standard specification for cement lined...

of 7

STANDARD SPECIFICATION FOR CEMENT LINED PIPING

DOCUMENT NO: 44LK-5100/L.02/001/A4

Rev No.

Issue Date Pages Rev Description PreparedBy

Checked By

ApprovedBy

0 02-01-2009 7 Issued for Feed ASJ PUP RMP / PVS

JACOBS HPCL, Mumbai Refinery

STANDARD SPECIFICATION FOR

Doc. No:- 44LK-5100/L.02/001/A4

DHT Project CEMENT LINED PIPING Rev. 0Date of Issue: 02/01/09 Sheet 2 of 7

TABLE OF CONTENTS 1.0 SCOPE

2.0 COADES & STANDARDS

3.0 MATERIALS

4.0 LINING APPLICATION

5.0 CURING

6.0 PROCEDURE QUALIFICATION

7.0 INSPECTION

8.0 REPAIRS OF LINING

9.0 PIPE JOINTS

10.0 FITTINGS & FLANGES

11.0 BRANCH CONNECTIONS

12.0 HANDLING & TRANSPORTATION

13.0 REFERENCE DOCUMENTS

JACOBS Doc.No:- 44LK-5100/L.02/001/A4 STANDARD SPECIFICATION

FOR HPCL, Mumbai Refinery

Rev. 0 CEMENT LINED PIPING DHT ProjectSheet 3 of 7 Date of Issue: 02/01/09

1.0 SCOPE

1 This specification shall be followed in connection with ANSI / AWWA C-205-95 for cement lining or piping at shop/field by the contractor. This covers the minimum requirements of materials, mixing, application of cement lining, curing, inspection, repair, handling & transportation of piping system carrying sea-water, brackish water up to 70 0C and 10.55 Kg/cm2 g (65 0C and 16.0 Kg/cm2 g for fire water) pressure for piping system 3” and above. The provisions of this specification shall govern over and above AWWA C205 and relevant piping material classes gives in job Piping Material Specification.

2.0 CODES AND STANDARDS

i) ANSI/ AWWA C205-95 Cement mortar protective lining and coating for steel water pipe-shop applied

ii) AWWA C602-83 Cement mortar lining of water pipelines in place

iii) ASME B31.3 ASME code for Pressure piping –chemicals Plant & Petroleum refinery piping

iv) IS: 12330 Specification for sulphate resisting Portland cement

v) IS: 383 Coarse & fine aggregates from natural sources for concrete

vi) IS: 456 Code of practice for plain & reinforced concrete

vii) ASTM A-82 Standard specification for steel wire, plain, for concrete reinforcement

viii) ASTM A-185 Standard specification for steel welded wire fabric, plain, for concrete reinforced

3.0 MATERIALS

3.1 Pipes & piping materials

Basic pipe fittings, flanges etc. shall be carbon steel or cast iron and designed as per ASME B-31.3 as per the relevant piping material specifications (A5Y) given in job PMS (Refer document no.44LK-5100-00/L.02/0101/A4 ) for the project.

3.2 Cements

Cement used in mortar lining shall be sulphate resistant as per ASTM C150 type-II or Portland cement conforming to IS: 12330. Cement shall be free of lumps.

3.3 Sand

Sand shall consist of inert granular material and the grain shall be strong, durable and uncoated. Sand shall be clean and free from injurious amount of dust, clay, flaky particles, oil, alkali, mica and other deleterious substances. Sand shall conform to IS: 383 grading zone III.

3.4 Water

Water used for cement mortar mixing and curing shall be clean and free from injurious ingredients or organic matter, alkali, oil, acid, salt, sugar or other impurities and shall confirm to IS: 456. Salt water shall not be used for mixing under any circumstances.

3.5 Reinforcement

Reinforcement shall consist of welding steel wire fabric. Wires shall conform to ASTM A-82. Steel wires shall be galvanised at finished size. Wire fabric manufactured in flat sheets to ASTM A-185 shall be 2”x 4” maximum steel wire mesh, with wire 12 SAG (2.6 mm minimum)



Doc. No:- 44LK-5100/L.02/001/A4


each way.

4.0 APPLICATION

4.1 Cement mortar mixing

Cement lining shall be done in the field shop, which may be outside the refinery boundary. Suitable mechanical equipment capable of mixing mortar and doing the lining work to a reasonable degree of uniformity w.r.t. thickness, density and strength shall be employed. Mortar shall be mixed in batches.

Mortar shall be composed of cement, sand and water and mixed well in proper consistency to obtain a dense, homologous lining that shall adhere firmly to the pipe surface. Cement mortar for lining shall consist of one part cement to not more than three parts sand by weight. Water-cement shall be between 0.3 to 0.4 by volume. Trial mixes shall be made to arrive at mix to achieve the requirements specified in procedure qualification clause 6.0 below.

4.2 Surface preparation & primer application

Pipes shall be welded in suitable length and immediately prior to lining, the surface shall be thoroughly cleaned removing all grease, scale, rust etc. by power tool to St.3 as per ISO 8501-1/ SIS 05 5900/ BS 4232. Surface cleaning shall be followed by spray application of welding grade of inorganic zinc silicate prefabrication primer from approved paint manufacturers with a dry film thickness of 25 microns at both the pipes ends up to 100 mm pipe length. The cement lining shall be done at least after 10 hours drying of the prefabrication primer to avoid damage of the primer. Suitable products are such as inter plate-11 from M/s AKZO NOBEL coatings (India) ltd., Banglore, Carboweld-11 from M/s Carboline product Chennai.

4.3 Application of reinforcement

Pipes & fittings in sizes 26” and above shall be cement lined with reinforcement. Wire fabric reinforcement shall be applied to the interior pipes and fittings.

Reinforcement shall be placed in pipe in such a way as to cover the whole pipe length or section to be lined. The reinforcement shall terminate at a distance of approx. 50 mm from the ends. The reinforcement then shall be suitably tack welded. There shall be an overlap of minimum 25 mm at the longitudinal joint of the reinforcement. For the pipe butt joints, reinforcement in the form of strip approx. 150 mm wide shall be placed and tack welded. There shall be an overlap of minimum 25 mm between two reinforcement sections.

4.4 Lining application

The lining shall be applied in one course for the pipe section. No unfinished surface shall remain exposed for more than 20 minutes. Mortar shall be handled so as to avoid any kind of segregation and excessive moisture loss. During mortar application pipes should be ambient temperature. If pipe is hot due to such reasons as lying in the hot sun, then the pipe must be cooled with the help of wet gunny bags prior to application of mortar. Lining shall be free of any sharp corners and edges and must be suitably contoured/rounded prior to curing.

For the lining at the joints of two pipes, reinforcement shall be applied as per 4.3 above. Old lining shall be suitably hacked to make it rough before filling mortar. Prior to mortar filling cement slurry may be applied on the surface.




Straight section of pipe shall be lined by using spinning method or a method known to provide equivalent results such as by a machine travelling through the pipe and distributing the freshly mixed mortar uniformly along the full section and long radius bends of the pipe. The lining machine shall be provided with attachment for mechanically trowelling the mortar. Both the application and trowelling of the mortar shall take place at the rear of the machine so that the freshly placed and trowelled mortar will not be damaged. The trowel attachment, the rate of travel of machine and the rate of discharge of mortar shall be such that the pressure applied to the lining will be uniform and produce a lining of uniform thickness with a smooth finished surface.

Hand patching of the end of the bore of the pipe, for length not more than 100 mm length, shall be permitted to rectify the thinning of linings. Fittings and specials shall be centrifugally spray lined to the same standard as straight pipes or, if this is precluded by their shape, be hand patched so as to achieve comparable results. The thickness of lining shall be as per figure-01. However to accommodate the disc movement of butterfly valve the cement lining of the mating flanged spool shall be suitably tapered keeping minimum 3mm lining thickness.

5.0 CURING

After lining, the pipe shall be marked with the date of lining and shall be cured either by misting curing as per AWWA C-205.

Moist curing shall starts after 24 hours of completion of cement lining and shall be done by continuous wetting or ponding. Under no circumstances the lining shall be allowed to dry during curing period. Curing shall be carried out for minimum period of 7 days.

6.0 PROCEDURE QUALIFICATION

Prior to the application of the shop cement lining the manufacturer shall perform procedure tests and qualify a working procedure to demonstrate that he is able to produce a lining system in accordance with design requirements. The constituents, mortar & finished pipe shall be tested. To establish the correct combination of sand & water, minimum of five samples shall be prepared. For each mix following shall be accurately checked and recorded:

For individual constituents

Cement / admixture

Sand

Water

Proportions & weight of respective materials. For cement mortar test specimen

Density

Compressive Strength

Water absorption



Doc. No:- 44LK-5100/L.02/001/A4


Test blocks of this material when subjected to testing as per IS 6441/IS 4031. shall exhibit compressive strength of not less than 200 Kg/sq. cm. After 28 days of curing and the density of cured lining shall be less than 2300 kg/cu.m. Water absorption as per ASTM C642 shall not exceed 10 % for the test specimen

Based on the test results a procedure shall be standardised for mixing of the materials. Inspection personnel shall witness the mixing of materials and sample preparations for procedure qualification. Test result shall be correlated with sample no. and a stand red procedure shall be evolved.

7.0 INSPECTION DURING PRODUCTION

The entire procedure of applying cement-mortar lining shall be subjected to continuous inspection by owner or their authorised representative. However, such inspection shall not relieve the contractor of the responsibility of meeting the specifications. The job shall be subjected to inspection at the following stages:

i. After surface preparation and prior to application of lining. ii. After the application of reinforcement if any iii. After application and curing

Any lining not applied in accordance with this standard or as per required thickness shall be subjected to rejection and replaced / repaired at the expense of the contractor. The inspector shall have free access to all areas and facilities concerned, and contractor shall furnish all reasonable assistance. The inspection of lining in pipe up to 24” dia. shall be made from both ends of the lined pipe segment by using strong lights and / or mirrors. The inspection shall be done before the lining has attained its initial set. For pipes 24” & above, a manual, visual inspection of the lined pipe interior shall be made. Defects in cement-mortar lining include, but are not limited to, sand pockets, voids, over sanded areas, honey comb, excessively cracked, drummy areas, areas of lining thinner than specified, and areas of unsatisfactory surface finish. The surface of lining shall be smooth and free from irregularities; cracks up to 0.8 mm wide and not over 300 mm in length are acceptable. Trough to crest height shall not exceed 1.0 mm.

8.0 REPAIR OF LINING

For pipes up to 24” dia, the defective lining shall be removed in total from the pipe segment before the initial setting. The pipe segment shall then be relined in full compliance with the specifications.

For pipes above 24”, small defective areas shall be repaired by manual removal of the defective lining and by hand reapplication of mortar lining. Defective areas encompassing the full dia of the pipe shall be replaced by machine wherever practical.

9.0 PIPE JOINTING

Refer Drg. no :44LK-5100/L.02/8401/A4 (1 OF 6) - figure-01 for joints details (Attached.)

10.0 FITTINGS & FLANGES

All fittings up to 24” size shall be flanged ends. Flanges may be welded in field shop prior to lining. For details refer Drg. no :44LK-5100/L.02/8401/A4 ( 2 of 6) fig-02(attached). Flanges faces shall be free of cement lining.

