f500-0000-pi-sp-5003-d2-specification for piping fabrication and erection.pdf

FOROOZAN OFFSHORE COMPLEX RENOVATION

AND RECONSTRUCTION PROJECT Contract No. 3898-86-2FGH

SPECIFICATION FOR PIPING FABRICATION AND ERECTION Rev. D2

Proj. Site Disc Doc. Seq. Page F500 0000 PI SP 5003 1 of 40

SPECIFICATION FOR PIPING

FABRICATION AND ERECTION

D2 31-Jul-10 Approved For Construction A.A. J.Afkar H.Dadgar A.Jahani H.Aramideh S.Azkat

D1 18-Aug-09 Issued For Approval S.S J.Afkar H.Dadgar A.Jahani H.Aramideh S.Azkat

D0 23-May-09 Issued For Comments S.S J.Afkar H.Dadgar A.Jahani H.Aramideh S.Azkat

Rev. Date Purpose of Issue Prep. Check. Approv. Approv. Approv.

ISI IOEC/NARDIS COMPANY





TABULATION OF REVISED PAGES

Sheet Revisions

Sheet Revisions

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TABLE OF CONTENT

1 INTRODUCTION ............................................................................................................................................. 5

1.1 General Description of the Project ............................................................................................................. 5

1.2 Definition ..................................................................................................................................................... 5

2 OBJECTIVE ..................................................................................................................................................... 6

3 REFERENCE DOCUMENTS .......................................................................................................................... 6

3.1 Codes and Standards ................................................................................................................................. 6

3.2 Specifications / Drawings, etc. .................................................................................................................... 6

3.3 Order of Preference .................................................................................................................................... 7

4 DESIGN ........................................................................................................................................................... 7

5 MATERIALS .................................................................................................................................................... 8

5.1 Storage / Handling of Materials .................................................................................................................. 8

5.2 Material Identification .................................................................................................................................. 9

6 FABRICATION .............................................................................................................................................. 10

6.1 Shop Fabrication ...................................................................................................................................... 10

6.2 Location of Field Welds ............................................................................................................................ 11

6.3 Field Fabrication ....................................................................................................................................... 11

6.4 Verification of Field Dimensions (New and retro-fit system) .................................................................... 11

6.5 Make-up Length ........................................................................................................................................ 12

6.6 Tolerances ................................................................................................................................................ 12

6.7 Minimum Distance between Welds .......................................................................................................... 13

6.8 Branch Connections ................................................................................................................................. 13

6.9 Galvanized Piping ..................................................................................................................................... 14

6.10 End Preparation ........................................................................................................................................ 15

6.11 Welding ..................................................................................................................................................... 16

6.12 Bending ..................................................................................................................................................... 16

7 INSTALLATION............................................................................................................................................. 17

7.1 Flange Assembly ...................................................................................................................................... 18

7.2 Threaded Connections ............................................................................................................................. 29





7.3 Pipe Supports ........................................................................................................................................... 29

7.4 Cold Spring ............................................................................................................................................... 32

7.5 Expansion Joints ...................................................................................................................................... 32

7.6 Final Corrections ...................................................................................................................................... 32

8 INSPECTION AND TESTING ....................................................................................................................... 34

8.1 General ..................................................................................................................................................... 34

8.2 Positive Material Identification Test .......................................................................................................... 35

8.3 Weld Examination ..................................................................................................................................... 36

8.4 Pressure Testing and Flushing ................................................................................................................. 36

9 CLEANING .................................................................................................................................................... 36

9.1 Weld Ends ................................................................................................................................................ 36

9.2 Piping ........................................................................................................................................................ 36

9.3 Completed Piping Systems ...................................................................................................................... 37

9.4 Degreasing ............................................................................................................................................... 37

10 PAINTING ...................................................................................................................................................... 37

11 DOCUMENTATION ....................................................................................................................................... 37

12 PREPARATION FOR SHIPMENT ................................................................................................................ 38

12.1 Spool Piece Marking ................................................................................................................................. 39

13 ADDITIONAL REQUIREMENTS ................................................................................................................... 40





1 INTRODUCTION

1.1 General Description of the Project

The project concerns the reconstruction and renovation of an existing oilfield in Persian Gulf. Foroozan

field is located approximately 100km southwest of Kharg Island export terminal. The field was initially

developed in the early 1970’s with the first production commencing towards the end of 1975. Peak

production of about 180,000 was briefly obtained in late 1978 but in more recent years production has

experienced a continuous decline associated with increased water production.

The oil and gas produced in Foroozan field are processed at 2 main offshore production complexes, FX and FZ.

1.2 Definition

Wherever the word "shall" has been used, its meaning is to be understood as mandatory.

Wherever the word "should" has been used, its meaning is to be understood as strongly recommended

or advised.

Wherever the wording "may be" has been used, its meaning is to be understood as a freedom of choice.

The following words and expressions shall have the meanings hereby assigned to them except where

the context of this document otherwise requires:

• "Company" mean Iranian Offshore Oil (COMPANY) Company.

• "EPC Contractor" mean Company mentioned in the Contract as party of the "other part" and

includes its successors and permitted assignees. (IOEC/Nardis)

• "Consultant" mean the company which provided engineering design of project. The name of this

company is "Intelligent Solution Incorporation" and abbreviation is "ISI".

• "Basic Consultant" mean the company which provided basic engineering design of project. The

name of this company is "Ranhill Worley Parson" and abbreviation is "RWP".

• "Vendor" means anyone who provides goods or services to a company. A vendor often

manufactures and/or sells their products to a customer.

• "NIOC" mean National Iranian Oil Company, a company incorporated under the laws of Iran,

whose Head Office is situated in Tehran, Iran.

Whenever terms appear in this document as capitalized terms, they shall have the meaning ascribed to them here above.





2 OBJECTIVE This specification covers the minimum requirements for fabrication and installation of steel piping, including pipe

supports.

Fabrication and installation of tubing, lined pipe and nonmetallic piping are excluded from the scope of this

specification and shall be executed in accordance with ASME B31.3/ASME B31.8 and manufacturer's

requirements and recommendations.

3 REFERENCE DOCUMENTS

3.1 Codes and Standards

ASME B31.3 Process Piping.

ASME B31.8 Gas Transmission and Distribution Piping Systems.

ASME B16.25 Butt-welding Ends.

API RP 686 Machinery Installation and Installation Design

3.2 Specifications / Drawings, etc.

F500F500-0000-PI-SP-5001 Specification for Piping Materials.

F500F500-0000-PI-DB-5000 Piping Design Basis

F500F500-0000-PI-SP-5010 Piping Standard Drawings

F500F500-0000-ME-SP-4001 Surface Preparation and Painting, Coating and Corrosion

Protection

F500F500-0000-PI-SP-5005 Pressure Testing, Flushing and Reinstatement of Piping

Systems.

