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SPECIFICATION FOR PIPING FABRICATION, WELDING, INSPECTION AND TESTING Rev. A
SPECIFICATION FOR PIPING FABRICATION, WELDING, INSPECTION AND TESTING Rev. A
REVISION SHEET
TABLE OF CONTENT
SCOPE .......................................................................................................................................................... 5
REFERENCE ................................................................................................................................................ 5
2.1 Codes ...................................................................................................................................................... 5
2.2 Standard and Specification ...................................................................................................................... 5
2.3 General .................................................................................................................................................... 5
2.4 Line Numbering ....................................................................................................................................... 6
SHOP AND AS BUILT DRAWING ................................................................................................................ 6
MATERIAL .................................................................................................................................................... 6
GENERAL FABRICATION ............................................................................................................................ 7
PIPING FABRICATION ................................................................................................................................. 7
6.1 General .................................................................................................................................................... 7
6.2 Welding .................................................................................................................................................... 7
6.3 Screwed Piping ........................................................................................................................................ 7
6.4 Cleanliness .............................................................................................................................................. 8
INSPECTION AND TESTING ....................................................................................................................... 8
7.1 General .................................................................................................................................................... 8
7.2 Radiography ............................................................................................................................................ 9
7.3 Ultrasonic Examination ............................................................................................................................ 9
7.4 Liquid Penetrant and Magnetic Particle Examination .............................................................................. 9
7.5 Hydrostatic Testing .................................................................................................................................. 9
7.6 Flushing ................................................................................................................................................. 10
PREPARATION FOR SHIPMENT, ASSEMBLY AND INSTALLATION ..................................................... 10
8.1 General .................................................................................................................................................. 10
8.2 Flange Joint & Bolting Procedure .......................................................................................................... 10
8.3 Fabrication and Installation Pipe Support .............................................................................................. 10
8.4 Installation of Valves .............................................................................................................................. 11
8.5 Installation of Instruments ...................................................................................................................... 11
8.6 Piping for Rotating Equipment ............................................................................................................... 11
WELDING AND JOINNING ......................................................................................................................... 11
9.1 Cutting and Preparation ......................................................................................................................... 11
9.2 Welder Qualification .............................................................................................................................. 12
9.3 Welder Qualification .............................................................................................................................. 12
9.4 Pipe Welding Requirements .................................................................................................................. 12
9.5 Weld Repairs ......................................................................................................................................... 13
9.6 Joining Methods..................................................................................................................................... 13
COATING .................................................................................................................................................... 13
INSULATION ............................................................................................................................................... 14
EXAMINATION ............................................................................................................................................ 14
SPECIFICATION FOR PIPING
FABRICATION, WELDING, INSPECTION
AND TESTING
Document No. Rev. : A
DED EXPANSION NICKEL HEAP
Page:
BMR-PIP-SPE-ST-0002 LEACH 5,000 T/Y
Page 4 of 15
SCOPE
This specification defines the minimum general piping fabrication, welding, inspection and testing for
design of piping systems DED EXPANSION NICKEL HEAP LEACH 5.000 T/Y.
The CONTRACTOR shall ensure that all equipment and services supplied meet the requirements of
this specification, and the codes, standards and specifications nominated herein, and shall be applies
to the following project :
REFERENCE
The latest edition of following publications shall be considered as an integral part of this specification.
If there are any conflicts between these codes and other related documents, the more stringent
requirement shall govern.
2.1 Codes
Applicable code for this project accordance with ASME B31.3 Process Piping.
2.3 General
The pipe line numbering system shall be formatted as per stated on P&ID.
Where pre-engineered, BMR will provide the CONTRACTOR with one (1) set of reproducible of the
construction drawings. If not provided by BMR, the CONTRACTOR shall prepare piping isometric
in all piping accordance with the Project Specification.
The CONTRACTOR shall ensure that all positions and locations of piping components, piping runs
and terminal points are maintained.
The CONTRACTOR shall verify that all spools, whether built from isometrics or shop drawings, are
of a length which will enable the spool to be trucked if necessary and enable spools to be easily
installed.