11.0 BRANCH CONNECTION

a. Branches in cement-lined pipes shall be of minimum of 3” size. Stub in branch connections of size 3” onwards shall be flanged as per figure-03.




b. Branches connections of sizes less than 3” shall be with 3” flanged stub as per figure-03 instruments branches for temperature and pressure instruments shall e as per figure-04 & 05. The 3” blind flanges shall be drilled to suit inst. / vent / drain size. The blind flanges used for instruments connections shall be as per instrumental standards. Other blind flanges used shall be internally FRE lined (refer figure-06).

c. Vents and drains on cement-lined piping shall be by 3” flanged stub with blind flange, which is internally epoxy (FRE) lined. The blind flange shall be provided 3/4” tapped hole and 3/4” vent/drain with valve and blind. Refer figure –06 for details of vents and drains

12.0 HANDLING AND STORAGE: Care shall be exercised during loading, hauling, unloading and storage to prevent damage to

any of the parts of lined pipes/fittings. Pipes and specials shall be suitably braced, supported to provide suitable bearing area to prevent damage to the coating and tied to prevent shifting or distortion of the pipes during transportation. Plastic end caps shall be securely fastened to pipe ends of completed pipes for protection of the cement mortar lining. End caps shall be maintained in place until time of installation.

13.0 REFERENCE DOCUMENTS (attached) : Cement lined Drg.No. 44LK-5100/L.02/8401/A4 (fig 1 to 6)

OF 15

0 13.07.2010 15

MUMBAI REFINERY

HINDUSTAN PETROLEUM CORPORATION LIMITED

DHT PROJECT

(PIPING)

TITLE : JOB SPECIFICATION FOR WELDING CHARTS

Rev No. Issue Date Total Pages Checked By

DRP/PUP

Prepared By

(PIPING)

YSP

Approved By

PVS/RMP

Rev Description

Issued for OSBL Mechanical Tender

DOCUMENT NO : 44LK-5100-00/L.02/0103/A4

OF 15

TITLE :

CLIENT :

44LK-5100INDEX - WELDING SPECIFICATION CHART

DHT

HPCL DOC. NO. : 44LK-5100-00/L.02/0103/A4

SHEET REV. NO.

DATE

Low Alloy Steel

PROJECT NO. :

ABBREVIATION:

0

13/7/2010

WPS:

PQR: Procedure Qualification Record

Welding Procedure Specification

Gas Tungusten Arc Welding

SMAW:

GTAW:

Shielded Metal Arc Welding

Carbon Steel

Stainless Steel

CS:

LAS:

SS:

OF 15

DATE 13/7/2010

2.1 Revision 0

REFERENCE STANDARDS :1.2

Standard Specification for Fabrication on Piping, 44LK-5100/L.02/0104

ASME B 31.3

ASTM E 10

GTAW process can be applied in place & SMAW process with a corresponding suitable filler

metal for the application.

Piping Material Specification, 44LK-5100-00/L.02/0101/A4.

ASME Boiler & Pressure Vessel Codes Section V, VIII (Div-1), IX, II-C

Standard specification for Fabrication & erection piping, 44LK-5100/L.02/0105

1.1

HPCL DOC. NO. : 44LK-5100-00/L.02/0103/A4

1.0

SCOPE :

Job Specification for Non-Destructive Examination Requirements of Piping, 44LK-5100-

00/L.02/0102/A4.

a)

GENERAL NOTES

CLIENT :

This document covers the Welding Specification for the piping classes covered in Piping

Material Specification ( 44LK-5100-00/L.02/0101/A4 ). WPS & PQR for the field fabrication

& erection of piping system shall be made in conformity with this document

Contractor to develop welding charts, if required for any additional Piping Specifications.

Practice to be followed as per existing Welding Charts and updated welding charts shall be

submitted for review / comments.


HISTORY OF REVISION2.0

1.3

SHEET REV. NO. 0

INDEX - WELDING SPECIFICATION CHARTDHTTITLE :

44LK-5100PROJECT NO. :

Indian Boiler Regulation (IBR)

This document shall have to be read in conjunction with the latest revision of the following

documents :

b)

c)

d)

h)

g)

e)

f)

0

0

0

0

0

0

0

0

0

0

0

WELDING CHART FOR PIPING CLASSES

SHEET REV. NO. 0

SR.NO









DATE 13/7/2010

11 J1M

1

2

3

4

5

6

7


8

9

10

A11A

A14A, A16A, A35A,B16A

A19A

B2A, D2A

A22A

A5Y, J2A, J3A

A5A, B5A

A52A, B52A

A3K

CLIENT :

44LK-5100

HPCL

DHTINDEX - WELDING SPECIFICATION CHART

DOC. NO. : 44LK-5100-00/L.02/0103/A4

A1A, A9A, A10A, B1A

WELDING CHART INDEX


TITLE :

PROJECT NO. :

DESCRIPTION

RE

VIS

ION

SMAW: SHIELDED METAL ARC WELDING, GTAW: GAS TUNGSTEN ARC WELDING

4. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS WELDING FOR SMALL BORE PIPING OF DIAMETER 2" &

SMALLER.

2. E6013 MAY BE USED FOR ROOT PASS PROVIDED UNIFORM ROOT PENETRATION IS OBTAINABLE AND IS

DEMONSTRATED THROUGH PROCEDURE QUALIFICATION.

3. PRE-HEAT TEMPERATURE OF ATLEAST 50°C SHALL BE PROVIDED FOR THE FIRST TWO PASSES FOR

THK>=12.7MM & <25.4MM.

CODE OF FABRICATION ASME B 31.3

TECHNICAL NOTES1. HEAT TREATMENT SHALL BE DONE AS PER ASME B 31.3 FOR WALL THICKNESS EXCEEDING 19 MM.

AT TEMPERATURE -

HARDNESS -

MECHANICAL PROPERTY REQUIREMENTS CHARPY 'V' NOTCH IMPACT TEST VALUE

MINIMUM - AVERAGE -

-

METHOD OF COOLING RATE OF COOLING

- -

-

CONTINUITY OF WELDING AND PREHEAT -

POST WELD HEAT

TREATMENT

(NOTE 1)

HOLDING TEMPERATURE HOLDING TIME

- -

RATE OF HEATING MIN. HOLDING TIME

-

- SHIELDING

PREHEATING

(NOTE 3)

PREHEAT TEMP 10°C MIN /

100°C(FOR THK>=25.4 MM)POST HEATING

JOINT PREPARATION ASME B 31.3

ARGON

GAS COMPOSITION PURGING - SHIELDING 99.995%

GASES PURGING

BACKING RING CONSUMABLE INSERT

- -

E6010 / E6013

(NOTE-2)

E7016 / E7018

FILLET JOINTS / SOCKET JOINTS E7016 / E7018

WELDING

MATERIALS

GROOVE JOINT

BUTT OTHER THAN BUTT

ROOT PASS FILLER PASS ROOT PASS FILLER PASS

E6010 / E6013

(NOTE-2)

ER70 SG/

ER70S-2

(NOTE-4)

E7016 / E7018

SMAW SMAW

FILLET JOINTS / SOCKET JOINTS SMAW

WELDING

PROCESS

GROOVE JOINT



SMAW

GTAW

(NOTE-4)

SMAW

OTHERS -

BASE METAL 'P' NO 1

13/7/2010

PIPING CLASS A1A, A9A, A10A, B1A.

MATERIAL

SPECIFICATIONS

PIPES ASTM A 106 GR.B, A 672 GR B 60 CL 12, API 5L GR B PSL1.

FITTINGS ASTM A 105, ASTM A 234 GR WPB, ASTM A 234 GR WPBW.

FLANGES ASTM A 105, ASTM A 516 GR. 70.

REV NO. : 0 ISSUE DATE :

CLIENT : HPCL SPEC NO. : 44LK-5100-00/L.02/0103/A4

PROJECT NO. : 44LK-5100WELDING SPECIFICATION CHART

CLASS

RE

VIS

ION

TITLE : DHT

SEE BELOW


CLASS

RE

VIS

ION

TITLE : DHT

SEE BELOWCLIENT : HPCL SPEC NO. : 44LK-5100-00/L.02/0103/A4

REV NO. : 0 ISSUE DATE : 13/7/2010

PIPING CLASS A11A

MATERIAL

SPECIFICATIONS

PIPES ASTM A 106 GR.B, ASTM A 672 GR B 60 CL 12


FLANGES ASTM A 105, ASTM A 516 GR. 70.

OTHERS -

BASE METAL 'P' NO 1

WELDING

PROCESS

GROOVE JOINT



SMAW

GTAW

(NOTE-4)

SMAW SMAW SMAW


WELDING

MATERIALS

GROOVE JOINT



E6010 / E6013

(NOTE-2)

ER70 SG/

ER70S-2

(NOTE-4)

ER7016/

E7018

E6010 / E6013

(NOTE-2)

ER7016/

E7018

FILLET JOINTS / SOCKET JOINTS ER7016 / E7018


- -


ARGON


GASES PURGING - SHIELDING

PREHEATING

(NOTE-3)PREHEAT TEMP

10°C MIN /

100°C(FOR THK >=25.4 MM)POST HEATING -


POST WELD HEAT

TREATMENT

(NOTE-1)

HOLDING TEMPERATURE HOLDING TIME

- -

RATE OF HEATING MIN. HOLDING TIME

- -

METHOD OF COOLING RATE OF COOLING

- -


MINIMUM - AVERAGE -

AT TEMPERATURE -

HARDNESS 200 BHN MAX.


TECHNICAL NOTES1. HEAT TREATMENT SHALL BE DONE AS PER ASME B 31.3 FOR WALL THICKNESS EXCEEDING 19 MM.

2. E6013 MAY BE USED FOR ROOT PASS PROVIDED UNIFORM ROOT PENETRATION IS OBTAINABLE AND

IS DEMONSTRATED THROUGH PROCEDURE QUALIFICATION.

3. PRE-HEAT TEMPERATURE OF ATLEAST 500C SHALL BE PROVIDED FOR THE FIRST TWO PASSES FOR THK.>=12.7 MM

& <25.4 MM.


4. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS WELDING FOR SMALL BORE PIPING OF DIAMETER 2"

AND SMALLER.


CLASS

RE

VIS

ION

TITLE : DHT

SEE BELOWCLIENT : HPCL SPEC NO. : 44LK-5100-00/L.02/0103/A4

REV NO. : 0 ISSUE DATE : 13/7/2010

PIPING CLASS A14A, A16A, A35A, B16A.