F500F500-0000-PI-SP-5009 Specification for Welding of Piping

F500F500-0000-PI-SP-5002 Specification for Pipe, Fittings & Flanges

F500F500-0000-PI-SP-5004 Specification for Valves





3.3 Order of Preference

In case of conflict between regulations, codes and standards listed shall be applied in the following

priority order:

• Purchase Order

• Material Requisition

• Data Sheets

• Project Specifications and Standard Drawings

• International Codes and standards

• National Codes and Standards

• Supplier Specifications.

Latest editions of all Codes and Standards as valid on date of Contract shall be applicable. Deviations

from applicable rules, codes and standards shall be subject to Purchaser’s/Owner’s written approval.

4 DESIGN

The Fabricator Contractor / Sub-Contractor will furnish piping detail drawings of plan and isometric. The

detail drawing will contain all the relevant dimensions for fabrication, together with a bill of materials.

The dimensions on the drawings will be true dimensions without any allowance for weld gaps.

Piping designed by Fabricator Contractor/Sub-Contractor shall meet the requirements of ASME B31.3

and where applicable, ASME B31.4/ASME B31.8.

Fabricator Contractor/Sub-Contractor shall be fully responsible for conformity between his detailed

sketches and the latest revision of drawings supplied by Design Consultant/Contractor.





5 MATERIALS

All piping materials shall conform to the requirements of the applicable general specifications or to

requirements on the drawings, inquiry and/or purchase order.

All materials included in the finished piping systems (free-issued materials and material purchased by

Fabricator Contractor/Subcontractor) shall be undamaged and fully in accordance with the piping

material class and pipe support drawings indicated on the piping drawing and/or P&ID. For piping

material classes, see specification F500F500-0000-PI-SP-5003: Specification for Piping Materials".

Material substitutions or deviations from the piping material classes shall not be made without prior

written approval of Owner’s/ Authorized representative.

Fabricator Contractor shall submit a written justification for each proposed substitute materials.

Fabricator Contractor/Subcontractor shall provide a copy of the mill certificates including chemical and

physical properties for all materials.

Fabricator Contractor/Subcontractor shall be responsible for any loss or damage to free issued

materials.

Fabrication of plastic and plastic lined steel piping shall be in accordance ASME B31.3 and the

manufacturer’s latest recommendation.

5.1 Storage / Handling of Materials

Piping shall be stored in a clean, dry or well-drained area on elevated dunnage and protected

against contact with salts or salty water.

Stainless-steel piping shall be stored on wooden blocks, separately from carbon, and

galvanized carbon steel.

Stainless-steel materials shall not be loaded, unloaded or handled with hoisting devices (e.g.

steel ropes and forklift trucks) containing zinc or other harmful materials.





Storage and control procedures shall be prepared by the Fabricator Contractor/Subcontractor

to be submitted for review/approval by Owner/Authorized representatives.

Pre-fabricated pipe work shall be properly stored on level grand with 50 mm thick supports to

avoid contact with moisture.

5.2 Material Identification Materials issued to Fabricator Contractor/Subcontractor shall be properly marked in

accordance with the requirements of the applicable material specifications and requirements of

the purchase order requisitions and/or local codes and regulations.

In an areas wherein material identification symbols are located near or along the proximity of

the weld or on a piece of material to be cut off; material shall be re-stamped prior to welding or

cutting to avoid loss of traceability.

The governing principle shall be that in the installed piping systems, all components can be

identified and traced to their origin and complete specifications.

Marking and re-marking by Fabricator Contractor/Subcontractor's representatives shall be

performed or executed by hard dye stamping or engraving, whichever is applicable.

All hard stamping shall be done by means of low stress stamps on pressure-bearing parts. Low

stress stamped shall have a round nose with a radius of 0.25 mm minimum.

Hard dye stamping or engraving is not allowed for galvanized piping.

For ferrous materials with a thickness of equal to or less than 5 mm (≤ 5mm) and austenitic

steel with a thickness of equal to or less than 10 mm (≤ 10mm), marking shall be performed by

engraving.

When similar materials (e.g. carbon - low-temperature carbon steel or 304-316 stainless steel)

are used for the same project, materials will be supplied with additional color coding to be able

to make a quick visual identification of different types of material.

Note: Color coding need not be transferred prior to welding or cutting.





6 FABRICATION

Pipe work shall be fabricated by welding, screwing, and/or flanging as specified on the design

drawing and specifications.

Fabricated metal piping shall meet local authority requirements for all piping requiring

inspection and approval by local authorities such as HSE requirement , wind or humidity.

All other fabricated metal piping shall meet the requirements of ASME B31.3 and where

applicable, ASME B31.4/ ASME B31.8.

In order to prevent corrosion of stainless steel, fabrication of carbon steel and galvanized

carbon steel shall be done in a separate area.

Area means different shops or two (2) areas in one (1) shop separated by suitable (temporary)

walls.

For the same reason as above, tools used for fabrication of carbon steel and galvanized steel

may not be used for fabrication of stainless steel. Only tools made of stainless steel are

allowed for grinding, brushing, clamping, etc.

These requirements apply to shop and field fabrication.

6.1 Shop Fabrication

Shop fabricated piping is define as piping components or fired heater tube assemblies (if

applicable) which are performed or welded together, in a pipe fabricating shop located offsite,

to form integral pieces ready for assembly and erection. This may include bending, forming,

threading, bevelling, welding or other operations necessary for such work and external

welded attachments where specified.

Shop fabrication under this specification shall include all the components of the pipeline or

parts thereof entering into fabricated assemblies (spools), but shall exclude all piping

specialties other than those with welding end constructions such as bolting, gaskets, flanged

valves and fittings, blind flanges, orifice plates and similar items. Fabricator

Contractor/Subcontractor will be responsible for selection of piping to be shop fabricated on

site or off site.

For some piping systems Fabricator Contractor/Subcontractor may have opt for preferential preference

for shop fabrication to a maximum extent possible, e.g.:

Lined piping.

The fabricator contractor shall keep on file the records and reports specified herein available for

examination by OWNER or its representative for at least eighteen (18) months after date of shipment.





6.2 Location of Field Welds

The size of spools and location of field welds shall be determined by the Fabricator Contractor/

Subcontractor.

Field welds shall be located so that the spools shall be as large as possible and consistent with shipping

limitations. Field weld locations shall be governed by the following:

Lengths of spools shall not be limited by "match lines" that appear on drawings. A line and its

branches which appear on more than one (1) drawing is not intended to mean that a field weld

is desired at the continuation point from one drawing to another.

Where piping is shown passing through a wall or floor, the first weld point on either side of the

wall or floor shall be made a field weld, provided it is located at least 150 mm away from the

end of the pipe sleeve.

Erection conditions shall be considered in determining the size of spools.

6.3 Field Fabrication

All piping or fired heater tube assemblies (if applicable) which are fabricated on site, including bending,

forming, threading, bevelling, welding, assembly of shop fabricated piping, or other operations

necessary for the erection and installation of a piping system.