CONTRACTOR shall maintain an up to date, complete and accurate record of all minor changes
made to design drawings during the fabrication and erection of the piping. Upon completion of the
project, the CONTRACTOR shall mark all changes on one
set of Shop Drawings and "As Built" Construction Drawings. BMR will not consider that Work is
completed until the as-built drawings are received. If CONTRACTOR was responsible for piping
design, the as-built marks shall be incorporated into CONTRACTOR's drawings for issue with final
documentation, in accordance with BMR Drawings Manual. Computer file copies of all AutoCAD
drawings in the "As-built" condition shall be made and given to BMR upon project completion.
MATERIAL
The CONTRACTOR shall assurance responsibility of the materials and the certification covering
the materials. The CONTRACTOR shall be responsible for the supply of all other materials
including temporary materials and consumables to enable the work to be completed.
Materials shall not be considered for use unless the CONTRACTOR is in possession of the
necessary documentation. No substitution of materials shall be permitted unless prior written
approval is obtained from BMR.
Should the BMR that out of specification" material has been utilized, or material has been
substituted without the written approval of BMR, the CONTRACTOR shall replace all non-
specification materials and take remedial actions as required to ensure compliance with
specifications. The cost of this work shall be borne by the CONTRACTOR.
The CONTRACTOR shall be responsible for the receiving, offloading, handling, storage, material
control and preservation of BMR furnished material. The CONTRACTOR shall ensure that the use
of BMR -furnished material is optimized to give economic utilization. All surplus and scrap material
remaining from CONTRACTOR furnished material shall be the CONTRACTOR's property and its
SPECIFICATION FOR PIPING
FABRICATION, WELDING, INSPECTION
AND TESTING
Document No. Rev. : A
DED EXPANSION NICKEL HEAP
Page:
BMR-PIP-SPE-ST-0002 LEACH 5,000 T/Y
Page 7 of 15
GENERAL FABRICATION
The CONTRACTOR shall ensure the "in process" material documentation is maintained on a daily
basis. All materials, which require documentation in use during fabrication or installation that cannot
be identified with documentation shall be immediately removed from the area and replaced at the
CONTRACTOR's expense.
Piping materials for the work whether purchased by BMR or CONTRACTOR shall be stored in a
designated area within the CONTRACTOR's facility.
The CONTRACTOR shall utilize shop tools and equipment compatible with materials in fabrication,
including but not limited to grinding discs and power brushes designed for use with stainless steel
and/or other high alloy materials, or including non metal pipe material
All spools shall have their piece number clearly designated on each spool piece, corresponding to
the appropriate isometric drawing.
CONTRACTOR shall provide padded slings or straps for handling coated pipe and nonferrous
padded slings for stainless steel and alloy pipe. CONTRACTOR shall exercise care in lowering,
assembling and installing all coated piping. Any damage to the coating caused by the
CONTRACTOR shall be repaired at CONTRACTOR'S expense to the satisfaction of BMR.
PIPING FABRICATION
6.1 General
a. All fabrication shall comply with the requirements of ASME B31.3, this Specification and
Company’s drawings. If there is a conflict between ASME B31.3 and the other applicable
Company document’s, CONTRACTOR shall immediately notify BMR in writing of BMR
resolves it.
b. All branch connections shall be joined to the header with full penetration welds.
c. Fabrication involving welding shall not be sublet to others without prior written approval by
BMR.
d. All fabrication for non metal pipe, as per vendor recommendation.
6.2 Welding
All welding shall be done per the requirements of JIS B 8285 Welding Procedure Qualification
or other standard applicable corresponding approval written by BMR.
When screwed piping is required by the drawings, screwed threads shall be clean cut with no
burrs or stripping. Dies shall be new, sharp, and properly designed for the piping material.
SPECIFICATION FOR PIPING
FABRICATION, WELDING, INSPECTION
AND TESTING
Document No. Rev. : A
DED EXPANSION NICKEL HEAP
Page:
BMR-PIP-SPE-ST-0002 LEACH 5,000 T/Y
Page 8 of 15
Immediately before fabrication, the piping, all thread of pipe and fittings shall be thoroughly
cleaned of cuttings, dirt, oil, or other foreign matter.
