ENGINEERING SPECIFICATION FOR FABRICATION AND INSTALLATION OF CARBON STEEL PIPEWORK To ASME B31.3 Fuel Farm Pipework 13.03.2015 First Issue REV. DATE DESCRIPTION DOCUMENT NO:CPCAVI-BIA-SPEC-M001. PROJECT NO. 03 1 ot28714, 1.2, CODES, STANDARDS AND TERMINOLOGY GENERAL Lia 142 113 The selection of Fabricator shall be subject to the approval of the company, the basis of the Fabricator’s experience of similar work, shop facilities, production methods, quality assurance procedures etc The Fabricator shall not sub-contract any part of the work without the Company's written approval. The Fabricator shall submit to the Company for review and approval the documentation required by the Quality Assurance Data Sheets attached to the order.The allowable timescale for submission of documentation and the required approval status prior to release for fabrication shall be as specified in the QA Data Sheets TERMINOLOGY 121 1.2.2 123 1.2.4 125 1.2.6 1.2.7 The COMPANY shall be taken to mean -that client identified as such in the tender enquiry. ‘The PURCHASE is the authority responsible for issuing the relevant enquiry or order, and will be The Company of the Company's nominated Contractor. The CONTRACTOR is the organisation appointed by the Company and responsible for the overall mechanical design and procurement of process plant for a particular project. ‘The FABRICATOR is the organisation responsible for supplying materials, carrying out the mechanical design where applicable, fabrication, preparation for shipment and delivery of equipment in accordance with the Purchaser's order. The INSPECTOR is the Company employee or duly authorised representative of the Company, appointed to monitor material quality, workmanship and conformance to data supplied, Standards and Codes during fabrication, testing ete. ‘The CERTIFYING AUTHORITY is the independent Inspection Agency or other body authorised to inspect the equipment through the various stages of fabrication, examine and approve all documentation including design calculations, and to certify that the equipment and documentation meet all requirements, Where matters have to be agreed or approved, this shall mean agreed or approved in writing between the Purchaser and the Fabricator. Where the Purchaser is a Contractor, he must first obtain Company agreement and approval concerning matters in this document. 2012871.3. CODES AND STANDARDS 1.4. ALL PIPEWORK FABRICATION, TESTING, INSPECTION AND INSTALLATION ‘SHALL MEET, AS A MINIMUM STANDARD, THE REQUIREMENTS OF ANSI 831.3.CHEMICAL PLANT AND PETROLEUM REFINERY PIPING. 2. DESIGN 2.1, WELDING END AND BRANCH ATTACHMENT JOINT DESIGN 2a Each piping branch reinforcement pad or segment therefore shall be provided with one hole (at the side and not at the crotch) drilled and tapped 1/4” NPT. 2.2, PROXIMITY OF WELDS 224 2.2.2 The minimum distance between toes of adjacent welds shall be the lesser of 40mm or twice the wall thickness of the thickest pipe/itting Dimensions less than those specified above are not permitted except where Company agreement has been obtained and the following additional requirements met: (a) Dependent on material, thickness and configuration, the Company may require an intermediate stress relief to be carried out. (b) Care shall be taken to minimise stress concentrations. Weld profiles shall be ‘as smooth as possible; at the discretion of the Inspector welds may be dressed. () When branch welds cross or are located closer than the allowable to main seams, such seams shall be radiographed or U/S tested for a distance on either side of the hole of not less than the opening diameter. (d) When attachments are located closer than the allowable to main seams they shall cross the seam completely. The seam shall be radiographed to the extent which will be covered by the attachment, plus on either side of the attachment, a distance of twice the pipe wall thickness. 2.3. THERMAL RELIEF PROVISION 23.1 Al protection sections of pipelines where locked in legs of product can exist shall be protected with thermal relief. Thermal Relief assemblies should straddle the isolation point closest to storage.it is likely that on one pipeline a series of thermal relief assemblies will be required. It is essential that the set pressure on the relief valves are properly selected to ensure the cascade effect valves limits the maximum line pressure to below the design rating of the pipeline and/or any underated piece of equipment that may be present on the particular system. Thermal relief assemblies “cascade” back towards storage. Each thermal relief assembly shall consist of flanged thermal relief valve. The contractor shall ensure all pipelines are adequately protected against thermal expansion of product throughout the phase of the work. 30128734. 32, 4a. PIPE CUTTING AND WELDING EDGE PREPARATION METHOD 3.1.1 Pipes shall be cut either by mechanical means or by thermal cutting. 3.1.2 End bevelling shall be done by machining, hand grinding or machine flame cutting. 3.1.3. Where thermal cutting is employed, all slag, oxides and traces of previously melted metal shall be removed from welding edges by grinding or machining to sound metal 3.1.4 The preheat level to be used for thermal cutting shall be as required by the relevant welding procedure. 3.1.5 The bevel geometry shall be the same as and within the tolerances stated in the approved welding procedure. INSPECTION 3.2.1 After the material has been prepared for welding it shall be visually examined to confirm the surface within 25mm of the bevel edge is smooth and uniform, free from cracks, tears, laminations, gouges and any other discontinuities which may affect the integrity of the weld. if there is any indication of defects the weld preparation area shall be subjected to surface crack detection.Where any defects are found the weld bevel shall be re- prepared and re-examined. PIPE BENDING GENERAL 4.1.1 Unless otherwise specified on drawings or Piping Class documents bends in piping shall be achieved using standard elbows, 4.1.2 Where bending is required this may be performed either in the hot or cold condition and shall be carried out in accordance with ANSI 831.3 except as modified below. The bending and heat treatment procedures proposed by the Fabricator shall be subject to the approval of the Company. 