Field fabrication under this specification covers, but is not necessary limited to, the following operations:

Erection of shop-fabricated piping.

Fabrication and erection of all field-fabricated piping.

Design, routing, fabrication and erection of all field-fabricated piping for which no isometric

piping or piping plan drawings are available.

Fabrication and erection of all pipe supports and auxiliary steel as detailed in the pipe support

drawings.

Design, fabrication and erection of all pipe supports for small bore piping, which shall form part

and to be executed in line with the available drawings for supports.

6.4 Verification of Field Dimensions (New and retro-fit system) Fabrication of piping and pipe supports shall be in accordance with the supplied design drawings.

However, due to equipment location and fabrication tolerances, field verification of overall dimensions

shall be made by Fabricator Contractor/Subcontractor prior to erection, to ensure a proper fit-up at all

connections to equipment and other piping.





Fabricator Contractor/Subcontractor is required to conduct a systematic form of field measurement

including elevation and dimension of existing facilities and new related tie-in and new piping works.

The requirement’s of engaging third party contractor for the laser scanning works(i.e. usage of a laser

survey) to verify elevation/dimension of all tie-in works, new piping and equipment to be installed on the

existing platforms is strongly advise and recommended.

6.5 Make-up Length

Fabricator Contractor/Subcontractor shall apply 150 mm make-up lengths in order to make adjustments,

necessary due to construction deviations. The required material shall be taken from the construction

allowances/contingencies.

6.6 Tolerances

6.6.1 Overall Dimensions

The dimensional tolerances of all fabricated lines shall not exceed the values given below:

Less 1.5 m

Length than 1.5 m and longer

Center to center }

Center to flange face } ± 1.5 mm ± 3 mm

Flange face to flange face }

The angular dimensions of bends shall be within ± ¼ degree.

Manufacturer’s tolerance shall govern where forged fittings are welded and join together.

6.6.2 Thinning of Wall Thickness and Ovality in Bends

The maximum decrease of wall thickness shall not exceed 10% of the nominal wall thickness.

For tolerances on the maximum flattening, refer to ASME B31.3 and where applicable, ASME

B31.4/B31.8

6.6.3 Flange Face Alignment

For flange joints in rigid systems (free unrestrained straight length less then 10D at one or both sides of

the flange) flange faces shall be aligned to the design plane within 2.5 mm/m.

For all other flange joints flange faces shall be aligned to the design plane within 5 mm/m.

Heating of pipework to achieve alignment of flanges at equipment shall not be permitted.





6.6.4 Position of Bolt Holes for Flanged Piping

Flange bolt holes shall be aligned within 3 mm maximum offset.

Unless otherwise detailed on the drawings, flange bolt holes shall straddle the north-south centerline

when the flange face is in the horizontal position and shall straddle the vertical flange centerline when

the flange is in the vertical position.

6.7 Minimum Distance between Welds

The minimum distance between weld edges shall be as per requirements of specification, “Specification

for Welding of Piping”, document no. F500F500-0000-PI-SP-5009.

The minimum distance between welded joints, including longitudinal welds, and openings, branch

welds, reinforcements, attachment devices, supports, etc. shall be as per requirements of Para 12.9 of

“Specification for Welding of Piping”

Fabricator Contractor/Subcontractor shall provide and or specify additional requirements (such as

radiography, ultrasonic inspection or postweld heat treatment) in case of deviations.

The longitudinal welds of two (2) adjacent rings or tubes shall be staggered approximately 90°.

Longitudinal welds shall not be situated at the bottom of the pipe.

In cases where staggering is not possible, e.g. fitting to fitting connections. The weld joint shall be

subjected to non-destructive testing.

6.8 Branch Connections

The requirements for branch reinforcements for piping shall conform to the applicable codes. Any

branch reinforcement’s requirements for fired heater tube assemblies will be furnished with the heater

tube assembly drawings and specifications.

Branch connection type shall be in accordance with the piping drawing or the piping material class,

when no drawing is supplied.Branch connection could be set on or set in.

Where openings for branches are cut in run of pipe, all materials which may drop inside the pipe shall

be completely removed before the branch line is welded into place.

Branch connection cut-outs shall be properly Bevelled and to accurately matched to form a suitable

groove for welding. To enable and permit complete penetration of the welds at all points, resulting in a

quality comparable with girth welds, in the same piping system.





Weld details for branch welds shall be included in the welding procedure specification.

Reference is made to the relevant section of ASME B31.3/ASME B31.4/ASME B31.8.

The centerline of the branch connections shall intersect the centerline of the header, unless otherwise

specified on the piping drawing.

Nozzle joints shall be of the "set-on" type, made so that the branch connection abuts the outside surface

of the run wall.

Threaded couplings shall subsequently be checked with a thread gauge to ensure against thread

damage or distortion.

Requirements of a 6 mm diameter vent hole in the reinforcing pad or saddle, to reveal leakage in the

weld between the branch and main run and to provide venting during welding and heat treating

operations, shall be provided. If the reinforcement pad consists of more than one piece, each piece

shall have a vent hole.

6.9 Galvanized Piping

Galvanized piping up to and including 2" (DN 50) nominal size shall in general be assembled from

threaded galvanized components.

Piping larger than 2" (DN 50) nominal size shall be pre-fabricated in accordance with this specification

and subsequently hot-dipped galvanized in accordance with ASTM A153.

Fabricator Contractor/Subcontractor shall take into account that after the spools have been galvanized

no welding will be allowed. This implies that field break shall be located at flanged connections or

connections using threaded couplings and that welded-on pipe supports shall be welded to the spools

before galvanizing.

Welding of galvanized steel to austenitic steel pressure parts is prohibited.

Subcontractor shall consider maximum dimensions of the galvanizing facilities he intends to use, when

determining spool dimensions and locations of field breaks.

Visual and dimensional inspections by Owners Authorized representative, nondestructive weld

examinations if applicable and hydrostatic testing shall be executed before spools are hot-dip

galvanized.

Threaded connections shall be reworked to clean thread depth.

Repair of galvanized piping shall be as per ASTM A780, as referenced in ASTM A153.





6.10 End Preparation

6.10.1 Cutting

Cutting pipes may be done either by mechanical means (preferred) or by flame cutting or plasma cutting

when the following is taken into account:

For carbon steel, flame (or arc) cutting and bevelling is acceptable only if the cut is reasonably

smooth and all oxides are removed from the surface by grinding to bright metal.

For stainless steel, flame cutting is prohibited, but plasma cutting may be applied.

Preheating during thermal cutting shall be the same as applied during welding (see

specification "Specification for Welding of Piping” document no. F500F500-0000-PI-SP-5009.

6.10.2 Bevelling End profiles of pipes and fittings to be butt welded shall be in accordance with ASME B16.25. Bevelling

is not required when a make-up length is provided.