6.4 Cleanliness
a. Cleanliness shall be maintained during all phases of fabrication. All stubs electrodes, flux,
slag and other foreign materials shall be removed from the fabrication.
b. Prior to welding, the pipe bevel and all surfaces adjacent there shall be thoroughly cleaned
of all scale, rust, grease., oil and other foreign material. Flux weld spatter and slag shall be
removed from each weld bead prior to depositing the next pass. All stub, rods, flux, slag
and other foreign material shall be removed from inside and outside the pipe, between each
pass and after completion or the final pass.
c. All tools and equipment shall be kept free of oil, grease and other contaminants detrimental
to fabrication. Wire brush material shall be compatible with the pipe and weld materials.
d. Upon completion of fabrication, but prior to hydrostatic testing and preparation for shipment,
all piping shall either be blown out using compressed air or flushed using clean fresh
corrosion inhibited water.
e. Cleanliness shall be maintained during all phases of fabrication of pipe non metal such
FRP pipe or fabrication of rubber line, adhesive or chemical fluid scattered in shop area.
7.1 General
a. Inspection of all piping shall be in accordance with the requirements of JIS-Z-3104, JIS-Z-
2305 and this specification.
b. CONTRACTOR shall be responsible for activities supervision and for the quality of work
during fabrication and erection. BMR will make inspections and tests as required to check
the progress and quality of the work, qualifications of CONTRACTOR’s employee, and
verify that work meets the drawings and specifications.
c. All non-destructive testing (NDT) shall be performed in accordance with written procedures
that comply with the JIS-Z-3104 requirements and the requirements of this specification.
CONTRACTOR shall submit procedures for all required NDT to BMR for approval, prior to
use.
d. CONTRACTOR shall visually inspect all welds after completion before submission to BMR.
Any indications of defects, undercutting, penetration roughness, poor contour and
dimensions, etc. shall be repaired prior to NDT or any heat treatment operation.
e. All prepared surfaces shall be visually inspected prior to jointing or welding. All prepared
surfaces shall be visually inspected prior to welding. All material indications of defect shall
be not to continue in work activities
SPECIFICATION FOR PIPING
FABRICATION, WELDING, INSPECTION
AND TESTING
Document No. Rev. : A
DED EXPANSION NICKEL HEAP
Page:
BMR-PIP-SPE-ST-0002 LEACH 5,000 T/Y
Page 9 of 15
7.2 Radiography
In area where radiographic examination can not be obtained or the results there of would be
unreliable, ultrasonic examination accordance with JIS G 0582 shall be used. BMR written
approval is required prior to substituting ultrasonic examination for radiographic examination.
a. Liquid penetrant and/or magnetic particle inspection will be performed at the discretion of
COMPANY, when radiography cannot be successfully employed or not required for
performed.
b. Interpretation and acceptance criteria for liquid Penetrant and magnetic particle inspection
shall be in accordance with JIS Z 2303 NDT Penetrant Testing and G 0565 Method for
Magnetic Particle.
c. Magnetic particle or penetrant inspection of a fillet weld shall be performed between
temperature 20ºC - 50ºC.
d. Examination of branch connection with the fillet weld shall be MPI or Penetrant test,
including connected to beveled pipe such as welded joining olet to pipe.
f. OWNER’s Quality Control representative shall witness all hydrostatic testing of piping
system.
g. Hydrotest shall be performed using clean water
7.6 Flushing
All piping to be pressure tested shall be thoroughly cleaned by flushing with the test medium.
Valves shall be in the fully open position during flushing operations. All instrumentation shall
be isolated from pipe during flushing. Disposal of all flushing media and debris shall be the
responsibility of the CONTRACTOR in accordance with applicable laws.
8.1 General
a. After all inspection have been completed, CONTRACTOR shall prepare all fabricated pipe
for shipment or installation in accordance with the following :
The inside of all piping shall be ensure blow dry to prevent corrosion.
Flange faces shall be cleaned, coated with a rust preventive and effect damage on face
of flange
Threaded or socket weld connections shall be cleaned and plugged, or capped with
metal or plastic protectors.