4.1.3 The bend centre line radius shall be 5 times the nominal pipe diameter unless otherwise stated on the drawings. 4.1.4 Pipe bends shall be fabricated using seamless pipe and shall have no girth welds. 4.1.5 Bends shall not be wrinkled, cracked, scratched, gouged, die marked or buckled and shall be in one plane. 4.1.6 Weld repair or pipe bends shall not be permitted. 4.1.7 ‘Cutand shut’, creased or corrugated bends are not permitted. 40128742. 43. 5.1. HOT BENDING 424 422 423 424 425 426 Hot bending shall be carried out and completed at a metal temperature above the upper critical point (AC3), within the range 900 degrees celsius. Heat treatment after bending is not required unless the finished bend hardness exceeds 225 BHN (237 VPN), or otherwise specified on the drawings or Piping Class documents, in which case a normalising operation shall be carried out at 900-950 degrees celsius. The temperature and furnace atmosphere shall be carefully controlled during the bending and any subsequent heat treatment cycle to avoid excessive scaling, carburisation or de- carburisation. It is recommended that pipes 2” n.b and larger be packed with dry, sulphur free silica sand before hot bending. The sand shall be completely removed after bending. The bore of completed bends shall be visually examined to ensure freedom from excessive scaling, which may be removed by pickling, blasting or mechanical means. When pickling is used the procedure shall be subject to Company approval. For pipework in sub-zero temperature service hot formed bends shall be normalised at 900 degrees celsius 950 degrees celsius, unless it can be demonstrated that the temperature control during hot forming results in the item having the same mechanical properties as if is was normalised. MITRE BENDS 43.1 432 Mitre bends shall only be used when specified by the drawings or piping Class documents. Mitre bends shall be produced by butt welding together segments cut from the same length of pipe. The maximum change of direction between adjacent segments shall be 30 degrees. FLANGED JOINTS GENERAL 5.11 Prior to welding on a slip-on flange the bore of the flange and the pipe end for a distance equal to the flange thickness plus 25mm minimum shall be cleared free from any protective coating, oil, grease, loose scale or rust. The difference between the diameter of the flange bore and the outside of the pipe shall not exceed Smm. Care shall be taken when applying the inside fillet weld to avoid damaging the facing. The flange shall be positioned such that the distance from the face to the pipe end is equal to the pipe wall thickness plus 3mm. 5012876.1. 5.1.2 513 5.1.4 515 Flange bolt holes shall straddle the vertical or NS centre line as applicable, except where otherwise specified on the piping drawings, and shall match the orientation of the mating flanges. Loose flanges shall be bolted to an adjacent flanged piece for shipment or supplied in hessian or canvas sacks securely attached to that part of the fabrication. Flange facing shall be in accordance with the applicable Piping Class document. Should warping take place during the fabrication the joint contact surfaces may be restored by machining to their original accuracy provided the flange thickness dimensions are not reduced below the minimum required by the relevant ANSI flange specification. Pipe ends connected to threaded flanges shall not project through to form part of the gasket surface. WELDING GENERAL 611 612 613 614 61s The Fabricator shall provide adequate and systematic supervision by competent personnel to ensure that the required quality levels are maintained. At the discretion of the Inspector, any welder who consistently fails to meet the standard shall be required to undergo re-training, re-testing or shall be removed from the job completely. All welding shall be carried out in accordance with qualified and approved weld procedures by welders who have been qualified to the relevant testing code. The Fabricator shall make maximum effort to ensure that arc strikes outside the welding groove are avoided. When these occur outside of the finished weld the arc strike shall be carefully removed by grinding, followed by a magnetic particle or dye penetrant inspection of the ground area to confirm it is defect free. Care shall be taken to ensure the ground area ‘blends in’ smoothly with the surrounding material such that no sharp notch results and the thickness is not reduced below the required minimum wall thickness shall be carried out in accordance with an approved repair procedure. The acceptance of arc strikes outside of the welding groove shall be at the sole discretion of the Inspector who shall be requested to inspect the damage and approve the repair procedure or reject the damage material as appropriate. Weld stops and starts shall be staggered by 50mm minimum such that adjacent passes or layers do not coincide. Weld stops and starts shall be ground or chipped prior to laying subsequent passes. The number of weld shall be minimised. Pipe lengths smaller than 1m shall not normally be welded together. 6 0128762. 63. 6.4, 65. 6.1.6 Internals of inline valves and equipment which may be damaged due to heat transfer from the welding process shall be removed prior to welding wherever possible. BUTT WELDS 6.2.1 All pressure containing butt welds shall be full penetration. Where access permits consideration shall be given to welding from both sides. 6.2.2 Permanent backing strips shall not be used. Temporary backing strips may be used only when approved by the Company. The material for temporary steel backing strips shall be of the same nominal composition as the parent material. After completion of welding the backing strips shall be removed and the area dye-penetrant examined to confirm the absence of significant defects. Alternative types of backing materials shall only be used where approval has been obtained from the Company. BRANCH WELDS 6.3.1 All welded branch connection shall be joined to the header with full penetration welds of comparable quality to, and subject to the same limitations (fit-up, alignment, welding process etc) as girth welds, unless otherwise specified. 