MATERIAL

SPECIFICATIONS

PIPES ASTM A 106 GR.B, ASTM A 672 GR B 60 CL 12


FLANGES ASTM A 105

OTHERS -

BASE METAL 'P' NO 1

WELDING

PROCESS

GROOVE JOINT



GTAWGTAW/

SMAW

GTAW GTAW/

SMAW

FILLET JOINTS / SOCKET JOINTS GTAW / SMAW

ROOT PASS FILLER PASSER70S-2 ER70S-2/

E7018

ER70S-2 ER70S-2/

E7018

FILLET JOINTS / SOCKET JOINTS ER70S-2 / E7018


- -


WELDING

MATERIALS

GROOVE JOINT


ROOT PASS FILLER PASS

ARGON



PREHEATING

(NOTE-2)PREHEAT TEMP

10°C MIN /

100°C(FOR THK >=25.4 MM)POST HEATING -


POST WELD HEAT

TREATMENT

(NOTE-1)

HOLDING TEMPERATURE HOLDING TIME595-650°C 1 HR PER INCH THICKNESS

RATE OF HEATING MIN. HOLDING TIME200°C/HR MAX 1 HR

METHOD OF COOLING RATE OF COOLINGCONTROLLED 200°C/HR MAX


MINIMUM - AVERAGE -

AT TEMPERATURE -



TECHNICAL NOTES1. POST WELD HEAT TREATMENT SHALL BE DONE FOR ALL WALL THICKNESS

2. PRE-HEAT TEMPERATURE OF ATLEAST 500C SHALL BE PROVIDED FOR THE FIRST TWO PASSES FOR THK.>=12.7 MM

& <25.4 MM.


TITLE :

HPCL

WELDING MATERIALS

BASE METAL 'P' NO 1

MATERIAL SPECIFICATIONS

PIPES

ASTM A105, ASTM A 516 GR. 70

-

FILLET JOINTS / SOCKET JOINTS

BUTT


BUTT


MIN. HOLDING TIME

SMAW

BACKING RING

ROOT PASS FILLER PASS ROOT PASS

GROOVE JOINT

E7016 / E7018

E7016 / E7018

1 HOUR

ASME B 31.3

FILLER PASS

CONSUMABLE INSERT

ER 70-S2 E7016 / E7018

-

1 HR PER INCH THK

RATE OF HEATING

ER 70-S2

RATE OF COOLING


HOLDING TIME

MINIMUM -

POST WELD HEAT

TREATMENT

(NOTE 1)

595°C-650°C

HOLDING TEMPERATURE

200°C/HR MAX.

METHOD OF COOLINGCONTROLLED

TECHNICAL NOTES1. POST WELD HEAT TREATMENT SHALL BE DONE FOR ALL WALL THICKNESSES.



RE

VIS

ION

CLASSWELDING SPECIFICATION CHART

44LK-5100

SPEC NO. : 44LK-5100-00/L.02/0103/A4

DHT

PROJECT NO. :

SEE BELOW

13/7/2010

200°C/HR MAX.

GROOVE JOINT

JOINT PREPARATION

99.995%

-

GASES

PREHEAT TEMP

PURGING -

SHIELDING

A19APIPING CLASS

ASTM A 106 GR.B, ASTM A 672 GR.B60 CL.22


OTHERS

WELDING PROCESSSMAWGTAWSMAW

ASTM A 105, ASTM A234 GR.WPB, ASTM A234 GR.WPB-W FITTINGS

FLANGES

GAS COMPOSITION

ARGONPURGING -

OTHER THAN BUTT

GTAW

OTHER THAN BUTT

PREHEATING

(NOTE 2)

10°C MIN /

100°C(FOR THK >= 25.4 MM)POST HEATING

SHIELDING


AVERAGE -

AT TEMPERATURE

HARDNESS

-


THK.>=12.7 MM & <25.4 MM.

CLIENT :

0 ISSUE DATE :REV NO. :


ISSUE DATE :

ASTM A 105, ASTM A234 GR WPB, ASTM A234 GR WPBW.

99.995%

GASES

GAS COMPOSITION

TITLE : DHT

HPCL

GROOVE JOINT

B2A,D2APIPING CLASS

ASTM A106 GR. B, ASTM A 672 GR. B60 CL. 12.

MATERIAL

SPECIFICATIONS

CLIENT :

JOINT PREPARATION

FITTINGSASTM A 105.

-

1

FLANGES

OTHERS

FILLER PASSROOT PASS FILLER PASS

OTHER THAN BUTT

PIPES


ROOT PASS

PROJECT NO. :


RE

VIS

ION


44LK-5100

SPEC NO. : 44LK-5100-00/L.02/0103/A4

0REV NO. :

SMALLER.

SEE BELOW

13/7/2010

SMAWSMAW

GTAW

(NOTE-4)

-

ASME B 31.3 & IBR

SMAW

FILLER PASS


4. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS WELDING FOR SMALL BORE PIPING OF DIAMETER 2" AND


THK.>=12.7 MM & < 25.4 MM.



AT TEMPERATURE

MINIMUM -

TECHNICAL NOTES1. HEAT TREATMENT SHALL BE DONE AS PER IBR FOR WALL THICKNESS EXCEEDING 19 MM.

-

CODE OF FABRICATION ASME B 31.3 & IBR

HARDNESS

200°C/HR MAX.

1 HR PER INCH THK

HOLDING TIME

200°C/HR MAX

RATE OF COOLING

-

AVERAGE -

HOLDING TEMPERATURE600+20°C

BASE METAL 'P' NO

GROOVE JOINT

E7016 / E7018

BUTT

WELDING

PROCESS


SMAWSMAW

PURGING

E7016 / E7018 E6010 / E6013

(NOTE-2)

- SHIELDING

-PURGING SHIELDING

CONSUMABLE INSERT

ARGON

E7016 / E7018

E6010 / E6013

(NOTE-2)

ER70 SG/

ER70S-2

(NOTE-4)

1 HOUR

-


PREHEATING

(NOTE- 3)PREHEAT TEMP�

POST WELD HEAT

TREATMENT

(NOTE- 1)

CONTROLLED

RATE OF HEATING

METHOD OF COOLING

10°C MIN /

100°C(FOR THK >=25.4 MM)POST HEATING

MIN. HOLDING TIME

WELDING

MATERIALS

-


BACKING RING

RE

VIS

ION

13/7/2010

CLASS

SEE BELOW

TITLE : DHT

ISSUE DATE :


REV NO. : 0

PIPING CLASS A22A


PIPES ASTM A 106 GR.B, ASTM A 672 GR.B60 CL.12

FITTINGS ASTM A 105, ASTM A234 GR.WPB, ASTM A234 GR.WPBW

FLANGES ASTM A105, ASTM A 516 GR. 70.

OTHERS

BASE METAL 'P' NO 1

WELDING PROCESS

GROOVE JOINT



FILLER PASS

FILLER PASS

SMAW /

GTAW (NOTE-4,5)SMAW

SMAW /

GTAW (NOTE-5)

SMAW


ROOT PASS


E6010 / E6013

(NOTE-2)

ER70SG / ER 70S-2

(NOTE-4,5)

E7016 / E7018

E6010 / E6013

(NOTE-2)

ER70SG / ER 70S-2

(NOTE- 5)

E7016 / E7018

FILLET JOINTS / SOCKET JOINTS E7016/ E7018

- -

JOINT PREPARATION ASME B 31.3 & IBR

WELDING MATERIALS

GROOVE JOINT



ARGON



PREHEATING

(NOTE- 3)PREHEAT TEMP

10°C MIN /

100°C(FOR THK >= 25.4 MM)POST HEATING -


POST WELD HEAT

TREATMENT

(NOTE 1)

HOLDING TEMPERATURE HOLDING TIME600+/-20 °C 1 HR PER INCH THK

RATE OF HEATING MIN. HOLDING TIME200°C/HR MAX. 1 HOUR

METHOD OF COOLING RATE OF COOLINGCONTROLLED 200°C/HR MAX.


MINIMUM - AVERAGE -

AT TEMPERATURE -

HARDNESS -

CODE OF FABRICATION ASME B 31.3 & IBR

TECHNICAL NOTES1. HEAT TREATMENT SHALL BE DONE AS PER IBR FOR WALL THICKNESSES EXCEEDING 19 MM.




THK>=12.7MM & <25.4MM.

4. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS WELDING FOR SMALL BORE PIPING OF DIAMETER 2" &

SMALLER.

5. GTAW SHALL BE EMPLOYED FOR THE ROOT PASS FOR ALL THE SIZES FOR PIPING CLASSES WITH 100%

RADIOGRAPHY.


CLIENT : HPCL SPEC NO. : 44LK-5100-00/L.02/0103/A4

MIN. HOLDING TIME

PURGING

PURGING - -

-

WELDING MATERIALS

BASE METAL 'P' NO


PIPES

OTHERS

ROOT PASS

BUTT

-

1

-

SMAWSMAW

PROJECT NO. :

-

RATE OF HEATING

-

-

AT TEMPERATURE

HARDNESS


CODE OF FABRICATION

TECHNICAL NOTES

POST WELD HEAT

TREATMENT

FILLER PASS

OTHER THAN BUTT

RE

VIS

ION

GASES

GAS COMPOSITION - SHIELDING

SHIELDING

BACKING RING

JOINT PREPARATION

GROOVE JOINT

CONSUMABLE INSERT

FILLER PASSROOT PASS ROOT PASS

-

RATE OF COOLING

-

HOLDING TIMEHOLDING TEMPERATURE

-

-

ASME B 31.3

AVERAGE -

METHOD OF COOLING

-

MINIMUM -


44LK-5100

SPEC NO. : 44LK-5100-00/L.02/0103/A4

DHT

13/7/2010

-PREHEAT TEMP

FILLER PASSROOT PASSFILLER PASSSMAWSMAW

FITTINGS

TITLE :


ASME B 31.3


PREHEATING 10°C MIN POST HEATING

WELDING PROCESS

ASTM A 106 GR.B, IS 1239, IS 3589 GR.330.

ASTM A 105 , ASTM A234 GR.WPB, ASTM A234 GR.WPB-W,

FLANGES

IS 1239 PART-II, IS 3589 GR.330

ASTM A105, ASTM A 285 GR.C

ISSUE DATE :

E6010 / E6013 E6013 / E7016 / E7018 E6010 / E6013 E6013 / E7016 / E7018

GROOVE JOINT

J2A, J3A, A5YPIPING CLASS

CLIENT :



HPCLSEE BELOW

FILLET JOINTS / SOCKET JOINTS E6013 / E7016 / E7018

REV NO. : 0

SMAW




GROOVE JOINT

A5A, B5APIPING CLASS


ASTM A 105, ASTM A234 GR.WPB, ASTM A234 GR.WPB-W


AVERAGE -

GAS COMPOSITION

PREHEATING10°C MIN /


SHIELDING


HOLDING TIME

-

FITTINGS

FLANGES

OTHERS

-

GTAW / SMAWGTAWGTAW / SMAWGTAW

WELDING PROCESS



ASME B 31.3

PURGING

JOINT PREPARATION

99.995%

-

GASES

PREHEAT TEMP

PURGING -

SHIELDING ARGON

RE

VIS

ION


44LK-5100

SPEC NO. : 44LK-5100-00/L.02/0103/A4

DHT

PROJECT NO. :

SEE BELOW

13/7/2010


200 BHN MAX.

-

MIN. HOLDING TIME

-

RATE OF COOLING

-

METHOD OF COOLING

TECHNICAL NOTES

-

MINIMUM -


AT TEMPERATURE

HARDNESS

FILLER PASS ROOT PASS FILLER PASS

2. REFER JOB SPECIFICATION FOR SPECIAL REQUIREMENT OF HYDROGEN SERVICE.

POST WELD HEAT

TREATMENT

(NOTE 1)

