MANUFACTURING PROCEDURE OF

SPOOL

CONTENT

1. OBJECTIVE

2. SCOPE OF APPLICATION

3. IMPLEMENTATION RESPONSIBILITY

4. REFERENCES

5. TERMINOLOGIES

6. DEVELOPMENT

7. QUALITY CONTROL CONSIDERATIONS

8. SUPPLEMENTARY PROVISIONS OF THE SECURITY AREA

9. CHANGE HISTORY

10. APPLICABLE RECORDS

11. ANNEXES
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1. OBJECTIVE
This document describes the activities related to the pre-fabrication process.
pipe sections (spools) in the workshop that will be dispatched in that condition to
work for the subsequent assembly of the project

2. SCOPE OF APPLICATION
Applicable to the pre-fabrication activities of pipes whose work will be carried out in

3. RESPONSIBILITY OF IMPLEMENTATION
Plant Manager / Project Administrator:
Responsible for the implementation of this procedure, disseminating it to all the
involved individuals
Provide the necessary resources for the development of activities and of the
corrections that took place according to the scheduling of activities
daily.
Maintain constant communication with the Client and the Quality Control Inspector
in order to carry out the inspection correctly and in a timely manner.

Coordinate, plan, and verify the allocation of human and material resources
for the development of daily activities according to the established planning.

Supervisor de Calidad:
Responsible for verifying compliance with this procedure before, during
and after the inspection.
Coordinate with the Quality Inspector the preparation of the controls of the
activities and the corrective actions for any deviations that occurred.

Security Supervisor:
Carry out the necessary procedures to obtain the authorizations.
required for the execution of activities and tasks.
Advise and verify the execution and quality of the 5-minute talks to the staff
involved in the assembly tasks.
Train staff on safety issues related to activities of
assemblies described in the present procedure.
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Manufacturing Supervisor:
Responsible for executing and complying with this procedure in such a way that
control the potential risks assessed for this task.
Direct responsible for the enabled works, preparation, assembly, and welding
of the carbon steel and stainless steel pipe spools available with the
personal, tools and equipment necessary for the completion of activities
scheduled daily.
Verify the compliance of the daily 5-minute safety talk with the staff
involved in the setup prior to the development of activities.
Comply with and enforce health, safety, environmental, and quality standards
established.
Plan in collaboration with the Quality Control Inspector the execution of
the non-destructive tests to be carried out, for which personnel, equipment and
tools for its preparation and execution.

Quality Inspector:
Responsible for executing and complying with this procedure, complete the
documentation on activity control and reporting deviations that
they took place regarding the technical specifications and contractual documents.
Keep track of the protocols issued in each of the activities of
manufacturing, which will be archived in the Quality Dossier.

Welding Supervisor
Responsible for controlling the parameters of the welding procedures and
establish coordination with the quality inspector for the execution of the
visual inspection of welding.
Responsible for executing the necessary corrective actions determined by the
Quality Inspector.
Qualified Welder
Responsible for evaluating the conditions of the materials and the state of the equipment
necessary for the execution of welding tasks.
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Responsible for producing field welds according to Procedures of

Welding Procedure Specifications (WPS) approved complying with established quality requirements in

contractual documents.
Identify hazards, assess risks, and implement control measures in your area
of work.
Responsible for identifying the welded joints that I perform on a daily basis.

4. REFERENCES
Approved plans last review.

5. TERMINOLOGIES
Spool: Refers to a pre-fabricated section of a piping system that includes
the piping and its accessories that are pre-assembled in a manufacturing plant and
which are later transported to the site. It is preferred to pre-fabricate spools in the workshop due to the

availability of equipment and tools in a controlled environment. The size of

the spools are limited by factors related to transportation to the site and the
ability to manipulate it on site during installation.

6. DEVELOPMENT
6.1. EQUIPMENT / TOOLS TO USE
Devices for pipe prefabrication: tripods, supports, tables, etc.
Welding machines (for GTAW, SMAW, GMAW processes, among others),
including feeders and protective gases, if applicable.
Forklifts and other lifting equipment
Oxy-fuel cutting equipment (hoses, torch, gas cylinders, etc.)
Hand tools (includes tape measures, squares, levels, etc.) and
consumables.
Grinders (7” and 4 ½” sanders).
Turbines.
Fireproof blankets.

6.2. PREVIOUS WORKS

6.2.1. Manufacturing plans.
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The pipe manufacturing supervisor must determine the lines that will be
assigned to each manufacturing group and deliver the spool plans of
approved lines for construction.

