and assembly severalcomponents into a complete system by means of welding.

• Fabrication can be carried in field and workshopFabrication can be carried in field and workshop

• Fabrication requirement decision depends on size, configuration,operating pressure and temperature.

Shop fabrication of pipework

ON SITE FABRICATION•Generally for pipe with nominal diameter<50 mm.

•For Screwed pipe•Need several specific equipment.

- Oxy-acetylene gear- Oxy-acetylene gear- Electric arc-welding plant

- Transformer- Rotary pipe cutter

- Manual /hydraulic bending equipment- Screwing machines

- Power saw- Scaffolding

- Ladder- Lifting equipment

SEVERAL SPECIFIC PROCESS TO BE CONSIDERED IN FABRICATION

• Hot and cold bending. • Induction bending.

• Mitre/gusseted bends. • Branch connection.

• Swaging.

Reinforcement of Welded Branch connectionAll welded branch connection shall meet the following requirements:

• For single connection, the design must be adequate to control the

stress levels in the pipe within safe limit

• Required cross sectional area, AR:

where:

d = greater of the length of the finished opening in the header wall measured parallel to the axis of the run or the ID of the

branch connection

t = the nominal header wall thickness required for the design

dtA R =

t = the nominal header wall thickness required for the design pressure and temperature

• The area available for reinforcement shall be the sum of the cross sectional area in the header thickness, branch wall thickness, and

reinforcement area.

Special Requirement for Branch Connection

Cold bending

Induction bending

Mitre bend Welded segments

Branch connections

INSPECTION

GeneralGeneralInspection must be conducted by a person who hasInspection must be conducted by a person who has

competency (inspector)Inspection responsibility Inspection responsibility

The responsibilities of the owner to give inspector so that inspection match the appropriate procedures

The inspector authorityThe inspector authorityInspectors shall have access to the pipeline installation, including

manufacturing, fabrication, heat treatment, assembly, erection, manufactu ing, fab ication, heat t eatment, assembly, e ection,examination, and testing.

Inspectors have authority to audit, to review all the certification and records to complete the responsibilities to the owner

INSPECTOR QUALIFICATIONSINSPECTOR QUALIFICATIONS

Inspector, which is chosen by the owner, is the employee of the owner or employee from engineering/scientific organization or p y g g gemployee from the insurance/inspection concern as the agent

owner. Inspector not come from manufacturer employee, fabrication.

Inspector must have experience more than 10 years in design, fabrication, and inspection to pipeline industries.

Inspector has responsibility to determine qualified men (as the inspector’s delegates) to do the inspections.

EXAMINATIONSEXAMINATIONS

GeneralThe manufacturer, fabricator, or erector does the quality

controls.

Examination responsibilities - Prepare all the materials, component, and the productions

processes as requirements- Do the examination based on the code requirements

- Prepare examinations account for the inspector needed

Fig. 2.1 Typical Weld Imperfections

Examination Requirements Examination Requirements

Normal examination requirements:Visual examination

• Adequate materials and components• At least 5% from fabricationAt least 5% from fabrication

• 100% fabrications for longitudinal weld• Random examination for screw, bolt and other connection

• Random examination during system installations• upright pipe examination for the broken data

Other examination• not less than 5% from butt circumferential weld and miter

groove have to inspected randomly with radiography or ultrasonic

• not less than 5% from all brazed joints have to inspected with in-process examination

Certifications and recordsCertifications and records

• Guarantee from the examiner that the materials and the components with the specified grade was already

through heat treatment process, examination, and testing with certifications, records or the other data

• Examiner have to prepare to the inspector that the quality control necessity has been organized

Examination – Category D Fluid ServiceMore over, pipes and those elements for Category D FluidService should inspected visually to convince examiner that thecomponents, materials, and production processing were fulfillthe codes and engineering design

Examination – Severe Cyclic Condition• Visual examination was done except for connection process

and pipes installations that was inspected• Other examination, all the welding connections inspected by

100 % radiography or by 100% ultrasonic. Socket welds andbranch connection welds inspected by magnetic particle orliquid penetrant

• In-process examination• Certification and records

Addition ExaminationAddition Examination

Spot RadiographyLongitudinal welds

Circumferential butt welds & other weldsAdvanced Sampling for examination

Welding has to checking

Hardness Test

Examination to overcome the hesitation

Examination PersonnelExamination Personnel

Qualifications and certificationsHas a training and experience equivalent with examinations necessity Superior has to signed records from examiner showed Superior has to signed records from examiner, showed date, and qualifications personal result

Special criteriaPeople which is doing the examinations should not production people

Examination ProcedureExamination Procedure

Based on BPV Code, Section V, Article 1, T-150.Superior has to signed records from examiner, showed date, and qualifications personal result

Examination TypesExamination Types

Regular Method, described on code, engineering design, or from inspector

Special Method, if not list on code

Definition100% examinationRandom examinationSpot examinationpRandom spot examination