-

HOLDING TEMPERATURE

RATE OF HEATING

-

BACKING RING

1. HEAT TREATMENT SHALL BE DONE AS PER ASME 31.3 FOR WALL THICKNESSES 3/8 INCH AND ABOVE.

-

ASTM A105

CONSUMABLE INSERT

ER 70S-2 ER 70S-2 / E7018 ER 70S-2 ER 70S-2 / E7018

E7018

GROOVE JOINT


ROOT PASS

TITLE :

HPCLCLIENT :

WELDING MATERIALS

BASE METAL 'P' NO 1


PIPES

-


GROOVE JOINT

A52A, B52APIPING CLASS


ASTM A 105, ASTM A234 GR.WPB, ASTM A234 GR.WPBWFITTINGS


HOLDING TIME

-


GAS COMPOSITION

PREHEATING10°C MIN /


SHIELDING

FLANGES

OTHERS

ASTM A105

WELDING PROCESS

-



ASME B 31.3

PURGING


-

HOLDING TEMPERATURE

RATE OF HEATING

-


JOINT PREPARATION

99.995%

-

GASES

PREHEAT TEMP

PURGING -

SHIELDING ARGON-

RE

VIS

ION


44LK-5100

SPEC NO. : 44LK-5100-00/L.02/0103/A4

DHT

PROJECT NO. :

SEE BELOW

13/7/2010


MIN. HOLDING TIME

-

RATE OF COOLING

--

MINIMUM -


AT TEMPERATURE

AVERAGE -

GTAW / SMAWGTAWGTAW / SMAWGTAW


ER 70S-2

1. HEAT TREATMENT SHALL BE DONE AS PER ASME 31.3 FOR ALL WALL THICKNESSES.

2. REFER JOB SPECIFICATION FOR SPECIAL REQUIREMENT OF HYDROGEN SERVICE.

POST WELD HEAT

TREATMENT

(NOTE 1)

E7018FILLET JOINTS / SOCKET JOINTS

METHOD OF COOLING

TECHNICAL NOTES

-


ER 70S-2 / E7018

GROOVE JOINT


ER 70S-2 ER 70S-2 / E7018

TITLE :

HPCLCLIENT :

WELDING MATERIALS

BASE METAL 'P' NO 1


PIPES

-

CLIENT :


44LK-5100-00/L.02/0103/A4

ER 308L

E 308-15/16 /

ER 308L

E 308-15/16

ER 308L ER 308L

METHOD OF COOLING

-

-

-HARDNESS

TECHNICAL NOTES



E 308-15/16 /

MINIMUM -


ASME B 31.3

PREHEAT TEMP

JOINT PREPARATION

GASES

RE

VIS

ION


44LK-5100

SPEC NO. :


PURGING


SHIELDING 99.995%

-

ARGON

PURGING

ARGON SHIELDING

AVERAGE -

PREHEATING


AT TEMPERATURE

-

-

10°C POST HEATING


SEE BELOW

13/7/2010

PROJECT NO. :

99.995%GAS COMPOSITION

POST WELD HEAT

TREATMENT

-

HOLDING TEMPERATURE

RATE OF HEATING

-

RATE OF COOLING

CONSUMABLE INSERT

MIN. HOLDING TIME

E 308-15/16 / E 308L-15/16

FILLER PASS

E 308L-15/16 E 308L-15/16

HOLDING TIME

-

ER 308/


GTAW / SMAWGTAW / SMAWGTAW

OTHER THAN BUTT

GROOVE JOINT

BUTT

GTAW / SMAW

WELDING

MATERIALS

BASE METAL 'P' NO 8

A3KPIPING CLASS

ASTM A 312 TP.304, ASTM A 358 TP.304 CL.1

ASTM A 182 GR F304, A 403 GR WP 304-S, A 403 GR WP304-WXFITTINGSMATERIAL

SPECIFICATIONS

PIPES

ASTM A 182 GR F304

-

FLANGES

OTHERS

FILLER PASS

- -

BACKING RING

E 308L-15/16

ER 308/ ER 308/ ER 308/

TITLE : DHT

HPCL

WELDING

PROCESS

GROOVE JOINT


ROOT PASS

TITLE : DHT

HPCL

WELDING PROCESS

CLIENT :


GTAW / SMAWGTAW

GROOVE JOINT

- -

ASTM A 182 GR F316.

-

FLANGES

OTHERS


ER316L

WELDING MATERIALS

BASE METAL 'P' NO 8

J1MPIPING CLASS

ASTM A 312 TP 316.

ASTM A 182 GR. F316, ASTM A 403 GR WP316-S.FITTINGSMATERIAL SPECIFICATIONS

PIPES


ER316L

ER316 / ER316/ ER316 / ER 316 /

ER316L ER316L

POST WELD HEAT

TREATMENT

-

HOLDING TEMPERATURE

RATE OF HEATING

-

METHOD OF COOLING-


TECHNICAL NOTES

GAS COMPOSITION

MIN. HOLDING TIME

-

RATE OF COOLING-

HOLDING TIME

-


SEE BELOW

13/7/2010

PROJECT NO. :

99.995%

FILLET JOINTS / SOCKET JOINTS E 316-15/16 / E 316L-15/16

10°C POST HEATINGSHIELDING 99.995%

-

RE

VIS

ION


44LK-5100

SPEC NO. : 44LK-5100-00/L.02/0103/A4


PREHEATING

ASME B 31.3

PREHEAT TEMPPURGING

PURGING ARGON SHIELDING ARGON

JOINT PREPARATION

GASES



AT TEMPERATURE

HARDNESS

MINIMUM - AVERAGE -



-

-

E316-15/16

E316L-15/16

SMAW

GTAW / SMAWGTAW / SMAW

OTHER THAN BUTT

GROOVE JOINT

BUTT


E316-15/16 /

E316L-15/16

E316-15/16 /

E316L-15/16

OF 12

0 13.07.2010 12

DOCUMENT NO : 44LK-5100-00/L.02/0102/A4

Rev Description


Prepared By

(PIPING)

YSP

Approved By

PVS/RMP

Checked By

DRP/PUP

(PIPING)

TITLE : JOBS SPECIFICATION FOR NON DESTRUCTIVE EXAMINATION

REQUIREMENT OF PIPING

Rev No. Issue Date Total Pages

DHT PROJECT

MUMBAI REFINERY

HINDUSTAN PETROLEUM CORPORATION LIMITED

OF 12

: Stainless Steel

: Indian Boiler Regulations

: Piping Material Specification

SHEET REV. NO.

AS

PMS

ASME

DP / LP : Dye / Liquid Penetrants

MP : Magnetic Particle

SS

ASTM

IBR

: American Society of Testing & Materials

: American Society of Mechanical Engineers

: Carbon Steel

: Alloy Steel

Dept. / Sect.

Doc. No.

:

: 44LK-5100-00/L.02/0102/A4

Client

Project

Location

: HINDUSTAN PETROLEUM CORPORATION LTD

: 44LK-5100

13/7/2010

: DHT, MUMBAI

ABBREVIATIONS:

CS

DATE

0

OF 12

Dept. / Sect.

Doc. No.

:

: 44LK-5100-00/L.02/0102/A4

Client

Project

Location


: 44LK-5100

: DHT, MUMBAI

PAGE NOS.

04 OF 121.0 GENERAL

TITLESR. NO.

3.0 NON DESTRUCTIVE EXAMINATION

2.0 VISUAL EXAMINATION

4.0 TABLE – 1

SHEET REV. NO. 0

DATE 13/7/2010

04 OF 12

05 OF 12

06 - 9 OF 12

(APPICABLE NOTES TO TABLE - 1) 10 - 12 OF 12

OF 12

Dept. / Sect.

Doc. No.

:

: 44LK-5100-00/L.02/0102/A4

Client

Project

Location


: 44LK-5100

: DHT, MUMBAI

General requirements for the non-destructive examination of shop & field fabricated piping are covered under

1.1 SCOPE

1.0 GENERAL

this specification.

1.2 RELATED CODES & ENGINEERING STANDARDS

Referred codes/ standards are as follows. Latest Editions of the codes / standards referred shall be followed.

A. ASME Boiler & Pressure Vessel Codes, Section V & VIII (Div.1) including addenda.

B. ASME B 31.3

C. ASME B16.5

D. ASME B16.34

E. Piping Material Specification, 44LK-5100-00/L.02/0101/A4

F. Welding Specification Charts for Piping Classes, 44LK-5100-00/L.02/0103/A4

G. Standard Specification for Fabrication & Erection Piping, 44LK-5100/L.02/0105

H. ASTM E10

2.0 VISUAL EXAMINATION

I. Standard Specification for Fabrication on Piping, 44LK-5100/L.02/0104

2.1 Weld shall be visually inspected wherever accessible in accordance with the following requirements:

A. Internal misalignment 1.5 mm or less

B. Cracks or lack of fusion Not permitted

C. Incomplete penetration (for other than 100% Depth shall not exceed the lesser of 0.8 mm or 0.2

radiography butt-weld) times thickness of thinner component joined by

butt-weld. The total length of such imperfections

shall not exceed 38 mm in any 150 mm of weld length.

D. Surface porosity and exposed slag inclusions Not permitted

(For nominal wall thickness 4.7 mm and less).

E. Concave root surface (suck up) For single sided welded joints, concavity of the root

surface shall not reduce the total thickness of joint,

including reinforcement, to less than the thickness

of the thinner of the components being joined.

F. Weld Ripples irregularities 2.5 mm or less

G. Lack of uniformity in bead width 2.5 mm or less

H. Lack of uniformity of leg length 2.5 mm or less

I. Unevenness of bead 2.0 mm or less

J. Weld undercutting 0.8 mm or ¼ thickness of thinner components joined by

butt weld, whichever is less (shall be smooth finished).

DATE 13/7/2010

SHEET REV. NO. 0

OF 12

Dept. / Sect.

Doc. No.

:

: 44LK-5100-00/L.02/0102/A4

Client

Project

Location


: 44LK-5100

: DHT, MUMBAI

weld reinforcement or internal weld protrusion from the adjacent base material surface shall not exceed the

following limits:

2.5 mm or less

K. Overlap 1.5 mm or less

by butt weld (mm)

6.4 and under

Over 25.4

L. Bead deflection

(mm) max.

with and shall merge smoothly into the component surfaces. The height of the lesser projection of external

Wall thickness of thinner component joined Weld reinforcement or internal weld protrusion

M. External weld reinforcement and internal weld protrusion (when backing rings are not used) shall be fused

1.6

Over 6.4 – 12.7 3.2

Over 12.7 – 25.4 4.0

Reduction of wall thicknessP.

4.8

0.7 or more.

between the nominal outside diameter and minimum

or maximum diameter at any cross section shall not

Nominal thickness of the thinner component XThroat thickness of fillet welds:N.

wall thickness of pipe

Reduction of wall thickness of a bend, as measured

by difference between the nominal thickness and

minimum thickness shall not exceed 10% of the nominal

DATE 13/7/2010

2.2 Welds having any of imperfections which exceed the limitations specified in various clauses of 2.1 shall be repaired by

welding, grinding or overlaying etc. number of times of repair welding for the same weld, however shall conform to

3.0 NON DESTRUCTIVE EXAMINATION

3.1 The type and extent of weld examination shall be in accordance with Table - I. All visual and supplementary methods of

girth weld examination shall be in accordance with ASME B31.3 and the requirements of this standard specification.

3.2 Welds between dissimilar materials shall be examined by method and to the extent required for the material having

the more stringent examination.

