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Field Fabrication and Installation - Process and Utility Piping
Field Fabrication and Installation - Process and Utility Piping
This specification has been revised as indicated below and described in the revision record on the following
page. Please destroy all previous revisions.
A 9/14/2010 P. D. Quinn 4
0 11/22/2010 P. D. Quinn R. C. Merrick 16
1 3/31/2011 R. C. Merrick C. Dwyer 16
Lead Engineer
Engineering Manager:
Client Approval:
TABLE OF CONTENTS
1.0 GENERAL...................................................................................................................................... 5
1.1 Summary..........................................................................................................................................5
A. Scope of Specification ........................................................................................................5
B. Terminology .......................................................................................................................5
C. Related Specifications ........................................................................................................5
D. Related Technical Requirements ........................................................................................6
1.2 References........................................................................................................................................6
A. ASME (American Society of Mechanical Engineers) ........................................................6
B. PFI (Piping Fabrication Institute) .......................................................................................7
C. Government Requirements .................................................................................................7
1.3 Drawing Presentation .....................................................................................................................7
A. Piping Isometric Drawings .................................................................................................7
1.4 Submittals ........................................................................................................................................7
A. QA (Quality Assurance) Manual ........................................................................................7
B. Pressure Test Records.........................................................................................................8
C. NDE (Nondestructive Examination) Records.....................................................................8
D. Weld Repair or Alteration Records.....................................................................................8
E. Welding Documentation .....................................................................................................8
F. MTRs (Material Test Reports) or COCs (Certificates Of Compliance) .............................8
1.5 Quality Assurance ...........................................................................................................................8
A. Field Fabricator...................................................................................................................8
B. Marafiq ...............................................................................................................................8
C. Contractor ...........................................................................................................................9
1.1 Summary
A. Scope of Specification
1. This specification prescribes the criteria for receiving, fabricating, and installing
pressure piping in accordance with applicable drawings.
2. Wherever a difference exists between this specification and the drawings, the
drawings shall govern. No deviation shall be made from this specification without
written authorization from Marafiq.
B. Terminology
2. Field Fabricate: Fabrication performed at the jobsite, either in a field shop or at the
installation site area.
3. Field Assembly Items: Includes items ranging from small branches or bolt-on
components to shop fabricated pieces such as vents, drains, instrument connections,
valves, gaskets, bolts, and in-line instruments.
C. Related Specifications
Coordinate Work prescribed by this specification with Work prescribed by the above
listed specifications.
Power and Water Utility Co. for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-P-5004
Project Name: Date: 31 Mar 2011
Contract Number: Page 6 of 16
Revision 1
1. Design Documents
a. Symbols for fittings, flanges, valves, and valve top works and accessories are
shown in Marafiq Specification MQ-SP-P-5001, Attachments 02 and 03.
b. Dimensional chart dimensions for fittings, flanges, and valves can be found in
applicable ASME standards (ASME B16.9 for wrought buttweld fittings,
B16.11 for forged socketweld fittings, etc.).
c. Acceptance criteria and evaluation of flange facing damage are shown in ASME
B16.5.
d. Detail drawings showing items such as shoes, anchors, and field supports to be
used by the Field Fabricator are shown on Attachments to Marafiq Specification
MQ-SP-P-5009.
Detail Number
Marafiq Prime Account Number
1.2 References
The publications listed below form part of this specification. Each publication shall be the latest
revision and addendum in effect at the time of issue of contract and of issue of this specification
unless noted otherwise. Except as modified by the requirements specified herein or the details of
the drawings, Work included in this specification shall conform to the applicable provisions of
these publications.
Note!!! The limits of piping governed by codes other than ASME B31.1 or B31.3
shall be indicated on the piping drawings, and piping shall be fabricated in
accordance with those codes.
Power and Water Utility Co. for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-P-5004
Project Name: Date: 31 Mar 2011
Contract Number: Page 7 of 16
Revision 1
C. Government Requirements
4. On piping drawings where only coordinates and elevations are used, the Fabricator
shall establish the required fabrication dimensions. Where fitting make-up and valves
are not dimensioned, the fabricator shall use the dimensional charts from the
applicable material product standards. Gasket thicknesses are specified in Marafiq
Specification MQ-SP-P-5002.
5. Except for ring joint flanges, references to dimensions, coordinates, and elevation are
based on the centerline of the pipe and the contact face of flanges. Ring joint flanges
are dimensioned to the extreme face of the flange and not to the contact surface of
the groove.
6. Dimensions locating Latrolets are based on the intersecting points of the centerline
of the pipe and the projected centerline of the Latrolet.
1.4 Submittals
Documents created and used by Contractor to produce, control, and manage this Work are subject
to review or approval by responsible representatives of Marafiq or Marafiq as follows:
2. The manual shall include the procedures, instructions, and QA systems to ensure that
assigned field construction, fabrication, assembly, installation, field purchased
materials and services, field engineering, workmanship, and other related services
conform with the specified code, approved design engineering specifications, design
drawings, and other contractual, jurisdictional, and legal requirements.