6.10.3 Tapering Weld alignment shall be in accordance with ASME B31.3 or ASME B31.4/ ASME B31.8.

6.10.4 Threading The threading of pipe shall be in accordance with the applicable standard. The type of thread is

indicated on the piping drawing or in the applicable pipe class.

6.10.5 Plain Ends

Pipes for sizes ≤ 1½” shall be cut square or will be specified by schudle .





6.11 Welding

The following activities shall be executed in accordance with the requirements as described in

specification “Specification for Welding of Piping”, document no. F500F500-0000-PI-SP-5009.

Alignment.

Preheating.

Tack welding.

Welding.

Repair welding.

Postweld heat treatment.

Backing ring and consumable inserts shall be prohibited unless approved in advance by OWNER.

Fields welds shall normally be butt-welded type rather than stub-in or miter type, unless otherwise

approved in writing by OWNER.

6.12 Bending

6.12.1 General Pipe bending may be considered as an alternate to welded fabrication. This consideration shall be

made prior to piping fabrication to take advantage of possible economics.

If bending is specified, the fabricator’s bending procedures shall be in strict accordance with ASME

B31.3/ASME B31.8 and shall be subject to prior approval by Owner/Purchaser’s representative.

Bending of pipes shall only be done where indicated on the isometric drawings or when allowed by the

applicable pipe class, otherwise welding elbows shall be used.

If the pipe contains a longitudinal weld, this weld shall be located in the neutral zone.

At site, cold pipe bending is not allowed.





Hot bending at site is not allowed, but shall be executed by Fabricator Contractor/ Subcontractors with

induction pipe-bending machines in accordance with the requirements of a bending procedure approved

by Owner.

Pipe bending shall be carried out in pipe bending machines or presses using formers. Tolerances for

thinning, flattening and wrinkling are specified in section 6.6.

6.12.2 Additional Requirements for Ferritic Steels

For feritic steels, with the exception of the quenched and tempered grades, a normalizing heat

treatment shall be applied when the hardness increase in Vickers or Brinell is more than 100, unless

local regulations are more stringent.

For quenched and tempered feritic steels an appropriate stress-relieving heat treatment shall be applied

when the hardness increase in Vickers or Brinell is more than 100, unless local regulations are more

stringent. Stress relieving shall be at least 10°C below the tempering temperature.

The use of water for cooling is not permitted.

7 INSTALLATION

Fabricator Contractor/Subcontractor shall be responsible for installation of all piping spools including

pipe supports, all piping components, such as bolting, gaskets, flanged valves and fittings, blind flanges,

etc., and all other items, such as flow meters, control valves, orifice plates and similar items necessary

to complete final piping erection with all lines cleaned, supported, pressure tested and ready for plant

operation.

Alignment of piping to equipment (machinery, vessels, exchangers, etc.) shall permit fit-up without

bending or springing the pipe under any circumstances. Alignment shall be checked and approved by

Owner/Authorized representative prior to bolt-up.

API RP 686 provide proper guide lines for installation sequence and bolting up of piping connected to

machinery.

Where a discrepancy between drawing dimensions and field dimensions exists, sufficient modifications

shall be made to eliminate unintended cold springing and cold forcing.

Deviations from the arrangement shown on drawings shall only be made after approval of Owners

representative. Fabricator Contractor/ Subcontractor shall submit alternative routing for review and

approval by Owner representative.





Alternative routing shall keep clear all access ways and equipment openings and shall maintain

accessibility of valves and instruments.

Cutting, welding and making attachments to structural members, vessels, exchangers and other

equipment, not detailed in the piping and piping support drawings, shall not be permitted without prior

approval of Owner representative.

Stainless steel shall be suitably protected during installation or modification of carbon-steel, and

galvanized carbon-steel piping at site.

All stainless steel pipe potentially exposed to zinc dust contamination shall be protected with polythene

sheeting. This requirement’s will apply also to piping under or close to at the same level, as galvanized

steel (grating/structural members/etc.). The sheeting shall be securely wrapped against tearing by wind

and shall be removed upon completion of the works.

Scaffolding, which is galvanized pipe, shall be kept at a distance of at least of 200 mm from stainless

steel pipe in order to prevent the possibility of surface contamination.

Pulling of pipe along piperacks is forbidden unless rollers are used.

Vents, drains, condensate drip legs, pressure instrument and other connections shall be installed where

indicated on the isometric drawings, in accordance with piping standards included in specification

"Piping Standard Drawings", doc. no. F500F500-0000-PI-SP-5008.

Protective devices on pipe ends, flanges and equipment openings shall remain in place until the piping

connection is ready to be made.

7.1 Flange Assembly

7.1.1 Tools

Usage of adjustable wrenches (Bahco) or wrench hammers is prohibited.

For application of correct tool related to flange size and rating, see table I.

The calibration of torque wrenches and tensioner’s shall be checked against manufacturer's

specifications upon receipt. Any tools that are out of calibration shall be rejected.

Requirement of verification and rechecking of the calibration shall be made as per tool manufacturer

standard. Any tool found to be out of calibration shall immediately be withdrawn or taken out of service for

repair.

All flanged joints secured with tools found to be defective shall be re-checked with a properly functioning

tool.





7.1.2 Flange Identification

Flanges subject to hydraulic bolt tensioning shall be numbered on the isometric or on the general

arrangement drawing by the subcontractor. Starting with the flow direction of each line number within one

(1) unit, the flange sets shall be identified as F1, F2, F3, etc., followed by the line number, e.g. F1-P30006.

The numbering system for flanged joints at equipment not part of a piping system, e.g. manholes, etc.,

shall be such that each equipment flange set is identified with the nozzle number as shown on the

equipment drawing, followed by the equipment number, e.g. M1-R1101.

The above described numbering system shall be used to relate each "assembly record" as described in

section 7.1.8 and section 12.1 to the relating flange set.

7.1.3 Torque Values

In case torque wrenches (manual or hydraulic) are used, bolts shall be tightened until torque values, as

indicated in table II, are reached.

In case tensioning equipment is used, bolts shall be tightened until bolt force values, as indicated in table II

are reached.

Listed values are NOT APPLICABLE for designed flanges over 60 inches. For these flanges the

equipment manufacturer shall indicate on his drawings the bolt torque value used in the calculation

made for the design of the flange.

For bolt material not listed in table II contact EPC1 Contractor to obtain correct torque and bolt force

values.

a. Listed values are based on the empiric bolt force in flanges according to ASME Section VIII, Div.

1, Appendix S.

b. Torque moments are based on the pitch of the thread, the friction resistance between the thread

surfaces and the bearing surfaces of the nut on the flanges.

c. Friction coefficient f = 0.1

7.1.4 Installation

Inspection of Material

Inspect the gasket material for possible damage or defects such as bends or creases.