6.2.2. Materials for manufacturing.

The group leader of manufacturing must withdraw the material from the warehouse for the
spools to be manufactured, this includes pipes and fittings.
The materials must be identified according to the technical specification of
client.
6.3. SPOOL MANUFACTURING
6.3.1. Pipe cutting
a. Cut with grinder
This cutting method can be used for all pipe diameters.
however, it will be avoided to use it frequently on the 14" diameter
nominal.
b. Cut with oxy-fuel cutting

This cutting method can be used for any diameter of pipes,

however, it will be avoided to use it frequently in pipes below 4 inches of
nominal diameter. It can also be done manually or with assistance from
auxiliary mechanical devices, such as orbital positioners or
similar.

6.3.2. Bevel Preparation

The preparation of pipe ends is an operation that follows the
pipe cutting activity, according to the type of joint to be used, is
the ends of the pipes will be tapered or
plans.
Beveled end pipes are required in joints.
pipe fittings and accessories that are commonly used in
diameters from 2" and larger.
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Once the bevel preparation is completed, a quick verification will take place.
from the angle obtained according to wps or plans.

Finally, the interior surface and the surface will be cleaned.

2” exterior from each end of the pipe.

At the ends of pipes indicated for adjustment on site, a

about a measurement of 100 mm.

6.3.3. Pipe Assembly

The assembly of pipes and their fittings will be carried out on tables.
supports, easels, or any other device that allows a good
handling of them. If necessary, clamps will be used or
clamps to facilitate the correct centering of the parts to be joined.
The coupling can be done to the limit, for pipes of diameter
nominal of 2" and larger, while for pipes smaller than 2" it will be
of the type socket or socket, in the latter case, care should be taken to ensure a

separation of approximately 1 to 1.5 mm between the flat end of the

pipe and the bottom of the fitting.
The minimum distance between 2 adjacent circumferential seams
joined fully, the measurement between the seams will not be less than 5
sometimes the wall thickness of the pipe or 1", whichever is greater.
The coupling will be performed by bracing with welding, this
bracing will be carried out by qualified welders seeking no
affect the root or heel face of the weld joint (use "spots").
The quality inspector will verify that the joint has the
geometry required in the welding procedure to be used.
A dimensional verification will be carried out before proceeding to the
welding.
If the welding is not going to be done immediately after the shoring, it will
will place adhesive tape (masking tape type) on the joint to prevent the
entry of dirt.

Welding
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The welding will be performed by qualified welders through

any of the processes indicated in the approved WPS of the project.
Before starting the welding on the joint, the joint will be identified.
according to what is indicated in the isometric.

The welder will place their identification code in a location

adjacent to the joint, the welding supervisor will check that each
the joint has the code of the welder (or welders) that welded, line or
isometric, WPS used, visual inspection of welding
(Aceptado/Rechazado)
The filler material used in the execution of the welding must
to be controlled.
Fireproof tents will be used during the welding execution.
An inspection of the electrical parameters will be carried out as needed.

6.3.5. Welding Repair

Determination of the repair
It is defined that a weld will be repaired when it does not meet
the inspection criteria according to standards or specifications
applicable or when the respective non-destructive testing report gives
as a result a defect (be it RT, PT, etc.), in relation to the standard
applicable to each case.
Removal of the defect
The removal of defective solder or portions of the base metal
It can be performed by grinding or cutting by consumable electrode.
For the case of sub-surface defects, the material must be removed.
carefully in such a way as to ensure that the defect is found
and removed.
Repair extension
The repair will be carried out over the length extension of the
welding that makes it unacceptable, that is, it must be removed as much
healthy material as necessary to carry out the repair, then after
this will proceed to apply the same non-destructive test on the
repair completed.
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Welding procedure
The repair will be carried out by a qualified welder using the same.
welding procedure specification (WPS) with which the
original welding. To select the welder who performs the
The repair will take into account your performance in similar meetings.
Re-inspection
The re-inspection of the repaired area will be carried out using the same method.

with which the defect was detected according to the procedures

established.
Only two repairs of the same joint will be accepted.