6.3.2. Piping branch reinforcement pads shall preferably be one piece but when not practicable pads may be split circumferentially or along the axial centreline and welded together by full thickness/full penetration welds 6.3.3 Reinforcing pads for branches and structural attachments shall be accurately shaped and fitted to ensure that the gap between the periphery of the pad and the pipe outside diameter is not greater than 1.5mm. FILLET WELDS 6.4.1 A minimum of two runs shall be deposited for all permanent attachments to pressure parts where strength requirements permit, one weld run shall be acceptable for weld to non-pressure containing parts. 6.4.2 All fillet welds shall be continuous and their surfaces shall be free from marked irregularities.All fillet welds shall be overlapped at the stop-start position by at least 10mm SOCKET WELDS 6.5.1 Care shall be taken during the assemble of socket weld joints to ensure there isa 1.5mm gap between the pipe end and root face of the fitting. 6.5.2. Welds shall be fillet welds deposited by the MMA or TIG process, with a minimum of two runs. The weld surface shall be free from marked irregularities. 70128766. 67. 68. ATTACHMENTS TO THIN WALL PIPES. 6.6.1 Where attachments are to be made thin walled piping ie. less than Smm thick, care shall be taken to avoid excessive oxidation or burn through. An inert gas purge shall be applied to the bore necessary. Where access to the bore surface for cleaning and inspection is not possible the inert gas purge is mandatory. 6.6.2 In order to demonstrate the suitability of the weld procedure the Company may require a test weld to be made on pipe of the minimum contract thickness. Similarly the Company may require Welders to be tested on their ability to weld attachments to the thin wall pipes even if their qualification range apparently covers the thin wall situation. ALIGNMENT 6.7.1. The ends of piping components to be butt welded shall be accurately aligned in accordance with the requirements on ANSI 831.3. The maximum internal misalignment shall be 1.5mm except that where the pipe wall thickness is less than 6mm the internal misalignment shall not exceed 25% of the wall thickness. 6.7.2. Where mis-match of the bores results in misalignment greater than that permitted above, this shall preferably be corrected by taper or counterboring in accordance with ANS! B31.3. Permitted alternatives to machining are: (a) Roller expanding for pipes up to 4” nb. () Cold drifting with a slow taper drift provided the diameter is not increased more than 3%. 6.7.3. Care shall be taken to ensure that the wall thickness after machining, expanding or drifting is not reduced below 87.5% of the nominal thickness. FIT-UP & TEMPORARY ATTACHMENTS. 6.8.1 Parts to be welded shall be carefully aligned and held securely in position by clamps, tack welds in the welding groove, bridge pieces or wedges. 6.8.2 All welding of fit-up tacks and temporary attachments shall be performed by qualified welders using qualified procedures and the preheat level specified by the procedure. 6.8.3 Where tack welds are to be incorporated into the main welds they shall be of a length such that they become part of the proposed root pass and their ends shall be ground. Defective tack welds, and those which are not to be incorporated into the root pass, shall be completely removed by grinding, following completion of welding 8 0128769. 6.10. 6.11. 6.8.4. Temporary attachments shall be of the same nominal composition as the parent material. They shall be removed by cutting 3mm above the surface followed by grinding flush. The area shall then be surface crack detected to confirm the absence of defects. PROTECTION FROM WEATHER 6.9.1 The welder and welding area shall always be adequately protected from the weather so that the weld integrity is not detrimentally affected by wind, rain or snow or from the decline of the welder’s ability when working at low temperatures or other adverse conditions. The continuation of welding indoor weather conditions shall be at the discretion of the inspector. 6.9.2. Weld areas shall be kept dry throughout the complete welding cycle until after the weld has cooled. Metal surfaces which are damp or below 5 degrees the commencement for a minimum of 100mm on either side of the weld, taking care to avoid hot spots. 6.3.3 Where gas shielded welding is employed, special care shall be taken to protect the welding area from draughts WELD CLEANING, BACK GOUGING AND REPAIR 6.10.1 After each welding pass the weld shall be thoroughly cleaned and all slag and foreign matter removed before the next run is deposited 6.10.2 Peening of weld runs or the finished welds shall not be permitted, 6.10.3 The removal of weld defects shall preferably be carried out by grinding, machining or chipping. Arc or oxygen gouging may also be used, provided all slag and oxidation is removed by grinding from the gouged surfaces. 6.10.4 Welds which have been repaired and remain defective shall be cut out completely and re- welded in accordance with the original procedure, except where the Inspector authorises one further repair attempt. In no case shall more than 2 repair attempts be permitted 6.10.5 All weld repairs shall be performed by qualified welders using an approved repair procedure. WELDED PROCESSES 6.11.1 Except where otherwise agreed, welds shall be made by the manual metal arc (MMA), tungsten inert gas (TIG), metal inert gas (MIG) or submerged arc welding (SAW) processes. 6.11.2 The oxyacetylene process is permitted only for joints in pipe sizes 6.11.3 Where root runs are made by the MMA process, the electrode shall not be larger than 2.5mm diameter. 9012877A. 72. 8.1. 