Inspect the mating flange facings for dirt, parallelism, flatness, surface roughness, mechanical damage

and corrosion. Use a suitable solvent to clean the surfaces.





The contact area of the flanges shall be free of excessive pitting, radial tool marks and scratches.

Flange facings which are found to be damaged during construction, shall be re-machined at

subcontractor's expense.

Inspect the studs and nuts. They should be free of dirt and corrosion and well lubricated. The studs shall

be straight and the threads free of nicks, burrs and chips.

The Subcontractor shall ensure that the correct gasket material and thickness as specified in the Piping

Material Classes and on the piping drawings will be used.

7.1.5 Assembly of Flange Connection

The Fabricator Contractor/Subcontractor shall ensure that all bolting materials and types used are in

accordance with the service requirements specified on individual material specifications (piping material

classes) and detailed on the piping isometrics.

All flanges bolting shall be checked for correct grade and to ensure that they are free from damage to

the bolt/nut and any coating prior to fitting.

The Fabricator Contractor/Subcontractor shall ensure that during the installation of galvanised or PTFE

coated bolts, care will be taken that the coating is not damaged when bolt tightening. Any coating that is

damaged shall be brought to the attention of the Owner Authorized representatives.

Align the flanges properly. For tolerances on flange joints see specification section 6.6. The bolt holes

shall match so that the studs can be inserted freely. Install the gasket. Gaskets shall not be lubricated.

Use four (4) studs at 0, 90, 180 and 270 degree angle as centering guides for the gasket. In the case of

spiral-wound gaskets, ensure that the inner diameter of the centering ring is at all points within the

outside diameter of the raised face. Clamp securely in place.

Insert the balance of the studs. Apply a suitable lubricant to the threads and the face of the nut that

contacts the flange.

Hand tightens all studs and nuts. Center studs between nuts so an equal number of threads projects at

each end. When hydraulic bolt tensioning is required, a threaded length equal to the bolt diameter

should protrude at the end where the bolt tensioner is to be placed.

For other sizes, each stud bolt shall be assembled with a projection of no more than one full thread

beyond the nut at one end.





7.1.6 Bolt Torque

Standard Wrench

a. Tightened bolts crosswise in at least two (2) stages. First stage to approximately 50% if the

estimated value based on experience. Second stage to 100% of the estimated value. Bolting shall

be tightened in a sequence assuring equal distribution of bolt loading.

b. Check all bolts for even distribution of required load. Steel to cast iron flanged joints shall be

made up with extreme care. In order to avoid breaking of cast iron equipment flanges, piping

flanges shall be brought up flush with gasket and equipment flanges into close parallel and

lateral alignment, before uniformly tightening bolts.

Manual or Hydraulic Torque Wrench

a. Tighten bolts crosswise in at least three (3) stages:

• First stage to 40% of recommended value as per table II.

• Second stage to 80% of recommended value.

• Third stage to 100% of recommended value.

b. Check all bolts at 100% of recommended value.





7.1.7 Hydraulic Bolt Tensioning

The application of bolt-tensioning equipment shall be in strict accordance with supplier's instruction

manual and safety procedures.

Fabricator Contractor/Subcontractor shall propose a supplier/subcontractor for hydraulic bolt tensioning

equipment and/or services, for approval by Owner Authorized representative. The personnel using the

equipment shall be adequately trained in the application of such equipment.

The tensioning of the bolts is carried out crosswise in a number of cycles, depending on the number of

tools that can be applied simultaneously.

As a minimum following number of tensioner’s shall be applied during each cycle:

NUMBER OF BOLTS NUMBER OF TENSIONERS TO USE

32 and less 50% of bolts

36 to 60 1/3 of bolts

64 and up ¼ of bolts

Bolt tensioning shall be executed in two (2) steps in accordance with the tensioning procedure as

supplied by the tensioning subcontractor (see section 12) at the hydraulic pressure as calculated by

tensioning subcontractor based on information supplied by Fabricator Contractor/Subcontractor.

After completion of bolt tensioning four (4) bolts at 90 degrees angle each shall be checked for the

break loose point. Flanges not meeting the required values shall be re-tensioned.

After bolt tensioning has been completed, the extended threaded part shall be greased and covered

with suitable caps to prevent damage and corrosion during operation of the plant.

Upon completion of bolt tensioning each flange shall be provided with a wire seal(s) as indicated below.





Flange numbers as described in paragraph 7.1.2 shall be low stress dye stamped on the rim of one of

the flanges.

7.1.8 Leaking Flange Assemblies

Flange assemblies found to be leaking during hydro-testing shall be tightened as listed below:

a. Flanges assembled with standard wrenches shall be tightened with manual torque wrenches using

procedure as described in subsection 7.1.6.

b. Flanges assembled with manual torque wrenches shall be tightened with hydraulic torque

wrenches using procedure as described in subsection 7.1.6.

Flange assemblies tightened with hydraulic torque wrenches or hydraulic bolt tensioning equipment and

found to be leaking during hydro-testing shall be dis-assembled, inspected and re-assembled in

accordance with the requirements of this specification.

Flange assemblies still leaking after tightening as described in subsection 7.1.5 shall also be dis-

assembled, inspected and re-assembled in accordance with the requirements of this specification.

Re-assembly shall be done with tools as described in subsection 7.1.6a and 7.1.6b. In case of re-

assembly a new gasket is recommended.





Subcontractor shall prepare an assembly record for all flanges which are dis-assembled and re-

assembled because of leakage problems.

The bolt tensioning subcontractor shall prepare design calculations for all applicable flange sizes, in

order to determine the required bolt loads and, consequently, the required pressures in the hydraulic

bolt tensioning equipment.

Calculations shall take into account the following design factors:

Minimum and maximum gasket seating stress.

Allowable bolt stress.

Flange material.

Design pressure.

Hydrostatic test pressure.

External loadings

The bolt tensioning fabricator contractor/sub-contractor shall issue a hydraulic bolt tensioning procedure

for approval by the Owner or Authorized representative. The procedure shall show all required

information such as

Type of bolt tensioning equipment.

Operation manual.

Record preparation instructions.

Establishment of the "break loose" pressure, based on minimum four (4) tensioners.

Any precautions to be taken.

Fabricator Contractor/Subcontractor shall prepare an assembly record for each flange joint which needs

to be tensioned. These records shall be issued as part of the turn-over packages.

Information to be shown on the assembly record shall be at least:

Identification:

• Unit.

• Line number.

• Pipe class.

• Flange set number.

• Flange size/rating.

• Company representative's name and signature.





Inspection of the flange facing:

• Roughness.

• Damage: Dents, tool marks.

• Cleanliness.


Flange fit-up:

• Gasket type.

• Gasket size.

• Bolt diameter and length.

• Number of bolts.

• Bolt material.

• Flange alignment.


Bolt tensioning:

• Pressure A, (the higher tool pressure, taking into account the maximum bolt stress, that

is applied to obtain at least the average bolt stress).