Visual Examination

Definition

Observations for parts of the components, joints, and the others pipeline elements which can be examined visually before during or after manufacturing factors fabrications before, during, or after manufacturing factors, fabrications, assembly, erection, examination, or (testing)

Includes verifications from code criteria and engineering design for materials, components, dimensions, joints, alignment, welding, bonding, brazing, or the others jointing process, support, assembly, and erection

Method, BPV Code, Section V, Article 9

Magnetic Particle ExaminationMagnetic Particle ExaminationMethod, BPV Code, Section V, Article 7

Liquid Liquid PenetrantPenetrant ExaminationExaminationMethod BPV Code Section V Article 6Method, BPV Code, Section V, Article 6

Radiographic ExaminationRadiographic ExaminationMethod, BPV Code, Section V, Article 2

Radiography types100% radiography

Random radiographyRandom radiographySpot radiography

Ultrasonic ExaminationMethod, BPV Code, Section V, Article 2

In-Process Examination

Definition Joint preparation, and cleanlinessPreheatingPreheatingFit-up, joint clearance, and internal alignment to joiningJoining processing parameters, includes filter materials(for weld) root pass conditions after cleaning, and add liquid penetrant / magnetic particle examination(for weld) slag elimination in weld

Method visualMethod, visual

Leak TestIn the owner option, for pipelines system in Category D fluid service, leak test is permitted.

The test can be changed by pneumatic test or combinations The test can be changed by pneumatic test or combinations from hydrostatic-pneumatic test, when the owner assumed that hydrostatic leak test were not practical.

If it still not practical, then used others testing types. These category includes:

Hydrostatic test will destroy linings or internal insulation, or contaminate process that can destroy the system, corrosion, or others damaged. P ti t t f il d (b ittl ) b th l Pneumatic test can cause failed (brittle) because the low temperature during the test

Leak Test Regular Criteria

Pressure limitationStrain over the crushed powerE i f fl idExpansion from fluidsPreliminary pneumatic test

Other criteria Leaking examinationHeat treatment Low TemperatureLow Temperature

Special criteria for testingPiping subassembliesFlanged joints

External Pressure Pipe

Jacketed pipingInternal part shall passed leaking test based on critical design pressure, both internal and external pressurej k t h ll d l ki g t t b d d ig jacket shall passed leaking test based on design pressure on jacket

Repairing or addition after leak test

Test recordsDateIdentification pipelines systemIdentification pipelines systemFluidPressureCertificate from examiner

Leak Test Preparation

Joints exposed, all the joints should detected visually during the test Temporary supports, needed to support fluids weightExpansion joints, it shall be tested without temporary restraint when testing pressure under 150% from design pressure. If more, temporary restraint are neededLimits of tested piping, equipment which hasn’t tested shall be isolated during the test

Hydrostatic Leak TestHydrostatic Leak Test

Fluids, water are recommended, but nontoxic liquid can be used. If the fluids (flammable), light point must under 490C (1200F) PressurePressure

Not more than 1.5 times pressure plan For temperature plan upper testing temperature, testing temperature determined by:

SPSP T

T5.1

=PT = Maximum (minimum) temperature

relative testingP = temperature design internal relative

ST =temperature testing strain

If temperature testing will result strain exceed yield strain in the testing temperature, thus pressure testing is decreased

ST =temperature testing strainS = temperature design strain (table A-1)

Hydrostatic test of pipes with container as one system

if pressure testing of pipes that adhere to container are equal or less than pressure testing for container, then system will be tested according to the pipe pressure test

if pipes pressure test more than container pressure test and if pipes pressure test more than container pressure test and assumed not practical to isolated pipes from container, thus the system will be tested according to the container pressure

Pneumatic Leak Test - reference

Preventive, this testing will involve energy release risk that being saved in compressive gas. Need further actions to minimalist the brittle failed probability. Release pressure equipments, to limit pressure.Release pressure equipments, to limit pressure.Gas Fluids, if not air, it must be nonflammable and nontoxicPressure , 110% pressure plan Procedure

Pressure will increase gradually until relative pressure less than 170 kPa (25 psi)Pressure is increased until reach test pressure Restrained a few minutes in every step to homogenizes strain Restrained a few minutes in every step to homogenizes strain to pipesPressure will be decreased until pressure plan before leaking examinations

HydrostaticHydrostatic--Pneumatic Leak TestPneumatic Leak Test

ProceduresPressure will be increased gradually to pressure operationRestrained a few minutes in every step to homogenizes strain to pipesto pipes

Examination for leaks, are permitted to avoid examination leaking from joints beforeSensitive leak test, testing sensitivity not less than 10-3 atmml/s

Lowest testing pressure are 105 kPa (15 psi) relatively, or 25% pressure plan Pressure will increased gradually to pressure relative 170 kPa(25 psi). Pressure is restrained a few minutes in every step to homogenizes strain to pipes

Alternative testing leaking Weld examination

• Circumferential, longitudinal, and spiral groove 100% radiographs

• All weld (except a) checking with liquid penetrant • All weld (except a), checking with liquid penetrant Flexibility analysis Testing method, sensitive leak test