6114 611s 6116 If the TIG process is proposed, a high frequency arc initiation unit and crater eliminating device shall be used. The electrode shall be 2% thoriated tungsten, 2.5 to 3.0mm diameter. The MIG process may be used where the Fabricator can demonstrate he is. capable of reliably producing full penetration, full fusion welds. The SAW process may be used for circumferential joint filler runs onto root runs made by some other acceptable process/method. Recycling of flux shall only be permitted after Company approval of the Fabricators WELDING CONSUMABLES SPECIFICATION & SELECTION Tad 712 743 All consumables such as coated electrodes, bare wire, fluxes and gases shall comply with the applicable AWS of British Standard. Other consumables may also be used provided full details of chemical and mechanical properties, and service experience are submitted and approval obtained from the Company. Shielding gases shall normally be one of the following, depending on the particular application (a) Argon to BS 4365 (b) Argon/oxygen mixtures consisting of argon to BS 4365 with up to 5% oxygen to BS 4365. Total impurities 0.07% maximum. (c)_Argon/carbon dioxide mixtures consisting of argon to BS 4365 with up to 25% carbon dioxide to BS 4105 type 1 and up to 5% oxygen (if required) to BS 4363, Other gases may also be considered where they have been proved satisfactory by the weld procedure qualification tests and any other tests deemed necessary by the Company. Gases for back purging shall be argon as specified above or nitrogen to BS 4366 type 1. STORAGE, PROTECTION AND BAKING 724 The Storage, protection and baking of all welding electrodes, filler wires and fluxes shall be in accordance with the Manufacturer's recommendations. WELDING PROCEDURE & WELDER QUALIFICATION GENERAL g11 All pressure containing welds and welds made onto pressure parts shall be made in accordance with a procedure written and qualified in accordance with the ASME Boiler & Pressure Vessel Code Section IX. No welding shall be carried out until the procedure have been approved and the test results accepted by the Company. 100126782. 10. B12 813 B14 Each welding procedure shall be given a reference number and shall be cross referenced to construction drawing and to the applicable qualification records, All welders shall be qualified in accordance with the requirements of the ASME Boller and pressure Vessel Code Section IX. Each Welder shall be assigned an identification number, letter or symbol, and a complete circumference of 5% of above ground welds shall be radiographed. The radiographs shall be retained for examination and approval by the Company. REPAIR PROCEDURES 821 All weld repairs shall be carried out in accordance with written procedures which shall be submitted to the Company for approval. FABRICATION TOLERANCES 94 9.2 93 94 Fabrication tolerances shall be in accordance with the specified codes and standards, supplemented by the requirements given below. Flattening of a bend, as measured by the difference between the maximum and minimum outside diameter at any cross section shall not exceed 8% of the original outside diameter of the pipe for internal pressure and 3% for external. Flange alignment tolerances shall be as stated in Appendix A figure 1. The tolerances on linear dimensions involved in the relative positions of branches, bosses, flanged ends, flow instrument tappings and changes of direction shall be as stated in Appendix A figure 2. Also given in this figure are tolerances on pipe bending and across the land of prepared welding ends. INSPECTION AND TESTING GENERAL 10.1.1 10.1.2 The Inspector shall have free access to all parts of the Fabricator’s Works engaged in the manufacture of pipework and shall have the right to inspect any aspect of the work during fabrication, installation, testing or an completion. The Fabricator shall afford the Inspector all reasonable facilities to allow these inspection functions to be fulfilled. All tests and inspections shall be conducted at the place of fabrication unless otherwise stated. The Fabricator is required to have an identification system such that each component part can be identified against the Mill Test Certificates and that all weld seems can be identified with the welder or welding operator and welding procedure specification. 110126710.2, INSPECTION CLASSES 10.2.1 Piping Systems are classified on the basis of service and material. The applicable inspection class shall be as specified on the Piping Class document. 10.2.2 The extent of inspection to be carried out for each inspection class is shown in table 14.2.2. 10.2.3 In addition to the requirements of table 14.2.2, the following welds shall be subject to 100% radiographic examination unless otherwise agreed with the Company. (a) Mitre bends {b) Underground Welds TABLE 14.2.2 EXTENT OF INSPECTION NozzLE | ATTACHMENT | SOCKET cuass | metHoD | uTTweLDs | Wein, WELDS WELDS Visual 100% 100% 100% 100% Radiographic 100% Ultrasonic 100% Magnetic 100% 100% 100% 100% Particie Visual 100% 100% 100% 100% 100% Exposure | Radiographic | “256. crjoints Magnetic Particie Visual 100% 100% 100% 100% 100% Exposure ur [Ragieeraphiec | 2086 of Joints Magnetic Particie Visual 100% 100% 100% 100% iy _ [Radiographic Magnetic Particie 1201267a PRESSURE TESTING 11.1 All flanged piping assemblies shall be hydrostatically tested in the Fabricator’s works prior to shipment. The test medium shall be potable water, unless otherwise specified. The water temperature shall be maintained above 7 degrees celsius or the ductle/brittle transition temperature, whichever is the higher, throughout the test. 11.2 _ Other piping assemblies, such as those with Welding ends, do not require to be hydrostatically tested at the Fabricator’s works. In this case however the Fabricator remains responsible for any defects causing leakage or failure in his fabrication found during the site test of the erected pipework 11.3. Erected pipework shall be pressure tested in accordance with ANSI 831.3 Chemical Plant and Petroleum Refinery Piping, 11.4 All pressure tests shall be carried out in the pressure of the Inspector and shall be to his satisfaction. The test pressure shall be maintained for a sufficient time to enable a thorough examination to be made for leakage and defects, with a minimum of 30 minutes. 11.5 _ Prior to pressure testing being carried out the inside of the pipework shall be clean and free from loose millscale and foreign matter. 12. QUALITY CONTROL 12.1 GENERAL 12.1.1 The Fabricator shall afford the Company and/or the Certifying Authority adequate opportunity and facility to verify that the design, material, construction and performance of the equipment is in accordance with Company requirements. 