• Pressure B, (the lower tool pressure, required to obtain the average bolt stress).

• Tool number.

• "Break loose" pressure (check B pressure at four (4) bolts at 90% each) or bolt torque

value.






TABLE I Selection of Tools

FLANGE RATING (ANSI CLASS)

150 300 600 900 1500 2500

½” 1 1 1 1 1 1

¾” 1 1 1 1 1 1

1” 1 1 1 1 1 1

1½” 1 1 1 1 1 2

2” 1 1 1 1 1 2

F 3” 1 1 1 1 2 2

L 4” 1 1 1 2 2 3

A 6” 1 1 1 2 3 4

N 8” 1 1 2 3 4 4

G 10” 1 1 2 3 4 4

E 12” 1 2 2 3 4 4

14” 1 2 3 3 4 -

S 16” 1 2 3 4 4 -

I 18” 2 2 4 4 4 -

Z 20” 2 2 4 4 4 -

E 24” 2 3 4 4 4 -

26” 2 4 - - - -

28”-30” 2 4 - - - -

32”-36” 3 4 - - - -

38”-48” 3 4 - - - -

50”-60” 4 4 - - - -

above 60” 4 - - - - -





LEGEND

TOOL BOLT SIZE

1. Standard wrench ≤ 1 inch

2. Torque wrench ≤ 1¼ inch

3. Hydraulic torque wrench ≤ 1½ inch (note 1)

4. Bolt tensioning equipment > 1½ inch

Note 1: Manual torque wrench with multiplier is an acceptable alternative.





TABLE II Bolt Torque and Bolt Force Values

BOLT DIA.

(INCH)

THREADSINCH

A193 B7, A193 B16 AND A320 L7, 26 IN. AND LARGER FOR 150 LB & 300 LB ASME B16.47

SERIES A (MSS)

A193 B7, A193 B16 AND A320-L7, OTHER SIZES/RATINGS ASME

B16.5

TORQUE VALUE IN

Nm

BOLT FORCE IN N

(note 1)

TORQUE

VALUE IN Nm

BOLT FORCE IN N

(note 2)

Carbon

steel

Stainless

steel

Carbon

steel

(note 1)

Stainless

Steel

(note 3)

1/2 13 70 70

5/8 11 125 125

3/4 10 195 195

7/8 9 290 290

1 8 300 200 71400 47600 400 95200

1 1/8 8 420 280 88940 59295 560 118590

1 1/4 8 560 370 107670 71780 740 143560

1 3/8 8 740 490 127640 85090 980 170180

1 1/2 8 900 600 148650 99100 1200 198200

1 5/8 8 1120 745 170770 113850 1490 227700

1 3/4 8 1360 905 193950 129300 1810 258600

1 7/8 8 1620 1080 218030 145350 2160 290700

2 8 1920 1280 243000 162000 2560 324000

2 1/4 8 2610 1740 295440 196960 3480 393920

2 1/2 8 3420 2280 351750 234500 4560 469000

Notes: 1. 65% of empirical values to ASME Section VIII, div. 1, Appendix S

2. 85% of empirical values to ASME Section VIII, div. 1, Appendix S

3. 43% of empirical values to ASME Section VIII, div. 1, Appendix S





7.2 Threaded Connections

All threaded connections shall be seal welded, except the following:

Connections in galvanized piping.

Screwed plugs in valved drains and vents.

Screwed thermowells and instrument connections.

Screwed control valves and safety/relief valves.

Screwed plugs in hydrostatic test vents and drains without valves shall be seal welded after completion

of testing.

Usage of sealing compound or teflon tape for all connections which are not seal welded.

Teflon tape is only allowed in utility services, at a design temperature of maximum 200°C.

7.3 Pipe Supports

7.3.1 Temporary Supports

During erection, piping shall be adequate temporary supported until the final supports are installed.

Temporary supports shall rest on structural beams.

Piping shall not be temporarily supported from platform grating or from scaffolding. Temporary supports

shall consist of wooden blocks and/or steel hoisting ropes.

Synthetic ropes or strings are not acceptable as temporary supports.

Steel temporary supporting materials for stainless steel materials shall preferably be stainless steel.

Usage of galvanized temporary support material is not permitted.

The use of adjacent structures or equipment as temporary supporting or lifting attachment shall not be

permitted unless authority has been obtained from the Company’s Representative in writing.

Temporary attachment shall be of the same material as the parent material and shall be performed by

qualified welders.

Pipework shall not primarily be supported via control or block valves.





7.3.2 General

Fabricator Contractor/Subcontractor shall adjust the pipe support to overcome construction measure

deviations. Shims used to achieve full bearing between a pipe and/or a pipe attachment and the main

support member must have sufficient area to carry the load. After erection, shims shall be welded to the

main steel to prevent slippage when the pipe moves during operation. Shims shall not be welded to the

pipe. Shims which are to be welded to pipe shoes shall extend the full length and width of the shoe.

Care shall be taken to avoid undue strain being placed on a vessel or item of equipment by unsupported

lengths of piping.

Flange connections to strain sensitive equipment shall be the last connection made on completion of a

line or interconnecting system of lines complete with permanent supports.

Alternative supports shall only be installed after approval by Owner/Authorized representative.

Pipe supports shall not be located at the weld point of piping welded construction.

Pipe support subcontractor shall remove fireproofing locally from steel columns and beams for a proper

installation of pipe support according to the pipe support drawings. Fireproofing shall be repaired on the

main structure and will not be installed on the additional pipe support, unless otherwise shown.

Any fireproofing around directional anchors from pipes which are free to move in the transverse

direction shall be kept free minimum 50 mm from the pipe anchor parts.

Should there be any expansion bolts to be installed or provided in the concrete members (if any), care

shall be taken not to undercut retaining bars in the concrete. Pipe supports shall be adjusted to suit the

final location of the expansion bolts.

Pipe supports shall not be welded to the pipe line unless specified in the design and piping drawings.

Force shall not be used to align pipes to support locations during installations.

Permanent pipe supports shall, where possible, be installed before the erection of the associated

pipework.

The Fabricator Contractor/Subcontractor shall ensure that provision of adequate support for heavy

valves and fittings before the pipework is erected or subjected to pressure test.

The burning of holes in structural steel work or component parts is strictly forbidden.

Supporting steelwork shall be set at the correct elevation, being true and level in all directions.





Metallic surfaces of supports which will be inaccessible after erection shall be prepared and coated

before assembly of the component in accordance with the “Painting, Coating and Corrosion Protection

Specification” document no. F500-0000-ME-SP-4001.

Hanger rods shall be adjusted to correctly hanging after tightening of all components parts, surplus

threading may be removed.

Pipe hanger shall not be used as temporary lifting attachments.

The use of adjacent structures or equipment as temporary supporting or lifting attachments shall not be

permitted unless with approval of the Fabricator Contractor/Subcontractor in writing.