Keep test records according to Marafiq Specification MQ-SP-P-5010. Test records are
subject to review by Marafiq or their representative’s upon request.
NDE procedures, personnel certifications, and NDE report forms shall be reviewed and
approved by Marafiq.
E. Welding Documentation
Approved Marafiq fabrication and welding guidelines and methods are used in compliance with
project requirements. Project Piping Engineers and Design Supervisors shall monitor and review
the activities of the fabrication and installation to ensure that applicable codes, standards, and
procedures are being followed to meet project quality goals.
A. Field Fabricator
The Field Fabricator shall be responsible for fabrication accuracy. Each piece shall be
subject to check by Marafiq.
B. Marafiq
Marafiq Inspectors shall examine and inspect the final product to ensure that Marafiq
quality criteria have been met.
Power and Water Utility Co. for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-P-5004
Project Name: Date: 31 Mar 2011
Contract Number: Page 9 of 16
Revision 1
The Contractor shall examine and inspect piping components for damage and improper
manufacturing prior to beginning fabrication, in accordance with ASME B31.3,
Paragraph 341 or ASME B31.1, as applicable. After fabrication has been completed,
components shall be re-examined and re-inspected for possible damage. Repairs shall be
made before installation.
2.0 PRODUCTS
2.1 Materials
A. Specification
B. Substitutions
Substitutions, including thicker wall materials, are not permitted without written
authorization from Marafiq Material Engineering.
C. Non-pressure Attachments
D. Bolt Length
1. Store material provided by Marafiq, or purchased for this project, in an area where
exposure to heat, dirt, and contamination is avoided.
2. Within the storage area, segregate pipe and fittings by material type, size, and
schedule.
Store stainless steel, aluminum, and high alloy piping under cover and clear of the
ground. Contact with ferritic steel is not permitted and contamination from ferritic
sources is not acceptable. Protect slings and hooks by plastic insulation or nylon. Storage
banding for pipe shall be of a non-contaminating and compatible material.
Power and Water Utility Co. for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-P-5004
Project Name: Date: 31 Mar 2011
Contract Number: Page 10 of 16
Revision 1
Upon receipt, Contractor shall visually inspect every pipe and component and then reject
items that contain an injurious defect. Injurious defects are internal or external surface
dents, scars, scratches, blisters, or discontinuities that produce a notch effect or reduce the
specified wall thickness by 5 percent or more.
3.0 EXECUTION
A. Piping
1. Welding, weld examination, and weld heat treatment shall be in strict accordance
with Marafiq Welding Specification MQ-SP-P-5029.
3. Adjacent sections of longitudinal welded pipe that are joined by butt welding shall
have the longitudinal weld seams positioned so that they are at least 30 degrees apart
above the horizontal centerline.
4. Wherever possible, the Fabricator shall not position the longitudinal weld seam on
the top or bottom of the line, in order to avoid locating branch connections such as
couplings and stub-ons on the seam.
B. Internal Misalignment
2. If the deviation factors are exceeded, use one of the following procedures listed in
order of preference:
1. Orient flange bolt holes as follows, unless otherwise indicated on the piping
drawings:
Note!!! The Fabricator shall ensure that this information is included on any
fabrication drawings.
2. Orifice flanges shall be fabricated with the taps in the exact orientation shown on the
piping drawings. The up and down stream sections of pipe to which the orifice
flanges are attached may be standard mill-run pipe, but each piece shall be a choice,
hand selected piece; and the interior of the pipe shall be round, smooth, and free
from blisters and scale. Welds shall be ground flush. Keep field welds at a maximum
distance from the face of the orifice.
3. Where line taps are called for, drill the hole square to the axial centerline; in
addition, make the hole clean, sharp, and free from burrs, wire edges, or other
irregularities. Drill the hole after attaching the connection fitting.
4. Weld slip-on flanges inside and outside. Refer to Figure 328.5.2B of ASME B31.3.
Apply the weld so that the flange face shall be free of weld spatter and shall not
require re-facing.
5. For acceptance criteria and evaluation of flange facing damage, refer to ASME
B16.5.
D. Reinforcing Pads
Install reinforcing pads only where called for on the piping drawing. Pad material shall be
the same as the pipe material unless otherwise authorized by Marafiq Piping Material
Engineering. The drawing shall specify size and pad thickness. Similar pad shapes are
preferred but the pad size may be altered, provided an equivalent cross-sectional area is
maintained and code requirements are met. Each pad or each piece shall have a DN 6
(NPS1/8) vent hole, drilled and tapped NPT (American National Taper Pipe Thread)
prior to installation (at the side and not at the crotch) of the pad. Each pad or each piece
(if pad is made from more than one piece) shall be pressure tested using 100 kPag
(15 psig) air. After the pressure test, fill the vent with a grease compound.
E. Non-pressure Attachments
5. Unless indicated otherwise on the drawings, center the pipe insulation shoes over
pipe supports in the cold position. Locate and attach shoes, preferably after the line
has been installed.