12.1.2 Any verification of quality carried out by the Company and/or the Certifying Authority shall not relieve the Fabricator of his obligations under the contract nor shall it preclude any subsequent rejection of items. 13, TREATMENT AFTER FABRICATION 13.1. CLEANING AND PROTECTION 13.1.2 On completion of the fabrication, prior to shipment, the Fabricator shall clean the inside and outside of all fabricated assemblies of loose scale, dirt, sand, weld spatter and swarf using any suitable method. The assembly shall then be blown out with compressed air, dried and the inside inspected for cleanliness. 13.1.2 Where there are any special requirements, such as wire brushing, spot or gritblasting, then these shall be specified on the fabrication drawings and purchase orders. 130126714. 14.1 1313 B14 B15 13.1.6 13.7 Welding ends shall be clean and ready for welding. Unless otherwise specified, the welding end shall be blanked off and protected from corrosion or mechanical damage. Rigid plugs or discs of non-absorbent material securely held in position shall be provided and the pipe ends, discs or plugs shall be sealed off using ‘Denso’ paste and tape or an approved alternative. flanged ends shall be blanked off using 10mm thick plywood or 3mm thick steel covers secured by a minimum of four bolts after the faces have been protected with a hard film coating to BS 1133, Section 6, Type T.P.la or agreed alternative. Threaded connections shall be sealed using distinctively colour-identified screwed plastic plugs or caps. Piping and components shall be stored under cover out of contact with the ground and shall be regularly examined to ensure the materials do not deteriorate. Corrosion protection shall be renewed as necessary. Pipe or piping components shall be protected from exposure to salt water or salt spray. The external surfaces of carbon steel pipework shall be coated with temporary corrosion preventative or base primed when specific in the fabrication drawings or purchase orders. 13.2. MARKING 13.2.1 All fabrication spool pieces shall be clearly marked and identified prior to shipment in accordance with the following paragraphs or as otherwise specified in the purchase order. All markings shall be applied after the application of any permanent protective coatings which have been called for. 13.2.2 Fabricated spools requiring trial shop assembly shall be match marked with scribed lines in white paint to facilitate erection, INSTALLATION GENERAL 14.1.1 All pipework shall be inspected prior to erection to ensure it is free from dirt, scale, weld spatter and other foreign matter. 14.1.2 Except where cold springing is specified on the piping drawings, all piping shall be installed in place without springing or forcing, 14.1.3 Field run piping is restricted to line sizes below 50 ns. It shall be run generally in accordance with the routing indicated on the piping drawings, in a neat and orderly manner consistent with good operation, safety of personnel and economy of material, with adequate provisions for expansion and flexibility. 140126714.2 14.3 14.4 FLANGED JOINTS 14.2.1 14.2.2 142.3 14.2.4 14.2.5 14.2.6 14.2.7 Flanged faces shall be cleaned of all dirt, grease and protective coating and shall be inspected for defects such as scratches or dents prior to installation, Flanges shall be properly aligned prior to the insertation of gaskets and bolts to avoid stresses or uneven gasket loads. See Appendix A figure 1 for flange alignment tolerance, Where specified by the Company, bolts shall be tightened by means of suitable torque wrenches or tensioning devices to ensure the correct bolt stress is obtained and the gasket is properly compressed in accordance with the design principals applicable to the gasket type. All bolts shall extend completely though their nuts. The use of washers or spacers to take up excess bolt length shall not be permitted. Stud bolts cut from length of studding shall have the material grade stamped on the cut ends. Steel to cast iron flanged joints shall be assembled with care to prevent damage to the cast iron flange. Joint Rings shall be non-asbestos 1.6m thick in accordance with the general specification. EQUIPMENT FLANGE CONNECTIONS 143.1 14.3.2 Flange covers shall not be removed from equipment flange connections until ready to connect the mating piping, Connections to strain sensitive equipment shall not be made until the mating piping has been fully erected complete with permanent supports. Prior to bolting up to the equipment flange the connection shall be checked for correct alignment. ‘SCREWED PIPEWORK 14.4.1 Pipe ends cut shall be cut square, threaded, reamed and cleaned to remove cuttings from internal and external surfaces. All threading shall be carried out after bending, forging or heat treatment but where this is not possible suitable thread protection must be provided. All screwed connections shall have taper threads in accordance with API unless otherwise stated. 1501267148 15 14.4.2 All joints shall be tightened using a suitable wrench; connection 50 ns and larger shall be tightened using a ‘RIGID compound leverage pipe wrench’ cr equivalent. Excessive wrench markings on pipe and fittings shall be cause for rejection of the fabrication at the discretion of the Inspector. 14.4.3 The joints shall be assembled using a suitable Petroleum resistant pipe jointing compound which shall be applied to the male thread only, taking care to ensure the compound does not reach the inside of the pipe. PTFE tape shall not be used. PIPE SUPPORTS. 14.5.1 Where pipe supports are required to be welded to the pipe, as specif the drawings, this shall be carried out during the fabrication of the pipe spool, with the exception of pipe support shoes which are generally welded during installation, 14.5.2 The Fabricator shall ensure there is adequate field fit margin in the pipe supports to allow the piping to be installed without forcing, 14.5.3. The burning of holes in structural steelwork or component parts shall not be permitted. 