7. QUALITY CONTROL CONSIDERATIONS

The quality inspector must verify the activities during the pre-fabrication of
pipes in workshop according to the approved inspection point plan (ITP) of
project.
The equipment used in the inspection of prefabricated elements must be
calibrated.
Los controles e Inspecciones tendrán por objeto asegurar a la Supervisión de Obra que
the prefabrication has been carried out in accordance with the requirements established in:
The isometric sketches and spool plans.
The specific specification of the spool.
Procedures and technical specifications of the project.
The activities of the engineer and quality inspector are as follows:

7.1. RECEPCIÓN DE MATERIALES

The quality inspector will verify the condition of the supplied material, using
with photographic views if deemed necessary. The material received must be new
and it must be possible to identify it with the accompanying documentation.

7.2. TRACEABILITY
The quality inspector must ensure that the following is met:

7.2.1. Transfer of trademarks

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The transfer of brands will be necessary for the case of pipes that will be
cut into appropriate dimensions to form the spools.
The flow of each pipe must be reproduced in each segment of
cut pipe. The pouring of all the materials used will be recorded in
the manufacturing plans.

7.3. VISUAL INSPECTION

7.4. INSPECTION BY PENETRANT DYES

7.5. RADIOGRAPHIC INSPECTION

It is considered to perform radiographic inspection (gammagraphy) on 10% of the joints.
soldered to the maximum, according to the technical specifications of the project.

7.6. CONTROL DIMENSIONAL OF PREFABRICATED ELEMENTS

Welding completed and found acceptable by inspection methods.

applied, dimensional control will be carried out according to the within
the dimensional tolerances established by the project or by the standard
project. In the absence of one of them, the applicable tolerances will be those that
shown in Figure 1.
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7.7. INTERIOR CLEANING

The prefabricated spools will be cleaned internally by means of application.
de aire comprimido para eliminar cualquier residuo acumulado en el interior durante
manufacturing.

7.8. SURFACE PREPARATION AND PAINTING

The prefabricated spools will undergo a preparation treatment.
superficial for posterior painting, according to the applicable procedure. The material
The employee for superficial cleaning will be steel shot.
The painting of the spools must be carried out according to the indicated painting system.
for line in the project line list.
The quality inspector will generate the PE OPER surface protection record.
2039 RG 014.

7.9. STORAGE OF PREFABRICATED ELEMENTS

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The prefabricated spools will be stored ensuring that their protection is not damaged.
superficial.
All openings of the prefabricated elements will be protected to prevent the entry of
dirt during storage.

7.10. RELEASE OF PREFABRICATED ELEMENTS

The prefabricated spools will be released for shipment to the site upon approval of
the shipping lists by customer supervision.

8. CONSIDERATIONS OF SECURITY, OCCUPATIONAL HEALTH AND ENVIRONMENT

ENVIRONMENT
All risk prevention actions must be carried out in accordance with
indicated in the present procedure, to the standards of the security area and to the
risk analysis that has been specifically developed for the activities
develop during the assembly operations of carbon steel pipes,
taking into account the following:
The workers involved must maintain the work areas in good condition.
cleaning and order conditions, preventing oil spills,
oils, additives or any type of contaminant.
Production supervisors will verify compliance with standards.
order and cleanliness in order to avoid pollution and/or harm to the environment, this
Order and cleanliness will contribute to reducing the possibility of incidents due to
stumbles, slips or falls caused by disorder.
Circulation routes should be established (properly signposted) that allow
walk or evacuate the area safely in case of emergency.
Mechanical and/or electrical work, if required, may only be carried out
by authorized competent personnel for this task.
The hot work of grinding or roughing, collaborators must use
google glasses, with elastic strap to secure the lens seal with the face of
operator and prevent the entry of foreign particles into sight.
The workers who perform grinding work when they finish their task or
Those who need to remove the Google glasses must quickly clean the helmet.
to eliminate particles that settle in the hull's flaps.
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Before using manual tools, every worker will verify their proper functioning.
state, taking into account the following:
The handles of hammers, shovels, and other tools that have handles.
incorporated wooden parts must be secured to the tool through
of metal wedges or shims properly placed and that provide the
safety that the tool will not shoot out during its use.
It is mandatory on the job site to use protective equipment at all times.
basic personnel and the special ones according to the jobs to be performed and required
for the project.
Before the start of the activity, the APR of the task must be correctly filled out.
to be signed by all personnel involved as a sign of acknowledgment and
acceptance.
Similarly, the risk analysis prepared specifically for the
activity, the competency standards of the task and the present procedure.
Before starting the activities, a daily dialogue of 5 to 10 should be conducted.
minutes of aspects related to the day's activity and the recommendations for
perform the work safely, with all personnel needing to register for the daily dialogue
in the established format that must be signed by all staff
involved.

9. CHANGE HISTORY

10. ANNEX