2. Small residual deviations following heat treatment may be corrected only by cold
straightening after obtaining the consent of the Marafiq Inspector or Examiner. Hot
straightening after heat treatment is not permitted (except for non-pressure
attachments).
5. Completed bends shall be free from harmful defects and in accordance with
ASME B31.3, Paragraph 332 or ASME B31.1, Paragraph 129, as applicable.
Unless otherwise noted, stub-ons shall be according to ASME B31.1, Figure 127.4.8,( A), (B),
(C); and Figure 127.4.8(D) Items a or c; or ASME B31.3, Figure 328.5.4, A, B, C; and Figure
328.5.4D, Items (1) or (3); whichever is applicable.
H. Fabrication Tolerances
1. The fabrication tolerances for fabricated piping shall be in accordance with PFI
Standard ES-3. When closer tolerances are required, they shall be noted on the
piping drawing.
4. The fabrication tolerances for piping over DN 600 (NPS 24) may require special
consideration. The requirements shall be reviewed for each project, with special
attention being given to lined pipe.
I. Pup-Pieces
Surface preparation and painting of piping shall be in accordance with Marafiq Welding
Specification MQ-SP-M-4039.
A. Welding
B. Flanges
1. ASME B16.5 Flanges shall have a gasket contact surface finish of 3.2 to 6.3
micrometer (125 to 250 micro inch) Ra. ASME B16.5 shall be used to determine
acceptance of the surface finish. Refer to Attachment 01 of this Specification for
allowable facing damage.
2. Make visual examination of each ASME B16.5 finish flange surface before coating
with rust preventative and before attaching the protective flange cover; refer to
ASME B16.5 and Attachment 01 of this Specification for acceptance.
C. Prefabricated Piping
1. Visually examine prefabricated piping internally to ensure the foreign matter has
been removed.
3.3 Installation
A. General
Except where shown otherwise on the drawings, piping shall conform to the following:
Power and Water Utility Co. for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-P-5004
Project Name: Date: 31 Mar 2011
Contract Number: Page 14 of 16
Revision 1
B. Flange Bolting
2. Unless specified otherwise, provide a bolt stress of 206 MPa (30,000 psi) minimum
or 310 MPa (45,000 psi) maximum using a lubricant on the bolt threads.
3. Prior to bolt-up, examine flange faces. Flange faces shall be in as-new condition, and
shall be wiped clean of any debris, excess oil, grease, and dirt. Restore damaged
flange faces to as-new condition. Do not perform weld repairs on flange faces or
flanges unless previously authorized by Marafiq.
4. Do not use washers or spacers to make up bolt length. Bolt lengths are specified to
prevent over sizing.
C. Joints
2. Seal weld threaded joints only where required by Marafiq Specification MQ-SP-P-
5002. Do not use thread compound on joints to be seal welded.
3. Leave underground line joints exposed until after completion of field pressure and
leakage testing unless partial backfilling is required for anchoring lines. Do not test
underground lines with concrete thrust blocks until the concrete has cured. Any
deviation to this requirement shall be approved by Marafiq.
4. Do not apply paint or insulation over any joints until testing has been completed.
D. Supports
1. Piping system vents and drains may not necessarily be shown on the piping design
drawings. Vent high points and drain low points. The Piping Contractor doing the
erection shall furnish and install additional vents and drains needed. Unless they are
connected to a header or run to a drain or tail pipe, plug or cap additional vents and
drains in accordance with the material specification for the service.
2. Vent and drain valve sizing guidelines are per Attachment 01 of this Specification.
Material is per Marafiq Specification MQ-SP-P-5002.
a. Vent Sizes
b. Drain Sizes
F. Branch Connections
1. Branch connections are defined for each service in Marafiq Specification MQ-SP-P-
5002, except nozzle weld reinforcing requirements that shall be noted on isometric or
plan drawings.
2. Take care in shaping the ends of branch nozzles, as well as holes burned into the pipe
for branch connections, to ensure fit with suitable provision for weld metal and so
that the branch connections do not project inside the pipes. Advise Marafiq before
cutting connections into existing lines. Refer to Marafiq Specification MQ-SP-P-
5018, Piping Tie-Ins.
G. Cleanliness of Piping
1. Open-end and flange protection shall be used throughout installation. Protect open
pipes at times when work on them is not actually taking place.
2. Inspect individual pipe sections, prefabricated spools, and pipeline items internally
during installation, and remove any foreign matter before final welding or bolting.
Power and Water Utility Co. for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-P-5004
Project Name: Date: 31 Mar 2011
Contract Number: Page 16 of 16
Revision 1
4. Piping contiguous with special equipment, which requires cleaning to the equipment
Manufacturer's procedure, shall be inspected by and have cleaning supervised by the
Manufacturer's representative.
Testing of installed piping systems shall be in accordance with Marafiq Specification MQ-SP-P-
5010.
4.0 ATTACHMENTS
End of Specification