14.5.4 Adjacent structures or equipment shall not be used as temporary supporting or lifting attachments without the permission of the Company. 14.5.5 Metallic surfaces of supports which will be inaccessible after erection shall receive a protective coating before assembly in accordance with Company Standard Surface Coatings. 14.5.6 Pipe reinforcement pads on supports, anchors, etc shall be provided with one hole (at the side and not at the crotch) drilled and tapped 1/4" N.P.T. ADDENDUM TO GENERAL PIPEWORK SPECIFICATION, 15.1 CLEANING All flanges of pipes, valves, fittings, filters, pumps etc are to be thoroughly cleaned of all rust, protective coatings etc, before assembly. At the completion of a days work and at any time when the end of a pipeline is left unattached, the end of the pipe shall be closed by a suitable protector in the form of a wooden blank. All piping after hydrostatic testing shall be thoroughly dried internally 15.2 PIPE OFFCUTS Wherever possible and economic the Contractor shall make use of short lengths of pipe. 180126715.3 15.4 15.5 16.1 BENDING All bends shall be true to radius and the bore of the pipe at any point after bending shall not vary be more than plus or minus 1/8” from the bore of the pipe before bending, Lobster back or gusseted bends will not be accepted. The bend centreline radius shall be 5 times the normal pipe diameter unless stated otherwise. BOLTING The contractor shall include in his supply for all studbolts, bolts, nuts etc. All bolts shall be the correct length to ensure that all thread on nuts are engaged and that the end of the bolt does not project more than 3mm from the upper face of the nut when tightened. TESTING Test pressures shall be held steady at the required pressure for a period of four hours, without further use of the test pressurising pump, Testing shall not be carried out when there is any likelihood of the water freezing in the pipework, the Contractor shall be responsible for repairing and re-testing the damaged pipework and fittings. For all tests, vents shall be located at the high points in the system, or of the section to be tested, in order to ensure compete displacement of air from the system. All equipment likely to sustain damage during the test is to be removed from the pipeline, control valves are to be left in the open position. Records are to be kept of each test. The information to be recorded is to be as follows: i) Pipeline or system tested ii) Testing Medium iil) Test Pressure iii) Temperature of Testing Medium iv) Date of Test vi) Signature of the Company's Engineer vil) Signature of Agent or Contractors Supervisor 16. STAINLESS STEEL PIPING AND FITTINGS Design ‘The design of piping systems shall comply the following: All pipework fabrication, testing, inspection and installation shall meet as a minimum standard the requirements of ANSI 831.4 ‘Chemical Plant and Petroleum Refinery Piping’. 70126716.2 16.3 16.4 16.5 16.6 16.7 16.8 PIPES Materials shall be in accordance with ANSI Type 316 Grade 18/8. Austenitic Stainless Steel, clean smooth and free from scratches to ASTM A-269 or equivalent, General Field run piping shall be run generally in accordance with the routing indicated on the piping drawings, in neat and orderly manner consistent with good operation safety of personnel and economy of material Connections All joints except where butt welded to change from tube, in nominal pipe size shall be gauge cable double ferrule compression tube fittings in 316 stainless steel Swagelok or approved equivalent, complete with gap inspection gauge. A thread sealant shall be applied when assembling threaded fittings, Liquid PTFE or approved equivalent. Flanges shall be drilled to ANSI class 150 to match existing. Flange bolts shall straddle the vertical or NS centreline as applicable. Joint rings shall be non asbestos 1.6mm thick in accordance with the General Specification. Supports Pipework shall be adequately supported in trays. Pipework shall be fixed to horizontal trays with Stauff polypropelene clamps or equivalent. Pipework shall be adequately supported and securely fixed immediately before and after a bend or offset and at 0.5m maximum pitch. All carbon steel supports shall be isolated from pipe to prevent electrolytic corrosion. Identification Each pipe shall be clearly identified; labels shall be fitted during erection or pipework Snubbers or Pulsation Dampers Where conditions for steady instrument readings are required due to pulsations a snubber or pulsation damper shall be provided. Testing- A pressure and operating test shall be applied to the complete assembled system. Testing shall be by pneumatic test to 20 PSI and a soap solution applied to all joints in accordance with the General Pipework Specification. All leaks shall be rectified and all connections proved fully leak proof before the system is considered acceptable. 180126716.9 16.10 Flushing of the system The injection system shall be final flushed using a suitable medium. During flushing, all injector cubicles, control valves and flow meters shall be removed, where practical, or by- passed using hoses. Installation Stainless Steel ipework The use of elbows shall be kept to a minimum, bends and offsets shall be cold formed wherever possible. Bends shall not be wrinkled, cracked, scratched, gouged or die- marked or buckled and shall be in one plane. Where connections are required in multi-line pipework, pipe connections shall be staggered to allow for maintenance. Welding ‘The Fabricator shall provide adequate and systematic supervision by competent personnel to ensure that the required quality levels are maintained. At the discretion of the Engineer, any welder who consistently fails to meet the standard shall be required to undergo re-training, re-testing of shall be removed from the job completely. All welding shall be carried out in accordance with the qualified and approved weld procedure by welders who have been qualified to the relevant testing code. ‘The Contractor shall make maximum effort to ensure that arc strikes outside the welding groove are avoided. When these occur outside of the finished weld the arc strike shall be carefully removed by grinding, followed by a dye penetrant inspection of the ground area to confirm it is defect free. Care shall be taken to ensure the ground is ‘blends in’ smoothly with the surrounding material such that no sharp notch results and the thickness is not reduced with an approved repair procedure. The acceptance of arc strikes outside of the welding groove shall be at the sole discretion of the Engineer, who shall be requested to inspect the damage and approved the repair procedure or reject the damaged material as appropriate. ‘The number of welds shall be minimised. Pipe lengths smaller than 1m shall not normally be welded together. Butt Welds All pressure containing butt welds shall be full penetration. Where access permits consideration shall be given to welding both sides. 