The open ends of pipe shall be protected with plastic caps.
b. CONTRACTOR shall adequately support pipe spool for transit. Particular attention shall
be applied to spools, which are susceptible to damage during transport or not
incompatibility during construction for repair.
a. For flange under range PN 20 and less at ambient temperature, gasket sheet neoprene
rubber or asbestos may be used.
b. All flanged joints shall be fitted up so that the gasket contact faced bear uniformly on the
gasket, and then made up with uniform bolt stress.
c. In principle, all stud bolts & machine bolts shall extend minimum 2 threads throughout their
nuts.
Pipe support shall be fabricated and installed in accordance with the Piping Layout Drawings
and Pipe Support Standard Drawings.
a. Prior to piping installation, pipe supports shall be fabricated accurately so that pipes can
be aligned easily. Temporary supports may be used only when temporary supports are
SPECIFICATION FOR PIPING
FABRICATION, WELDING, INSPECTION
AND TESTING
Document No. Rev. : A
DED EXPANSION NICKEL HEAP
Page:
BMR-PIP-SPE-ST-0002 LEACH 5,000 T/Y
Page 11 of 15
more practical than installation of permanent supports, but must be replaced with
permanent supports.
b. If additional supports are required to prevent shaking of piping in the field, they shall be
installed in accordance with the instructions of the BMR.
a. Valves shall be installed in the closed condition, and shall not be opened during the
construction work.
b. Before installation of the valves, they shall be leak tested as per API 598 requirement and
be witnessed by BMR
c. Globe valves, check valves, control valves and other similar valves shall be installed
correctly to their direction of flow.
d. Before installation of the safety valves, they shall be tested and certified to confirm or
adjust their set pressure.
a. In-line instruments such as control valves, orifice plates, and rotameters shall be installed
after flushing of the lines. For piping assembly, spools having same face-to-face
dimensions of the instruments shall be fabricated and installed.
b. Orifice flanges providing more than two jack bolts shall be so installed that each jack bolt
may be located in the maximum distance from the other bolt.
c. When installing orifice plates, the orifice number, flow direction shall be confirmed. In
general the handle of orifice plates shall direct upwards (in Vertical lines) and the side
punched with the number, etc.
a. The protective covers placed on the nozzles of pumps and other rotating machines shall
not be removed until piping is to be connected.
b. After the covers are removed, temporary blind gaskets or galvanized iron sheets shall be
placed between the nozzle flanges and the pipe flanges for preventing entry of foreign
materials into the rotating machines. These temporary blind gaskets or galvanized iron
sheets shall be replaced with proper gasket when the rotating machines are finally aligned.
The ends of all pipes to be butt-welded shall be prepared in accordance with JIS B 3454 Point
8.3 and the governing Welding Procedure Specification.
SPECIFICATION FOR PIPING
FABRICATION, WELDING, INSPECTION
AND TESTING
Document No. Rev. : A
DED EXPANSION NICKEL HEAP
Page:
BMR-PIP-SPE-ST-0002 LEACH 5,000 T/Y
Page 12 of 15
Bevels shall be made by machine tool or machine thermal cutting. Manual thermal cutting shall
not be permitted unless specifically approved by BMR or good performed.
The beveled ends shall be smooth and uniform, and dimensions shall be in accordance with
the qualified welding procedural requirements. Burrs, small scuffmarks, indentations or small
defects within the joint preparation area shall be blended out by grinding, otherwise the joint
should be re-prepared.
The pipe ends and faces forming part of a welded joint shall be cleaned down to sound metal
immediately prior to making the joint. All paint, grease, scale, rust, and other extraneous matter
shall be removed. The cleaning shall extend for at least one (1) inch from the edge of the bevel
on both the internal and external faces of the components to be welded.
Welder Qualifications to be in accordance with the BMR requirements. The CONTRACTOR shall
be all costs for qualifying all welders.
Welding shall not be performed when atmospheric conditions (temperature, wind, and
humidity) do not permit satisfactory workmanship or adequate inspection as determined by
BMR.