Certain categories of critical piping are classified under inspection class IV (100 % radiography) as follows:3.3

: As defined by ASME B 31.3

: Classes 900# and above.

: Below temperature of -45°C.

& such other critical services.

High PressureA.

B. Severe cyclic

D. Critical service

C. Low temperature

F. High Temperature : Above 500°C

: Hydrogen, Oxygen, NACE, Caustic, Chlorine

: 5% Cr. & above for all pressure classes.E. High alloys

SHEET REV. NO. 0

applicable notes to table 1 - 6.0(B.)B.5.

O. Flattening

exceed 5% of the nominal outside diameter of pipe.

Flattening of a bend, as measured by difference

OF 12

4.

A.

B.

1.

---HDPE

CUPRO NICKEL

LP TEST NOT APPICABLE TO NON - METALLIC CLASSES.

13/7/2010

0

VISUAL

LP

(NOTE 4, 6, 9)

TABLE - I (WITH APPICABLE NOTES)

150# UPTO

10.55 KG/CM2

---34 -29 TO 60

A3K, J1M

8

---

5

0 TO 186

-29 TO 186

-20 TO 50

43

CARBON STEEL

AUSTENIC SS

1

8

21

CATEGORY "D"

FLUID SERVICE

I

PRESS. CLASS

B16.5 / B16.34

9 10 116 7 13

APPICABLE

PIPING CLASS

TYPE OF

EXAMINATION

12

J2A, J3A

TYPE OF WELD EXAMINED

---

100% 100%

---

100%

--- 10%

100%

10%

100%

: HINDUSTAN PETROLEUM CORPORATION LTD Dept. / Sect. : Client

: 44LK-5100 Doc. No. : 44LK-5100-00/L.02/0102/A4Project

: DHT, MUMBAILocation

SHEET REV. NO.

FABRICATED

BRANCH WELD

(NOTE - 1)

FABRICATED

WELDS OF

MITRES / REDUC.

TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION

INSPECTION CLASS : I

TEMP. (°°°°C.)P. NO. MATERIAL

(NOTE 3)

DATE

GIRTH BUTT

WELD

SOCKET WELD

(NOTE - 2)

ATTACHMENT

WELD

REMARKS FOR ABOVE TABLE :-

INSPN.

CLASS

SERVICE

OF 12

A.

B.

C.

D.

1.

2.

3.

4.

: HINDUSTAN PETROLEUM CORPORATION LTD Dept. / Sect.

: 44LK-5100 Doc. No.

Client

Project

:

: 44LK-5100-00/L.02/0102/A4

10%---

DATE

NOTE 7


SHEET REV. NO.

FABRICATED

BRANCH WELD

(NOTE - 1)

10%

---

TABLE 1: CLASS, TYPE & EXTENT OF WELD EXAMINATION (CONTI..)

INSPECTION CLASS : II


(NOTE 3)

GIRTH BUTT

WELD

SOCKET WELD

(NOTE - 2)

ATTACHMENT

WELD

INSPN.

CLASS

SERVICE TYPE OF WELD EXAMINED

50%

100%

50%

Location : DHT, MUMBAI

PRESS. CLASS

B16.5 / B16.34

100%

CARBON STEEL

(IBR)

100%

---10%

100%

7 13

APPICABLE

PIPING CLASS

TYPE OF

EXAMINATION

12

A1A, A9A, A10A, A11A,

FABRICATED

WELDS OF

MITRES / REDUC.

21 5 8 9 10 11643

1CARBON STEEL -29 TO 400

A22A

150# VISUALA5Y

A. ALL SERVICES COVERED

UNDER INSPECTION

CLASS - I BUT EXCEEDING

CATEGORY 'D' PR. / T

LIMITATIONS.

B. ALL SERVICES OTHER

THAN THOSE COVERED

UNDER INSPECTION

CLASS - I BUT NON -

TOXIC NOT SUBJECTED

TO SEVERE CYCLIC

CONDITIONS.

II100%

FOR A22A IBR SERVICE NOTE 8 IS ALSO APPLICABLE.

HARDNESS NOTE 7 NOTE 7 NOTE 7

RADIOGRAPHY ---

---

(NOTE 5, 6)

MP* / LP

(NOTE 4, 6,

EXTENT OF HARDNESS TEST FOR A11A IS 100%.

FOR A5Y FIRE WATER SERVICE NOTE 12 IS ALSO APPLICABLE.

* - FILLET WELDS SHALL BE MP TESTED ONLY.

0

13/7/2010

10, 11)

NOTE 7

OF 12

A.

B.

C.

D.

1.

2.

: HINDUSTAN PETROLEUM CORPORATION LTD Dept. / Sect.

: 44LK-5100 Doc. No.

:

: 44LK-5100-00/L.02/0102/A4

1CARBON STEEL

CARBON STEEL

(IBR)

B1A

0

13/7/2010

FOR IBR SERVICE B2A AND D2A NOTE 8 IS ALSO APPLICABLE

* - FILLET WELDS SHALL BE MP TESTED ONLY.

SHEET REV. NO.

(NOTE 5, 6)

NOTE 7

RADIOGRAPHY

HARDNESS

VISUAL

B2A, D2A

---

MP* / LP

(NOTE 4, 6, 11)

NOTE 7

5

ABOVE -29

-45 TO 200

-29 TO 425

43

CARBON STEEL

KILLED CARBON

STEEL

1

21

III A. TOXIC , NON-LETHAL

& FLAMMABLE

B. FLAMMABLE/ NON

FLAMMABLE & TOXIC /

NON-TOXIC, NOT

SUBJECT TO SEVERE

CYCLIC CONDITION

ALL GENERAL SERVICES

EXCEPT THOSE

SUBJECTED TO SEVERE

CYCLIC CONDITION

PRESS. CLASS

B16.5 / B16.34

9 10 116 7 8 13

APPICABLE

PIPING CLASS

TYPE OF

EXAMINATION

12

---100%

---

20%

100%

---

20%

100%

---

NOTE 7

---

NOTE 7

---

20%

100%

INSPN.

CLASS


---

100%

Client

Project


FABRICATED

BRANCH WELD

(NOTE - 1)

FABRICATED

WELDS OF

MITRES / REDUC.


INSPECTION CLASS : III


(NOTE 3)

100%

DATE

GIRTH BUTT

WELD

SOCKET WELD

(NOTE - 2)

ATTACHMEN

T WELD


150#

150# TO 600#

300# TO 600#

NOTE 7

OF 12

A.

B.

C.

D.

1.

2

100% 100%

NOTE 7 NOTE 7

CARBON STEEL

& 0.5 TO 9 Cr.

Mo. STEEL

1, 3,

4, 5

SPECIAL SERVICES (NACE, O,

H, CAUSTIC)

---

11,13)

Ni. ALLOYS

LP / MP*


H, CAUSTIC)

3.5 Ni. STEEL 9

SERVICES SUBJECT TO

SEVERE CYCLIC CONDITIONS


H, AMINE, CAUSTIC), VACUUM

SERVICES SUBJECT TO


SERVICES SUBJECT TO


ALL SERVICES

612 Cr. STEEL

(TYPE 410 SS)

41,

42,

43

45

(NOTE 5, 6)

EXTENT OF HARDNESS TEST FOR CLASSES A5A, A52A, B5A, B52A IS 10% AND

FOR CLASSES A16A, A19A, A35A, B16A IT IS 100%.

* - FILLET WELDS IN CS/AS CLASSES SHALL BE MP TESTED ONLY.

---

0

13/7/2010

---

---

--- HARDNESS

(NOTE 4, 6, 10,

A5A, A16A, A19A, A35A, A52A,

8

VISUAL---

B5A, B16A, B52A,

---

5

ALL

PRESS. CLASS

B16.5 / B16.34

9 10 116 7 13

APPICABLE

PIPING CLASS

TYPE OF

EXAMINATION

12

100%

100%

---

100%

RADIOGRAPHY

NOTE 7

100%

--- ---

---

NOTE 7


100%

100%

100%

Client : HINDUSTAN PETROLEUM CORPORATION LTD Dept. / Sect. :

Project : 44LK-5100 Doc. No. : 44LK-5100-00/L.02/0102/A4


SHEET REV. NO.

FABRICATED

BRANCH WELD

(NOTE - 1)

FABRICATED

WELDS OF

MITRES / REDUC.


INSPECTION CLASS : IV (CONTI..)


(NOTE 3)

DATE

GIRTH BUTT

WELD

SOCKET WELD

(NOTE - 2)

ATTACHMENT

WELD


ALL

INSPN.

CLASS

1 2 43

IV

(CONTI.)

NOTE 7

10%

OF 12

Two additional examinations of same type shall be made of the same kind of item (if welded joint, then by the

13/7/2010

SHEET REV. NO. 0

DATE

B. If required random examination reveals a defect requiring repair, then

B.1.

same welding procedure or operator or both).

A.

Dept. / Sect.

Doc. No.

:

: 44LK-5100-00/L.02/0102/A4

: DHT, MUMBAI

Client

REPAIRS OR DEFECTS/ ACCEPTANCE CRITERIA6.0

Wherever radiography or other non destructive inspection is specified, the acceptance criteria for repair or defects shall

In case of 100% examination, any unacceptable weld shall be repaired and re-inspected.

be as follows:

In process examination shall not be substituted for any required radiographic examination.B.

Number of radiograph per one circumferential weld shall be as per ASME Sec.V Article 2 and 22.C.

to examine the entire weld length of field welds for either random or 100% radiography, and if the same impossibility is

agreeable to site-in charge, then a single 120 deg. exposure of the weld length may be given a Magnetic Particle test or Liquid

Penetrant test. However in such cases for ferro-magnetic materials, only MP test shall be acceptable for classes higher

than 600#.

two welds made by each welder shall also be radiographed in case of “Random Radiography”. Welds selected for examination

shall not include flange welds and shall be radiographed for their entire length. However, where it is impossible or impracticable

Project

Location

: 44LK-5100

A. “Random 10% or 20% radiography” shall mean examining not less than one from each 10 welds or less in case of “Random

5.0 RADIOGRAPHY


E. Girth weld, branch weld, attachment weld & socket weld of 3-1/2% Ni steel shall be Liquid Penetrant tested only when

Wherever MP / LP testing is specified, either MP or LP test may be used. But wherever only MP test is specified,

LP method of examination may be used only if MP examination is impracticable in the field as concurred by

2.0

3.0

procedure or welder or both. Irrespective of percentage, no. of welds to be radiographed shall be minimum 1. However first

welded with austenitic material, where MP test has been specified.

4.0 Magnetic Particle & the Liquid Penetrant method of examination shall be in accordance with Section V of the ASME

B. “Random 10%” of Liquid Penetrant / Magnetic Particle test shall mean testing, by applicable test, one weld for each

A.

Unless specifically stated, all materials shall be for “Non IBR” service.

Seal welds of threaded joints shall be given the same examination as socket welds.

Branch welds shall consist of the welds between the pipe & reinforcing element (if any), nozzles & reinforcing element

and the pipe & nozzle under the reinforcing element. Reinforcing element to be interpreted as Pads, saddles, Weldolets,

1.0

sockolets etc.

ten welds or less made by the same welding procedure or operator or both. Similarly “random 20 %” shall mean

testing, by applicable test, one weld for each five welds or less made by the same welding procedure or operator or both.