1901267Fillet Welds ‘A minimum of two runs shall be deposited for all permanent attachments to pressure parts All fillet welds shall be continuous and their surfaces free from marked irregularities. Socket Welds Care shall be taken during the assembly of socket weld joints to ensure there isa 1.5mm gap between pipe end and the root face of the fitting. Welds shall be fillet welds deposited by MMA or TIG process with a minimum of two runs, ‘Attachments te Thin Wall Pipes Where attachments are to be made to thin walled piping i.e. less than Smm thick, care shall be taken to avoid excessive oxidation or burn through. An inert gas purge shall be applied to the bore surface. In order to demonstrate the suitability of the weld procedure the Company may require a test weld to be made on pipe of the minimum contract thickness. Similarly the Company requires Welders to be tested on their ability to weld attachments to the thin wall pipes even if their qualification range apparently covers the thin wall situation, Alignment ‘The ends of piping components to be butt welded shall accurately aligned in accordance with the requirements of ANS! B31.1. The maximum internal misalignment shall be 1.5mm except that where the pipe wall thickness is less than 6mm, the internal misalignment shall not exceed 25% of the wall thickness. Weld Cleaning, Back Gouging and Repair Aiter each welding pass the weld shall be thoroughly cleaned and all slag and foreign matter removed before the next run is deposited. Peening of weld runs or the finished welds shall not be permitted. The removal of weld defects shall be carried out by grinding, machining or chipping. Arc or oxygen gouging shall not be used. Welds which have been repaired and remain defective shall be cut out completely and re- welded in accordance with the original procedure, except where the Inspector authorises one further attempt. In no case shall more than 2 repair attempts be permitted. 2o0f20716.10.1 16.10.2 16.103 All weld repairs shall be performed by qualified welders using an approved repair procedure. Welding Processes Except where otherwise agreed, welds shall be made by the manual metal arc (MMA), tungsten inert gas (MIG) or submerged arc welding (SAW) processes. Where root runs are made by the MMA process, the electrode shall not be larger than 2.5mm diameter. if the TIG processes, a high frequency arc initiation unit and crater eliminating device with a 10 second minimum delay sequence shall be used. The electrode shall be 2% thoriated tungten, 1.5 to 3.0mm diameter. Welding Consumables Specification and Selection All consumables such as coated electrodes, bare wire, fluxes and gases shall comply with the applicable AWS or British Standard. Other consumable may also be used provided full details of chemical and mechanical properties, and service experience are submitted, and approval obtained from the Company. Welding electrodes and filler wires shall be selected to give a deposited weld metal similar in composition to the parent metal. Unless otherwise specified austenitic welds have a ferrite content of between 3% and 10%. Filler metal for welds between austenitic stainless steels and ferritic or ferritic alloy steels shall be subject to agreement but shall normally be of the £309, Incoweld A or Inconel 182 type or equivalent. Where Post Weld Heat Treatment is required, the Incoweld A or Inconel 182 type shall be used. Preheat and PWHT shall be required by the ferritic material. ‘The shielding gas for the TIG process shall be argon to BS 4365. The purge gas shall be argon to BS 4365 or dry nitrogen to BS 4366, type 1. No other gas or gas mixture shall be used without prior approval of the Company. ‘Storage, protection and Baking ‘The storage, protection and baking of all welding electrodes, filler wires and fluxes shall be in accordance with the Manufacturer's recommendations. Protection from Weather ‘The welder and welding area shall always be adequately protected from the Weather so that the integrity is not detrimentally affected by wind, rain or snow or from the decline of the welder’s ability when working at low temperature or other adverse conditions. 2 of20717 BLANK 18 MATERIAL SPECIFICATIONS. Maximum Pressure Maximum Temperature Piping Design Code Line Pipe Si e Range (NPS) 15-40 50-150 200-350 Flanges — Forged Butt Weld Fittings Reinforced Branch Fittir Gaskets Bolting 19.2 Bar for class 150 systems soc ‘ASME B31.3 Seamless A.P.I. SL Gr B (Carbon Content 0.23% Max) Description Schedule 80 P.E, Schedule 40 B.E. Schedule 40 B.E. MAT ASTM A105 N (Carbon Content 0.23% Max) DIMN ANSI 8 16.55 CLASS 150, Finish — MSS SP 44 incl Welding Neck — Note: To Match Pipe Wall Thickness Slip-on Blind Matt ASTM A234 WPB (Carbon Content 0.23% Max) DIM ANSI B16.9 Incl Eccentric Weld Reducer Concentric Weld Reducer Equal Tee 90% Long Radius Weld Elbow 45% Long Radius Weld Elbow NOTE — All To Match Pipe Wall Thickness mat! ASTM A105 N (Carbon Content 0.25% Max) ‘Spec Bonney Forge Or Equal Incl Weldolet Sockolet Elbolet Thredolet Latrolet NOTE- Weight / Rating To Match Pipe Wall Thickness Non Asbestos Klingersil C4400 (OR EQUAL) 1.6 Mm Thk Flat Ring - Richard Klinger Stud Bolts ASTM A193 Gr B7 Nuts ASTM A194 Gr 2H mot2e7NoTEs: Minimum pipe size 15nps All forgings shall be normalised & tempered Carbon content shall be limited to 0.23% max for pipe & 0.25% max for other items (carbon equivalent shall be limited to 0.45% max) Where flanges mate with cast iron equipment the