7.3.3 Variable Spring Supports

Installation

The spring hanger list included in the pipe support drawings will give, for each spring:

a. The operating load.

b. The cold set load.

c. The amount and direction of travel.

When the spring is delivered, it will have been loaded to the preset load and locked into this position by

means of the cold setting stops. Depending upon the manufacturer, the cold setting stops will take the

form of a plain rivet through section bar inserted above and below the piston plate inside the load scale

slot.

The cold setting stops must remain undisturbed until the hydrostatic test on the line has been

satisfactorily completed, after which the following procedure shall be carried out:

a. At some time between the hydrostatic test and start-up, the cold setting stops shall be removed.

Ultimate force must not be used.

b. With the cold setting stops removed, it may be noticed that the line has a tendency to bow up or

sag down. This is to be expected as when the line is cold and empty it is obvious that it can be

either over supported or under supported since it is designed to be correctly supported at the

hot operating condition. Do not readjust the spring load, but contact Owner/Consultant

representative when there is doubt.





7.4 Cold Spring

Cold spring or fullness (cold strain) shall not be used accomplished by any case during constrction or

fabrication.

7.5 Expansion Joints

Expansion joints shall be installed following thoroughly the instructions of the manufacturer regarding

the removal of shipping supports and attachments, adjusting tie-rod nuts, pre-compressing bellows, flow

direction, etc. If the joints have welding ends, protection shall be given to the bellows to prevent any

injurious effects during welding.

7.6 Final Corrections

7.6.1 Carbon Steel Piping

If corrections are required after fabrication, they may be carried out by a method approved by

Owner/Authorized representative. Following correction method is acceptable and recommended:-

a) Local heating

b) Application of force with local heating

The following restrictions apply to the heating; forcing of piping made from carbon steel, low alloy steel or

austenitic stainless steel:

i. For carbon steel which does not require a PWHT – the maximum temperature during alignment

corrections shall be 6000C. Temperature-indicating manometer or contact thermometers shall

be used to measure the maximum temperature. If temperature-indicating manometer are used,

a margin of 500C shall be taken to allow for measurement inaccuracy (i.e. the reading with the

manometer shall not exceed 5500C. Forcing may be applied if necessary). For carbon steel

which requires a PWHT – the maximum temperature during alignment corrections shall be the

maximum PWHT temperature. Temperature-indicating manometer or contact thermometers

shall be used to measure the maximum temperature. If temperature-indicating crayons are

used, a margin of 500C shall be taken to allow for measurement inaccuracy (i.e. the reading with

the crayon shall not exceed the maximum PWHT temperature minus 500C). Only heating with

application of local force shall be used and no quenching shall be used. The area shall either be

heated in full compliance with the PWHT procedure or the area which is heated (and corrected)

shall be post weld heat treated.





7.6.2 Austenitic Chromium Nickel Steel Piping All corrections to the piping should preferably be made in the cold condition.

If cold correction is not possible the piping may be heated after written approval by Owner/Authorized

representative. The heating shall be applied uniformly and carefully controlled. The temperature shall

not exceed 400°C.

7.7 Valve 7.7.1 Wherever possible, valves should be kept near grade level. All operating valves installed 1600 mm or

more above floor, platform or other point of easy access shall be hammer blow chain wheel operated.

Hammer blow chain wheels shall have U-bolt clamps, not J-bolt clamps.

7.7.2 Hand wheels and stems shall be kept out of operating aisles, where practical, otherwise elevated to

1600 mm from grade to bottom of hand wheel.

7.7.3 Valves shall not be installed with stem below a horizontal position (90 degrees reference angle from a

vertical plane).

7.7.4 Block valves, when required, shall be installed at nozzles of pressure vessels or in lines connected to

nozzles to permit operating valves from grade or a platform. Equipment shall be capable of being

isolated if:

• Operations can continue without disruption.

• Depressurising associated facilities will delay maintenance on the equipment.

7.7.5 Gate valves shall be provided with an equalizing globe valve bypass with a minimum size of NPS 1 for

the following:

• Class ANSI 150 - NPS 12 and larger.

• Class ANSI 300 and greater - NPS 8 and larger.





7.7.6 All valves shall have sufficient clearance to facilitate removal of the bonnets, plugs and internals.

7.7.7 Ball valves shall not be used for throttling service.

7.7.8 Valve instruments and other equipments, which may required to be monitored, adjusted or serviced

during operation shall be accessible from platform or grade.

7.7.9 Valves shall be oriented in the line as detailed on the piping isometric drawings and shall be readily

operable, and removable as required or maintainable, where specified, in-situ. Where no indication

exists on isometric or piping GA, gate, butterfly, globe and ball valves in horizontal lines shall be

installed with their stems oriented as follows in order of preference:

a) Horizontal restriction:

• Downward Stem

• 60O Stem Max Orientation

• 315O Stem Max Orientation.

b) Vertical restriction:

• None

7.7.10 Actuated

a) Gate, Globe (including 3 way and Y type) shall only be mounted with the stem vertically

upwards.

b) Rotary valves (butterfly, throttling, ball etc.) shall be mounted with the stem horizontal or vertical.

The Contractor shall provide for the checking of gland packing’s in all valves during hydrostatic

testing.

8 INSPECTION AND TESTING

8.1 General

Test and measuring equipment used shall be calibrated every six (6) months.

All inspection and testing is the responsibility of Fabricator Contractor/Subcontractor. Owner/Authorized

representatives shall always have the right to witness inspection.

Any defects revealed by any of the examinations performed shall be reworked and retested. All

assemblies indicating irremediable defects, excessive repairs, improper fabrication or not being in





accordance with the requirements of this specification shall be subject to rejection, even if the conditions

are discovered after acceptance at Fabricator Contractor/Subcontractor's shop or revealed during field

testing. All costs related to repairs and/or re-fabrication shall be for Fabricator

Contractor/Subcontractor's account.

8.2 Positive Material Identification Test

Positive material identification (PMI) on alloy materials shall be executed with a Texas Nuclear or equal,

as follows:

a. Incoming materials in Fabricator Contractor/Subcontractor warehouse will be examined at

random by Owner authorized representative to check attached certificates. “At random” is

defined as a random check of materials as per material type (independent of size, rating, wall

thickness and type of piping item) up to a maximum of 1% of the total supplied quantity of

material.

b. Installed material shall be checked for 100% of installed quantity by subcontractor to eliminate

possibility of accidental material substitution.

c. All installed materials with poor readability of heat numbers or materials where doubt exists

concerning the accuracy of the heat numbers if deemed required and upon requested by the

Owner or Authorized representative shall be checked by Fabricator Contractor/Subcontractor.

PMI is only required for the following materials:

MATERIAL SERVICE

Stainless Steel All Services

Carbon Steel All Services

Fabricator Contractor/Subcontractor will be responsible for execution and documentation of PMI as

described under paragraph 8.2b. and paragraph 8.2c.