When Liquid Penetrant examination is specified, the surface shall be free of peened discontinuities. Abrasive blast C.

cleaning shall be followed by light surface grinding prior to Liquid Penetrant examination.

Inspection shall be performed in the welds excluding those for which radiography has been done.D.

10% Radiography” or one from each five welds or less in case of “Random 20% Radiography” made by the same welding

APPLICABLE NOTE TO TABLE - 1

Boiler and Pressure Vessel Code, Article VII and VI respectively. The entire area of the accessible finished weld surface

shall be examined. Selected root runs, subject to a maximum of 10%, before finished weld, may also be examined, at

site-in charge.

the discretion of the engineer-in-charge.

OF 12

Dept. / Sect.

Doc. No.

:

: 44LK-5100-00/L.02/0102/A4

: DHT, MUMBAI

Client

Project

Location

: 44LK-5100


i.

ii.

7.0

treatment.

D. A minimum of 10% of welds of hot formed and hot bent material in each heat treatment batch which are furnace

heat treated and 100% of those which are locally heat treated, shall be hardness tested.

All weld which are given heat treatment shall be hardness tested. Hardness test shall be performed after heat

A.

G.

Hardness test shall be in accordance with ASTM specification E10. Hardness tests of the heat affected zone

shall be made at the point as near as practicable to the edge of the weld. One test per weld shall be performed.

The hardness limit applies to the weld and heat affected zone. Following hardness values shall be maintained:

of thickness and to the extent (% age) as mentioned therin.

C.

F.

Repaired or replaced and re-examined as required.

Fully examined and repaired or replaced as necessary, and re-examined as necessary.

HARDNESS TEST

2 OR LESS

Welds not found acceptable for allowed number of times of repair as per B.5. above shall be replaced and re-examined.

these examinations shall be either:

B.6.

If any of the items examined (as required by B.4.) above reveals a defect requiring repair, all items represented by B.7.

OTHERS

Al & Al BASE ALLOY 2 OR LESS

Cu & Cu BASE ALLOY 2 OR LESS

AUSTENITIC S.S. 2 OR LESS

3.5 Ni STEEL 2 OR LESS

KILLED STEEL 2 OR LESS

LOW ALLOY STEEL 2 OR LESS

C.S. UPTO 300 # 3 OR LESS

C.S. ABOVE 300 # 2 OR LESS

Number of times repair welding could be done for the same weld before acceptance shall be as follows:B.5.

MATERIAL NO. OF TIMES REPAIR WELDING IS ALLOWED

items shall be examined for each defective item found by examination.

B.4. If all the items examined as required by B.3. are acceptable, the items requiring repair shall be repaired or replaced

and re-examined as required, and all items represented by this further examination shall be accepted.

B.3. If any of the items examined as required by B.1. above reveals a defect requiring repair, two further comparable

B.2. If the group of items examined as required by B.1. above is acceptable, the items requiring repair shall be repaired

or replaced and re-examined as required and all items represented by this additional examination shall be accepted.

Hardness test requirement not covered in B. & E. above shall be as per ASME B31.3.

BASE METAL GROUP

13/7/2010

Hardness test where specifically called out in Table - 1 of this specification or in PMS, shall be carried out irrespectiveB.

E. For C - 0.5 Mo. Steels, a minimum of 10% of welds shall be hardness tested.

SHEET REV. NO. 0

DATE

MAXIMUM BRINELL HARDNESS (BHN/RC)

CS 238BHN / RC22

CS (NACE) 200BHN

Cr 0.5% OR LESS 225BHN

Cr > 0.5% & UPTO 2% 225BHN

Cr.2.25% - 10% 241BHN

18/8 SS (NACE) RC22

OF 12

Dept. / Sect.

Doc. No.

:

: 44LK-5100-00/L.02/0102/A4

: DHT, MUMBAI

Client

Project

Location

: 44LK-5100


Piping 4” NB and under, but not less than 1½” NB:B.

LP test shall be done on the final pass of welding only, in addition to visual examination, root LP test & other

LP / MP test shall be done on root pass and final pass.

11.0 BRANCH CONNECTIONS

specified NDT.

9.0

LP / MP Test shall be done on root pass in addition to radiography applicable to circumferential joint of respective piping class.

10.0 MITRES AND FABRICATED REDUCERS

13.0 In addition to 100% radiography, butt weld joints for A16A, B16A & A35A classes shall be wet fluorescent magnetic

14.0

shall be field weld joints.

DATE 13/7/2010

12.0 As per TAC requirements, 10% of the butt welded joints shall be radiographed, however, 50% of these butt weld joints

particle tested.

For lined specs, testing (MP / LP / Radiography etc.) shall be performed before lining.

SHEET REV. NO.

D.

FABRICATED FITTINGS

Piping over 4” NB:

10% of welds made by each welder on a pipeline with a minimum of two welds per welder, selected at random,

shall be subjected to radiography.

Retest

If any test specimen is unsatisfactory, two further weld specimens for retests shall be selected from the

C.

pipeline for the visual examination and bend tests.

Two percent of welds made by each welder on a pipeline with a minimum of one weld per welder, selected at

carried out by this welder subsequent to the previous test shall be given special consideration.

random, shall be subjected to radiography or may be cut for visual examination and tests.

Piping less than 1½” NB:

production welds and subjected to tests. In the event of failure of any retest specimens, the production welds

Special tests are not normally required but 2% of welds by each welder on a pipeline may be cut out from the

0

8.0

A.

In addition to the Clauses 4, 5, 6, 7, 12 and Table - I, following IBR requirements shall apply. In case of conflict

between above notes and these requirements, the more stringent ones shall apply. IBR piping shall be erected of IBR

inspector approved material and the construction procedure. Erected piping shall be hydrotested, inspected and

approved by IBR inspector.

IBR SERVICE LINES

H. In case hardness values are mentioned in both Welding Specification Charts for Piping Classes, 44LK-5100-00/L.02/0103/A4

table given in Note - 7.G. the lower of the two values shall be applicable.

of 17

HINDUSTAN PETROLEUM CORPORATION LTD. MUMBAI

DIESEL HYDROTREATER PROJECT

TITLE PAINTING SPECIFICATIONS

DOCUMENT NO. 44LK-S100-00-V.02-0002-04

CHECKEDREV ISSUE PAGES REV DESCRIPTION PREPARED APPROVED NO. DATE BYBY BY

A 30.07.2008 17 Issued for Client's approval MVS CR HSC

o 1705.12.2008 Issued for FEED HSC

1

f!'o, SNK CR ..

22.09.2010 Issued for FEED 17 HSC@PMVS~

JACOBS HPCL-MUMBAI PAINTING SPECIFICATIONS Page2of17

44LK-5100 Rev. 1

DOC.NO. 44LK-51 00-00-V.02-0002-A4 Date: 22.09.2010

TABLE OF CONTENTS

ANNEXURE - I PAINTING SPECIFICATION

ANNEXURE - II PAINTING SYSTEM FOR UNIT EQUIPMENT & PIPELINES

ANNEXURE -II HPCL SPECIFICATIONS FOR PAINTS TO BE USED IN PAINTING OF UNITS

ANNEXURE - IV COLOUR CODE FOR PAINTING

44LK-5100-00-V.02-0002-M- Rev. 1 - Painting spec.doc

JACOBS HPCL-MUMBAI PAINTING SPECIFICATIONS Page 3 of 17

44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

ANNEXURE -I

PAINTING SPECIFICATION

1.0 PAINTING SYSTEM & PAINT SPECIFICATIONS:

The painting system for equipment and piping in units shall be as follows: Painting System: It shall be as per Annexure - II (3 Pages) Specifications of the paints: It shall be as per Annexure - III (5 Pages). Color Code for painting - Annexure IV (1 page)

2.0 GUARANTEE:

The paint manufacturer shall specify the following guarantee period of the system.

"Four years for all surfaces"

The paint manufacturer! authorized painting contractor shall furnish a performance bank guarantee to this effect. All mechanical damage to painting (after completion of painting) will be excluded from this guarantee. Client shall have the sole discretion to invoke the bank guarantee in full or part in case of paint failure.

After completion of the job a report shall be generated every three months by Client about the paint condition and the manufacturer shall make good all areas with paint failures within 30 days of reporting of defects.

In case the agency is an approved manufacturer, it should give the guarantee for the paint supplied as well as for defects in the paint application. Any defect in the guarantee period (as per Client report) should be rectified free of cost immediately.

If the painting company is not able to take the job directly for some reason, it can authorize any reputed painting contractor to paint on its behalf. In this case as the agency is not an approved manufacturer but is a painting contractor authorized by the paint manufacturer to paint on its behalf, it shall give a joint performance guarantee with the approved paint manufacturer and any defect in the paint application during the guarantee period (as per Client report) will be rectified by the agency free of cost immediately. It shall be the responsibility of the paint company to supervise the painting work and make sure that good quality painting work is carried out. However, if the authorized painting contractor fails to make good the defects reported by Client within stipulated time frame, it will become the responsibility of the paint manufacture to repair all defects reported by Client. Non-rejection by the paint manufacturing company does not in any way constitute acceptance of any defective work.

3.0 APPROVAL OF PAINTS:

Vendor shall indicate his offered paint system in line with applicable paint system along with vendor's product catalogue & painting instructions. Vendor shall submit the paint (each and every tin of all types of paint) along with the test certificates for Client approval at least 15 days prior to its proposed date of application in field. The test certificate from the manufacturer shall clearly state type of paint, base of paint, Batch No., Date of manufacture, Color, finish, shelf life, Temperature resistance, mixing ratio, spreading rate, Density, Viscosity, Volume solids, Recommended DFT & Corresponding WFT, Touch dry time, Hard dry time! Overcoat interval, % of metallic Zinc by weight in dry film for Inorganic Zn silicate and Zn rich epoxy primers, % of epoxy resin by weight in mixed resin coal tar blend for coal tar epoxies and other details specified by Client. Paints with test certificates without these details shall be rejected.

Client reserves the right to check the paint quality independently at any laboratory. The complete lot of paint shall be accepted or rejected on this basis.

44LK-5100-00-V.02-0002-A4- Rev. 1 - Painting spec.doc


44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

4.0 SURFACE PREPARATION:

Shot blasting/girt blasting is the most preferred method of surface preparation. Power tool cleaning and Hand tool-cleaning operation could be allowed in area where shot blasting is impractical due to approach problem or height.

Three types of surface preparations have been specified by Client.

a) Shot Blasting:

It shall be as per Sa 2 1/2 (Near White Metal) of Swedish Standard SIS-05-5900 1967 / ISO 8501-11988. Contractor shall use Client approved equipment, shots for blasting, and moisture & oil free air. It shall be the responsibility of the contractor to provide suitable protection for the nearby equipment and insulation while carrying out shot blasting to avoid damage to them.

b) Mechanical or Power Tool Cleaning:

It shall be as per ST 3 of Swedish standard SIS -05-59001967/ ISO- 8501-1-1988. Depending upon the locality, the contractor may be advised to use Client approved non sparking type brass mechanical striking tools, brass chipping hammers, grinding wheels or rotating brass wire brushes.

c) Manual or Hand tool cleaning:

It shall be as per St 2 of Swedish Standard SIS -05-5900 1967/ ISO -8501-1-1988. Depending upon the locality, the contractor may be advised to use Client approved only non sparking type (brass) - Hand descaling / hammering tools, hand scrapers and wire brushes.