mating flange face shall be a smooth 1 2 3 finish Allunconnected branches 40 nps and below shall be class 6000 1b / schedule 160 For selection of reinforced branch connections see detail drgs Buried lines shall be coated & wrapped in accordance with specification. All aviation product pipes lines shall be internally lined in accordance with the specification 3326- 0025. Material test certificates to din 50049.3.1b Branch Connection Chart Header Si e 350 300 250 200 150 100 80 RB RB RB RB RB RB RB RB BB BB BB BB a ow wor t RB. RB. RB. RB. 201207 RB RB RB RB RB RB RB RB 65 50 40 25 20 15 RB RB RB RB RB OT RB RB RB ORB OT RB ORB RB OT RBOW oT wot t LEGEND RB ~ RE-INFORCED BRANCH B— UN RE-INFORCED BRANCH W- WELDOLET T- BUTT WELD EQUAL TEE‘Appendix A — Schedule of Rates ‘Al DEFINITION OF TERMS USED IN THESE SCHEDULES OF RATES ‘ALI The terms ‘erect, ‘install’ and ‘set-up’ shall mean taking delivery, off-loading, loading, handling, storing, transporting to and from the fabrication area to the final position and fixing to correct levels including lining up all pipework described including the taking of all necessary measurements. Pipework shall be measured nett and all specials, elbows, valves, flanges, jointing and cutting etc have been measured separately. ‘AL.2__ The term ‘supply’ shall mean the cost of purchase, delivery and transporting to score on site and storing, AL.3_ Where items have been described as ‘extra over’ the Contractor is to include for making such labours as described. AL.4 The term ‘cut pipe’ shall mean the unit of measurement per cut for the cutting of a square end to both sides of the cut to receive bevelled ends, screwed ends or slip-on flanges. ALS The term ‘bevel end’ shall mean the unit of measurement per end for preparing ends of pipe for welding, AL.6 The term ‘make flanged joint’ shall mean to include for all fitting work and the supply and fixing of all gaskets, studbolts, nuts and washers. ‘Schedule of bolts for flanged ioints Pipe Diameter | Number of Bolts| Dia Stud Length | Bolt Length {mm) {mm) 15mm 4 a2" 55 44 20mm 4 yo" 55 51 25mm 4 yr" 65 51 40mm 4 a2" 70 57 50mm 4 5/8” 75 70 80mm 4 5/8” 90 76 100mm 8 5/8” 90 76 1somm 8 3/4" 95 83 200mm 8 3/4" 100 89 250mm R 78" 1s 85 300mm 2 78" 115 102 350mm R v 25 108 400mm 16 v 130 a4 450mm 16 11/8" 150 aa 24 of 207AL? ALB AL9 a2 Ada A22 a3 ABA 03.2 03.3 034 Aas A36 The term ‘make screwed joint’ shall mean the unit of measurement per end of pipe or fitting for making a screwed joint, including all fitting work and preparing ends with specified jointing material. The term ‘make 90 degrees branch’ shall mean to include for the cutting of holes in the main pipe, shaping of branch ends, fitting, bevelling tacking and the finished welding of the branch No distinction has been made in the description between main pipes of differing diameter. Only the branch diameter has been stated. The Contractor should make any allowance necessary in his prices for this lack of distinction, The term ‘make weld joint’ shall mean the unit of measurement per end of pipe or fitting for making a socket weld joint. To include all cutting of pipe end, preparing pipe end, all fitting work and finished welding of the joint. SCHEDULE OF RATE FOR MECHANICAL WORKS, The Contractor should enter a rate against all items. Items with no rate shall be deemed to have been included in rates for other items. This schedule of rates is to be used in the costing of the works or variations to the works deemed necessary by the Engineer, and in accordance with the General Conditions of Contract. RATESTO INCLUDE For all handling and distribution costs, insurances, subsistence allowances, non productive overtime in accordance with the working week which forms the basis of this schedule, supervision, overheads, etc Non-productive overtime charges will only be allowed if specific instructions have been given to carry out extra work during overtime hours. Normal Working hours are as stated in Section 2, Form of Tender. Handling and distribution costs shall be deemed to be inclusive of taking from allocated safe working area to erection site and all necessary double handling as a result of NO hot work being allowed in erection areas. For all work up to a height of 2.00m and all depths in all locations on the site. Any safe working platform required for any work over 2.00m will be reimbursed at cost. Any air supplied breathing apparatus for work below 1.3m under ground level will be reimbursed at cost. Provision of all consumables and sundry materials such as, but not limited to:- i) Welding rods and electrodes. ii) Cutting discs. iii) Oxygen and Acetylene. iv) Inert Gas, v) Pipe jointing material other than gaskets. vi) Nuts, bolts and studbolts. 2501207A37 A3.8 03.9 vii) Fuel for generators and welding sets. viii) Fuel for Contractor's plant and transport. ix) Provision of all necessary plant and equipment such as, but not limited to: x) Temporary lighting and power. xi) Temporary screens, fencing and guard rails. xii) Welding plant and associated equipment. Small hand tools, air operated or manual. xvi) Temporary supports. Provision of all non structural steelwork supports (bottom of pipe to be supported less than 1.5 meters above grade) including levelling and aligning before erection and final bolting down on prepared foundations (foundations and bolts by others); for pipe-lines at any level below 2 meters above ground level. For site checking of dimensions before fabrication for proper execution of work. All working platform above 2.00m will be provided by the contractor. he shall use the terminals nominated specialist contractor, the cost of which shall be reimbursed on a cost plus basis as nominated in the Form of Tender, Section 2. ‘A3.10 All powered lifting equipment shall be provided by the contractors as deemed necessary to execute the works safely and efficientiy. He shall use the terminals nominated specialist contractor, the cost of which shall be reimbursed on a cost plus basis as nominated in the Form of Tender. ‘A3.11 All water used on site for the purposes of wetting down during hazardous work and hydrostatic testing shall be provided by the company unless otherwise stated. 201207