8.3 Weld Examination

For weld examination requirements, see specification " Specification for Welding of Piping”, document

no. F500-0000-PI-SP-5009.

8.4 Pressure Testing and Flushing

For pressure testing and flushing of completed piping systems, see Specification for Pressure Testing,

Flushing and Reinstatement of Piping Systems", document no. F500-0000-PI-SP-5005.

Except when specifically noted on the drawings, spools shall not require shop hydrostatic testing. This

shall not, however, relieve subcontractor of the responsibility for any defects in materials and/or

fabrication that may be revealed during field hydrostatic testing.

9 CLEANING

9.1 Weld Ends

During weld preparation ends of all components shall be freed from any traces of oil, grease,

paint, rust, scale, etc., over a distance of 50 mm minimum from the weld edge.

9.2 Piping

9.2.1 Internal

During fabrication and installation, Fabricator Contractor/Subcontractor shall prevent foreign materials

such as oil, grease, sand, dirt, scale, loose particles from cutting and grinding, etc., from entering the

pipe or pipe component.

Any foreign materials which may be presence or have entered the pipe or pipe component, they shall

immediately be removed before assembly of the parts by a suitable cleaning method, such as blowing

through with air or degreasing with suitable cleaning agent or solvent.

Cleaning agents and solvents used for degreasing shall not contribute or have any properties that may

cause corrosion to the piping.





9.2.2 External

Piping to be painted shall be cleaned in accordance with the requirements of specification "Painting,

Coating and Corrosion Protection Specification" document no. F500-0000-ME-SP-4001.

Piping system whereby painting requirements is not required, piping shall be properly cleaned by a

suitable cleaning method to removed excessive rust, scale or grease only.

Cleaning agents and solvents used for degreasing shall not contribute or have any properties that may

cause corrosion to the piping.

9.3 Completed Piping Systems

Unless otherwise indicated in the pipe class or on the piping drawings or P&ID's, recommended

flushing methodology as described in “Specification for Pressure Testing, Flushing and Reinstatement

of Piping Systems" document no. F500-0000-PI-SP-5005 will be adopted and implemented.

9.4 Degreasing

For certain services, lines need to be degreased to prevent operation problem. This requirement will be

address in the pipe class or on the piping drawings or P&ID's and will form part of the additional

specifications to be supplied by Fabricator Contractor/Subcontractor.

Cleaning agents and solvents used for decreasing shall not contribute or have any properties that may

cause corrosion of the piping.

10 PAINTING

For painting requirements, reference is made to specification "Painting, Coating and Corrosion

Protection Specification", document no. F500-0000-ME-SP-4001.

11 DOCUMENTATION

Both shop and field fabrication include administration of material certificates, welding operations,

destructive and non-destructive examinations and all testing operations as required by the applicable

specifications and codes.

Fabricator Contractor/Subcontractor shall be responsible for planning and documenting all activities and

controls which include, but are not necessarily limited to, the following operations:

Material receiving (including administration/filing of certificates).

Material traceability





Cutting.

Bending (at subcontractors for induction bending).

Welding.

Welders identification

Qualification test and records of repairs

Heat treatment.

Destructive and nondestructive testing.

Hydraulic bolt tensioning and/or torquing.

Hydrotesting.

Flushing.

Cleaning.

Fabricator Contractor/Subcontractor shall provide Owner/Authorized representative with two (2) copies

of material test certificates for all materials purchased by Fabricator Contractor/Subcontractor.

Documents relating to assemblies to be shipped shall be submitted to Owner/Authorized representative

for review/approval.

Documents shall be made available to Owner/Authorized representative at all times.

For each piping system (defined as piping items welded together of same material and same design

pressure/temperature, e.g. line from a pump to a vessel) Fabricator Contractor/ Subcontractor shall

provide a fabrication book containing documents showing all above-listed operations.

12 PREPARATION FOR SHIPMENT

Before shop-fabricated assemblies are prepared for shipping, Fabricator Contractor/ Subcontractor's

inspector shall check following:

Overall dimensions as per piping drawing.

Required documentation as per subsections 11.

Material identification as per subsection 5.2.

After assembly has been released by Fabricator Contractor/Sub-contractor's representative inspector,

Fabricator Contractor/Subcontractor shall prepare material for shipping as follows:





All assemblies shall be dry and free from water, dirt and loose or foreign materials.

Flange faces, machined surfaces and threads in carbon-steel piping shall be coated with a

corrosion preventive compound (Rust Ban 324, or equal) before applying the cover, cap or plug.

Plastic caps shall be used over all plain, Bevelled or threaded open ends.

Wood, metal or plastic covers shall be bolted or strapped to open flanged ends.

All protective coverings of piping for shipment and shipping containers shall be of sturdy

construction in order to withstand normal shipping abuse.

Provisions shall be made to prevent damage to all subassemblies during loading, unloading or shifting

of the cargo in transit.

Small items shall not be shipped loose, but shall be bagged, boxed or crated. Each container shall be

tagged with a description of the contents and destination.

Carbon, low-alloy and galvanized carbon steel, stainless steel and duplex stainless steel shall be

shipped separately from each other.

For stainless-steel and duplex stainless steel spools, subcontractor shall not use steel hoisting devices

as described in subsection 5.1 and shall provide suitable transport packing to prevent spools from

contacting surfaces containing zinc or other harmful materials during the transportation.

12.1 Spool Piece Marking

The appropriate pipe identification, consisting of the line number and spool number, shall be hard dye

stamped into the spool. Marking shall be circled with yellow paint.

Fabricator Contractor/Subcontractor shall be responsible for ensuring that throughout fabrication all pipe

spools are marked and can be identified by the numbers assigned to them by the isometric drawings.

The use of die stamping, scratching, etching or bead welding for pipe identification marking shall not be

permitted.

Pipe spool identification markings shall be clearly written on the pipe using an alkyd, brilliant white

colour paint, in two places at diametrically opposite sides and one metal tag secured to the spool piece

by multi-strand stainless steel wire or strap.

Austenitic stainless steels and Copper Nickel materials shall not be marked with crayons or paint

containing sulphur, zinc, lead, aluminium, or compound sulphur.





All post weld heat treated (stress relieved) fabrications shall be clearly marked on both sides “WELDING

PROHIBITED”

In addition to the pipe spool identification, the welder’s identification reference shall be painted adjacent

to each weld using an approved paint / crayon.

The position chosen shall be transferred to the radiographic records for each respective weld.

This transfer shall be carried out to the satisfaction of the Owner and or Authorized Inspectors.

13 ADDITIONAL REQUIREMENTS

For additional or deviating requirements concerning fabrication and erection of steel piping, see

specifications listed below:

F500-0000-ME-SP-4005: Insulation Specification

f500-0000-pi-sp-5003-d2-specification for piping fabrication and erection.pdf

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