It may be noted that in case of power tool cleaning or shot blasting, manual cleaning may be allowed solely at HPCL discretion for the pockets/ areas where shot blasting or power tool cleaning is not possible.

5.0 WASHING WITH FRESH WATER:

All bare lines/ vessels/ equipment shall be fully cleaned by fresh water before cleaning / shot blasting to remove all possibilities of salt deposits. The subject surface shall be also cleaned before application of next coat if area is subject to salt water sprays. Suitable arrangement for covering shall also be made to avoid salt water sprays for complete duration of cleaning and painting till final coat cures completely).

6.0 PAINTING AFTER CLEANING:

The primer coat shall be applied within 4 hours of cleaning. However, if rust spots appear even during this interval, the same shall be re-c1eaned and re offered for inspection before applying the paint.

7.0 OVERCOAT DURATION:

The contractor shall strictly adhere to the minimum and maximum overcoat intervals for any painting system as per paint manufacturer's recommendations. In case the contractor is not able to apply the subsequent coats within the specified time frame, he will have to clean the surface to bare metal again as per original specifications and reapply the total paint.

8.0 COLOR CODE:

.The contractor shall follow Client Color code. The contractor shall provide the finish coat such that it meets the color code of the refinery. Contractor shall verify the RAL shade with the engineer in charge before application. In rare circumstances, if the manufacturer cannot supply the requisite color of the finish coat, the vendor shall apply approved color bands (epoxy or enamel) at Client approved locations free of cost.

44LK-51 OO-OO-V.02-0002-A4- Rev. 1 - Painting spec.doc


44LK-5100 Rev. 1

DOC.NO. 44LK-5100-00-V,02-0002-A4 Date: 22,09.2010

9.0 SINGLE SOURCE OF SUPPLY FOR PAINTS:

All the coats of a painting system shall be from the same manufacturer. No waiver regarding this aspect shall be considered.

10.0 DOCUMENTATION:

The contractor shall maintain the following documentation:

a) Quality Plan - It is advisable to divide the location in various zones and maintain zone-wise details.

b) Daily Progress Report with clear details of job done in the form of daily logbook. (Both approved and rejected jobs).

c) Results of approval of surface preparation, water washing, and measurement of paint OFT

d) Colors and batch nos. of paint material used.

It shall be the responsibility of the contractor to obtain written approvals of the inspector at each stage of painting before proceeding for the next stage of painting.

11.0 RESTRICTIONS:

Surfaces shall not be coated in rain., wind or in environment where injurious airborne elements exists, when the steel surface temp is less than -15°C above dew point, when the relative humidity is greater than 85%,or when temp is below 4.4 OC & when temp is above 50 OC.

12.0 MEASUREMENT OF SURFACE PROFILE & PAINT OFT:

The contractor shall bring his own gadgets/ devices for checking the surface preparation and OFT (at each stage from bare metal to every coat), These equipment shall be duly approved/ calibrated by Client. Client shall check the OFT and any shortfall in OFT (max +/- 5%) shall be rectified. The contractor shall check and record the OFT readings. Client will cross check these readings at any number of spots randomly. The contractor shall provide proper scaffolding for checking of painting at stage.

13.0 QUALITY OF PAINTING:

Good quality shall be maintained at every stage of painting. The painting shall have an aesthetic appearance in addition to quality. Any defect noticed during the various stages of inspection shall be rectified to the entire satisfaction of Client inspectors before proceeding further. Final inspection shall include OFT measurement, Adhesion, Holiday detection check and workmanship. Irrespective of the inspection, repair and approval at the intermediate stages of work, contractor shall be responsible for making good any defects found during final inspection or agreed guarantee period. It would be prudent if the application contractor and paint supplier from recommended list come together to share the gurantee requirements by application supervision provided by the paint supplying company.

14.0 STENCILING OF EQUIPMENT / LINE NUMBER:

The scope of work of the contractor shall include stenciling of equipment number, line number, product's name and flow direction by contrasting black or white colors at the existing locations. The style and size of letters of the stenciling shall be approved by Client.

15.0 QUALITY OF MANPOWER:

The contractor shall use only skilled manpower who have at least three years of experience. Painting contractor shall use only qualified painters and supervisors who shall be conversant with paint material characteristics, surface preparation grades, Paint application techniques, measurements of OFT. precautions to be observed during painting/surface preparation and safety precautions in painting. All the painters shall have to undergo a painter qualification test.



44LK-5100 Rev. 1

DOC.NO. 44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

16.0 FIRE -PROOFED STRUCTURES:

All fireproofed structures shall be cleaned and coated with two Coats of Client approved weatherproof cement paints from reputed manufacturers.

17.0 PAINTING FOR R.C.C SUPER STRUCTURE.

All R.C.C shall be painted with two coat of anti-fungal, anti-flaking and water proof paint approved by client / consultant

18.0 PRECAUTIONS:

All nameplates, manufacturer's identification tags, machined surfaces, instrument glass, finished flange faces, control valve stems and similar items shall be masked to prohibit coating deposition. If these surfaces are coated, the component shall be cleaned and restored to original condition.

19.0 DETAILS OF EXPERIENCE:

The contractor shall supply documentary evidence of similar jobs (similar system of painting) carried out in the past with location of site, type of painting and value of work executed.

20.0 PAINTING FOR PLATFORM AND LADDER

Ladder and platform has to be galvanized and painted for colour coding as per required system for galvanized structure. Gratings shall be galvanized but No further painting is required.

21.0 SYSTEM OF PAINTING:

It is recommended that for any particular location / unit! area the contractor shall quote as following:

System "a" BARE VESSELS/ EXCHANGERS

System" b" STRUCTURES

This has been divided into two parts.

Part 1 Structures & platforms till 15mts height or till the topmost O/H Condenser level whichever is higher.

Part 2 All structures higher than sections covered under first part

System "c" BARE PIPING (including piping in O/H Pipe-racks etc.)

System "d" ROTARY EQUIPMENT, VALVES, PSV, INSTRUMENT Etc.

System "e" WALKWAYS, MONKEY LADDERS, and CHECKERED PLATES ETC. PRONE TO FOOT TRAFFIC:

Two optional systems are provided. Anyone of the options can be chosen by the vendor/contractor. Further, under each option two categories have been defined.

Part 1 Walkways, platforms etc. till 15mts height or till the topmost O/H Condenser lever whichever is higher.

Part 2 All platforms, walkways etc higher than sections covered under first part.

System "f' CLADDED EQUIPMENT & PIPING (on top of cladding)

System "g" HOT SURFACES (100-300 deg C)

System "h" EQUIPMENT YET TO BE INSUALTED



44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

System "i" STRUCTRE AND EQUIPMENT YET TO BE FIREPROOFED

System "j" FIRE PROOFED STRUCTURE (CEMENT PAINT):

To be quoted as LUMPSUM for manual tool cleaning and painting.

System "k" GALVANIZED STRUCTURAL SURFACES

It should be noted that system g, h or i mayor may not be required to be carried out. Hence it is required to be quoted as unit rate (Rs.l sq. mts.). For similar reasons unit rates for sand blasting also have to be quoted.

If sea transportation is involved SS surfaces shall be suitably protected using Epoxy Coating materials, which have minimum leachable chlorides or Cello film.

22.0 CLAUSE FOR EXCLUSION OR EXTRA PAINTING:

For every system of painting for which rates have been quoted as lump sum, the vendor should specify rate of per square meter of painting. This shall be used to either carry out extra painting in that unit or to deduct a proportionate amount from the lump sum amount for the areas, which could not be painted due to unforeseen circumstances. It shall be solely HPCL's prerogative to invoke this clause. Under no circumstances shall this rate be used to make claims for payments for areas which the vendor has inadvertently missed while quoting or for making part payments for the areas in which the vendor has failed to carry out painting.

23.0 RATE FOR SHOT BLASTING:

The vendor shall quote unit rate for shot blasting on per square meter basis. This shall be used solely at HPCL discretion for areas where painting permission cannot be given after shot blasting due to unforeseen circumstances.

24.0 TIMING SCHEDULE OF PAINTING SYSTEM

Timing schedule of painting system have to be followed as per Paint manufacturer's specification. Final coat shall be before Rainy season, giving due consideration to shelf life and lead-time required for primer and intermediate coat.

25.0 PREFERRED PAINT MANUFACTURE

BERGER PAINTS ASIAN PAINTS SIGMA COA TlNGS SHALIMAR PAINTS CLEAN COATS PVT. LTD. CHUGOKU JENSON & NICHOLSON LTD GOODLASS NEROLAC PAINTS LTD. KIRLOSKAR BROTHERS GRAND POL YCOA TS COMPANY PVT. LTD.

* For very high performance coatings.


JACOBS

HPCL-MUMBAI PAINTING SPECIFICATIONS Page 8 of 17

44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

Annexure-II

PAINTING SYSTEM FOR UNIT EQUIPMENT & PIPELINES

I) SYSTEM - "a": BARE VESSELS/ EXCHANGER~ (Maximum Design Temp = 100 deg C): - To be quoted as Lumpsum for each vessel/Exch. ill

OPTION -1: WITH SHOT BLASTING:

Specification No of Application Thickness Coats Method (DFT in microns)

Surface Preparation: ShotlGrit Blast to Sa 21/2

Primer - Inorganic Zinc Silicate Stripe Coat - Epoxy HB MID

Tie Coat - HB MID Epoxy Stripe Coat - HB Epoxy I HB MID Epoxy

Inter - High Build 2 pack epoxy Or, HB MID Epoxy

Stripe Coat: Acrylic Aliphatic PU

Finish - Acrylic Modified 2 pack Polyurethane (Recoatable)

ONE

ONE

ONE

ONE

Airless spray 1 X 75 = 75




TOTAL: OFT = 325 microns

(OPTION-2): WITH POWER TOOL CLEANING: (Recommending if shot blasting becomes practically impossible because of approach or height.)

Specification No of Application Thickness Coats Method (OFT in microns)

Surface Preparation: Power tool cleaning ST 3

Stripe Coat- Self priming Epoxy -

Primer - Self Priming Epoxy Aluminum Airless spray ONE 1X 125 =125 Stripe Coat- MID 2 Pack Epoxy

Mid coat - MID 2 Pack Epoxy Airless spray ONE 1 X 100 =100

Inter - High Build 2 pack epoxy Airless spray ONE 1 X 100 =100 Or, HB MID Epoxy

Finish - Acrylic Modified 2 pack Polyurethane Airless spray 1 X 50 = 50ONE (Recoatable)

TOTAL: OFT = 375 microns



44LK-5100 Rev. 1

DOC.NO. 44LK-51OO-OO-V. 02-0002-A4 Date: 22.09.2010

II) SYSTEM -"b" : STRUCTURES: (To be Quoted as Lumpsum)

PART l : Structures & Platforms upto the height of topmost overhead condenser or upto a height of 15 metres whichever is higher.