The edges of pipe to be butt-welded which longer than 20 feet in length shall be aligned with
suitable line-up clamps. Line-up clamps shall be left in position until the tack welding has been
completed.
Any pinholes, cold lap, slag, flux, or other impurities that appear on any surface during or after
welding shall be removed by grinding or chipping before depositing the next successive bead.
SPECIFICATION FOR PIPING
FABRICATION, WELDING, INSPECTION
AND TESTING
Document No. Rev. : A
DED EXPANSION NICKEL HEAP
Page:
BMR-PIP-SPE-ST-0002 LEACH 5,000 T/Y
Page 13 of 15
All weld repair shall be as per determined in QA/QC procedure. Weld repair shall be identified
and mark in weld map.
a. Pipe and fittings for non metallic pipe in this specification shall be joined by Adhesive
Socket Joint or vendor / manufacture standard, and larger size the butt and strap method
except when connections to metallic components are required and then flanges shall be
used.
b. Flange Joint
Face of flange and dimension shall be adjusted to the flange to be connected.
Flanges shall be supplied with stub ends of sufficient length to permit a full strength joint
for the “butt-and strap” joining system.
Gasket for Flanged joints shall be full faced and shall be made of a material having
suitable chemical resistance. Flanges gaskets shall have a minimum thickness 3 mm.
Where FRP piping is to be flange mated to steel valves or other non-FRP equipment
the matching flanges shall be flat faced where possible.
Where flat face fiberglass reinforced plastic flanges must be mated with raised face
steel flanges, A full face gasket shall be used.
c. Fitting
For non metallic material, all elbows shall be contact-molded to produce sweep fittings
or corresponding piping & fitting data sheet. However, It is preferred that all fittings in all
sizes be sweep type. If the Vendor cannot supply material to the above requirement,
vendor shall state recommended alternates.
Bushings are not acceptable as reducers.
Reducer wall thickness shall be at least that of the wall thickness of the largest piece
being jointed.
COATING
All process piping and components shall be coated in accordance with Specification of this project.
In general, piping shall be blasted and painted up to the final coat of paint prior to installation on
skid packages or platform interconnected. Flange faces shall receive the full paint system prior to
installation.
Coating system shall be as per Specification for Piping painting and Wrapping.
SPECIFICATION FOR PIPING
FABRICATION, WELDING, INSPECTION
AND TESTING
Document No. Rev. : A
DED EXPANSION NICKEL HEAP
Page:
BMR-PIP-SPE-ST-0002 LEACH 5,000 T/Y
Page 14 of 15
INSULATION
Insulation shall be applied in accordance with Specification of this project. Unless otherwise
specified, insulation shall be applied only after final assembly and testing.
EXAMINATION
Table 12.1.1
UT***
100% 0 0
(Branch Welds)
a. Group 1
Following conditions apply :
PN 100 when the service or fluid content is :
• GA Gas Acid
• GF Fuel Gas
• GP Gas Product
• GR Gas Raw
• GT Gas Treated
SPECIFICATION FOR PIPING
FABRICATION, WELDING, INSPECTION
AND TESTING
Document No. Rev. : A
DED EXPANSION NICKEL HEAP
Page:
BMR-PIP-SPE-ST-0002 LEACH 5,000 T/Y
Page 15 of 15
• HM Heating Medium
• RH High Pressure Flare
• RP Refrigerant Propane
• CC Chemical Corrosive/Caustic
• CF Chemical Flammable
•P Gasoline (Petrol)
• XR Amine Rich
• XL Amine Lean
• XD Amine Drain
b. Group 2
Following conditions apply :
PN 50 when the service or fluid content is :
• GV Gas Vent
• FW Fire Water
• WP Water Produce
•Z Diesel Fuel
c. Group 3
Following conditions apply :
PN 5 up to PN 16 when the service or fluid content is :
• Al Air Instrument
• AU Air Utility
• SU Steam Utility
• WS Water Spec
• WF Water Fresh
• LO Lube Oil
• HFO Heavy Fuel Oil
Note : If the fluid content not stated in P&ID, line pressure range may be used to grouped or
based on terms of BMR.