Specification Noof Application Thickness Coats Method (OFT in microns)

Surface Preparation: Shot Blast to Sa 2 1/2

Primer - Zn Rich Epoxy

Stripe Coat- Epoxy HB MIO

ONE Brush I Spray 1 X 50 = 50

Mid coat - MIO 2 Pack Epoxy

Stripe Coat- HB Epoxy

ONE Brush 1 X 100 =100

Inter - High Build 2 pack epoxy

Or, HB MIO Epoxy

Stripe Coat - Acrylic Aliphatic PU

ONE Brush 1 X 100 =100

Finish - Acrylic Modified 2 pack PU (Recoatable) ONE Brush 1 X 50 = 50

Total OFT = 300 microns

PART 1\: All structures and platform above the height mentioned in "PART l" earlier (ie above 15 m height or topmost condenser height whichever is more) - Lumpsum

Specification ApplicationNo of Thickness Coats Method (OFT in microns)

~rface Preparation: Power tool cleaning ST 3

I Stripe Coat - Self priming epoxy -- ---- -----Primer - Self Priming Epoxy Aluminum ONE Airless spray 1 X 125 =125

Stripe Coat- MIO 2 Pack Epoxy ---- ------ -------Mid coat - MIO 2 Pack Epoxy ONE Airless spray 1 X 100 =100

Inter - High Build 2 pack epoxy ONE Airless spray 1 X 100 =100

Or, HB MIO Epoxy

Finish - Acrylic Modified 2 pack Polyurethane ONE Airless spray 1 X 50 = 50 (Recoatable)

Total OFT= 375 microns


I


44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

III) System "c" : BARE PIPING (including lines in olh pipe rack) (Maximum design temp= 100 deg C) :

To be quoted as Lumpsum 6 Specification


Stripe Coat - Self Priming Epoxy

Primer - Self Priming Epoxy Aluminum

Stripe Coat- MIO 2 Pack Epoxy

Mid coat - MIO 2 Pack Epoxy

Inter - High Build 2 pack epoxy

Or, HB MIO Epoxy

Finish - Acrylic Modified 2 pack Polyurethane (Recoatable)

No of Coats

Application

Method

Thickness

(OFT in microns)

----ONE

-----ONE

ONE

-----Airless spray

--------Airless spray

Airless spray

------1 X 125 :: 125

-----------1 X 100 :: 100

1 X 100 = 100

I

ONE Airless spray 1 X 50 :: 50

Total OFT= 375 microns

IV) System "d": PSV, MOTORS, PUMPS, COMPRE~ORS, INSTRUMENTS, Valves etc.: Maximum design Temperature: 100 deg C - LUMP SUM ~


Surface Preparation: Manual Cleaning to ST 2

Stripe Coat- Self Priming Epoxy --- --- ----Primer - Self Priming Epoxy Aluminum ONE Brush 1 X 125 = 125

Stripe Coat- MIO 2 Pack Epoxy ------ ----- -------Mid coat - MIO 2 Pack Epoxy ONE Brush 1 X 100 = 100

Inter - High Build 2 pack epoxy ONE Brush 1 X 100 = 100

Or, HB MIO Epoxy

I Finish - Acrylic Modified 2 pack Polyurethane ONE Brush 1 X 50 = 50 (Recoatable)

I I




44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

V) System "e" : Carbon Steel Checkered Platel Walkwayl Rungs of Monkey Ladder etc. areas which are prone to foot traffic and consequent abrasion.

OPTION I (Upto 15 m height or till the level of topmost o/h condenser whichever is higher) Lumpsum


Surface Preparation - Shot Blast to Sa 2 1/2

Primer - Zn Rich Epoxy ONE Airless spray 1 X 50 = 50

Stripe Coat- Epoxy HB MIO

Mid coat - MIO 2 Pack Epoxy ONE Airless spray 1 X 100 =100

Stripe Coat - HB Epoxy


Or Epoxy HB MIO

Stripe coat- Coal Tar Epoxy

Finish - Coal Tar Epoxy (Recoatable) ONE Airless spray 1 X 150 = 150


OPTION I (Above 15 m height or above the level of topmost o/h condenser whichever is higher) Lumpsum


Surface Preparation: Manual Cleaning to ST 2

Stripe Coat- Self Priming Epoxy --- --- ----Primer - Self Priming Epoxy Aluminum ONE Airless spray 1 X 125 =125

Stripe Coat- MIO 2 Pack Epoxy ----- ------ --------Mid coat - MIO 2 Pack Epoxy ONE Airless spray 1 X 100 =100


Or Epoxy HB MIO

Stripe coat- Coal Tar Epoxy

Finish - Coal Tar Epoxy (Recoatable) ONE Airless spray 1 X 150 = 150




44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

OPTION \I (Upto 15 m height or till the level of topmost olh condenser whichever is higher) Lumpsum

Specification No of Application Thickness Coats Method (OFT in microns) I

Surface Preparation: Shot Blast to Sa 21/2

Primer - Zn Rich Epoxy One Airless spray 1X 50 =50

Stripe Coat - Epoxy HB abrasion Resistant

OneII Intermediate- Epoxy HB abrasion Resistant Airless spray 1 X 75 =75

Stripe Coat - Epoxy HB abrasion Resistant. I

Mid Coat- Epoxy HB abrasion Resistant One Airless spray 1 X 75 =75

Finish - Epoxy HB abrasion Res. (Recoatable) ONE Airless spray 1 X 75 =75

Total OFT= 275 Microns

OPTION II (Above 15 m height or above the level of topmost olh condenser whichever is higher)Lumpsum



Stripe Coat- Self priming epoxy ~-~~---- ------------ ---------II

Primer - Self priming epoxy Airless spray 1X 125 = 125

I Stripe Coat - Epoxy HB abrasion Resistant ONE Airless spray 1 X 75 = 75

Intermediate- Epoxy HB abrasion Resistant ----- ------- ----------Mid Coat- Epoxy HB abrasion Resistant ONE Airless spray 1 X 75 = 75

Finish - Epoxy HB abrasion Resistant ONE Airless spray 1 X 75 = 75

Total OFT= 350 Microns

VI) System "f" Cladded Equipment and Piping (To be applied on top of GllAlum clad sheets) LUMPSUM


Surface Preparation: Manual by wire brush and degreasing if oil spill is there.

Primer - Wash Etch Primer ONE Brush 1 X 10 =10

Finish - HR Alum Paint ONE Brush 1 X 20 =20




44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

VII) System "g" :ALL OTHER BARE EQUIPMENT, LINES ~ SURFACES For WHICH Design Temperature is between: 100 to 300 Deg C - UNIT RATE ~


Surface Preparation: Shot Blast to Sa 2 %

Primer - Heat Resistant AI-Silicone Paint ONE Brush 1 X 20 = 20

Finish - Heat Resistant AI-Silicone Paint ONE Brush 1 X 20 = 20 I

Total OFT = 40 microns Note: No temperature curing is allowed for the Heat Resistant paint of this system.

VIII) System "h" Structure, Lines and Equipment which are to yet to be insulated and (UNIT RATE) .& PART 1: Whose design temp is less than 100 deg C


Surface Preparation: Shot Blasting to Sa 2 %


Finish - MIO 2 pack epoxy TWO Airless spray 2 X 100 = 200


PART 2: Metal surfaces, hines to be insulated (CS/LAS only and before insulation) - hot insulation between 100 to 400°C. 0

OPERATION OPERATING DESCRIPTION

A) Surface Preparation Blast cleaning to Swedish Specification SIS-05-5900 with grade SA2%-3

B) Priming Inorganic Zinc Silicate DFT of 75 Microns (Ethyl Silicate based)

Note:

Where surface preparation by blast cleaning is impracticable mechanical cleaning is to be carried out followed by two coats of silicon based heat resisting aluminum paint of 40-50 OFT total microns instead of inorganic zinc silicate primer of 75 microns OFT.



44LK-5100 Rev. 1

DOC.NO. 44LK-51 00-00-V.02-0002-A4 Date: 22.09.2010

IX) System "i" : Structure and Equipment which are to yet to be fire-proofed: (UNIT RATE)

Specification No of Application Thickness Coats Method (DFT in microns)

Surface Preparation: Shot blasting to Sa 2 %


Finish - Epoxy tie Coat ONE Airless spray 1 X 25 = 25

Total DFT = 75 microns

X) System "j" : FIRE PROOFED Structure and Equipment : (LUMPSUM)


Surface Preparation: Manual Cleaning

Primer - Weather Resitant Cement Paint ONE Brush/ Spray

Finish - Weather Resistant Cement Paint ONE Brush /Spray

XI) System "k" : Galvanized Structural surfaces

Specification No of Application Thickness Coats Method (OFT in microns) I

~Urface Preparation: Manual by wire brush and degreasing if oil spill is there.

Primer - Wash Etch Primer 1 X 5 = 5 ONE Brush

Brush 1 X 125 =125 ONEMid Coat - High Build Polyamide cured Epoxy (2- Pack ,System) --t

1 X 50 = 50 I Finish - Aliphatic Acrylic modified (Iso-Cyanate) ONE I Brush I cured 2-Pack Polyurethane (Re-coatable)


NOTE:

1. After application, every coat of paint should be of average minimum OFT as indicated in the above mentioned respective painting systems.

&

2.

3.

Stripe Coat: Stripe coat should be applied using half to one inch brush to only weld joints, nut bolts etc. and confined areas before application of full coat. This is to provide additional protection to these areas, as these are usually the starting points of corrosion.

Wrapping and coating system for underground C.S. pipes has been included in Engineering Design Basis - Piping (Doc. no. 44LK-5100-00/L.02/002/A4).


JACOBS HPCL-MUMBAI PAINTING SPECIFICATIONS Page 150f17

44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

Annexure-III

Specifications for Paints to be used in Painting of Units

1

2

3

4

5

6.

7.

Required Specifications

Inorganic Zn Silicate

Zn Rich Epoxy

Self Priming Epoxy

Epoxy Tie Coat

MIO 2 Pack Epoxy

Two Pack Epoxy (High Build)

Two Pack Epoxy Abrasion Resistant



44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

8. Brand Name DFT (Microns) fCoat =50 Continuous Service Temp (Deg C) =0-125 Volume soilds (minimum) =55% It should be a two pack PU. It Should be Re-Coatable after Completion of guarantee

Required Specifications

9.

Aliphatic Acrylic Modified (Isocynate) Cured Two Pack Polyurethane Finish

Heat Resistant AI. Paint (Acrylic! Silicone Based)

period subject to sound condition of total system.

C

10. High Build Amine Cured Epoxy

12 Epoxy Coal Tar

ments

14 HR Aluminum Paint (Alkyd Based)

13 Wash etch Primer

Brand Name To be used as primer for painting of AI sheets! GI sheets of insulation c1adding.(2 component based on Poly Vinyl Butyral) DFT(microns) f Coat =10; Color =Yellow Volume Solids



44LK-5100 Rev. 1

DOC.NO.44LK-5100-00-V.02-0002-A4 Date: 22.09.2010

ANNEXURE-IV

COLOUR CODE FOR PAINTING

SI. No. SERVICE COLOUR BAND

1. PROCESS LINES:

1a. All Lines below 120 dec C Grey -

1b. All lines above 120 deg C Aluminum -

2. UTILITY LINES: -

2a. All Lines except cooling & Fire Water Lines < 120C Grey -

2b. All Lines except coolinq & Fire Water Lines> 120C Aluminum -

2c Cooling water Lines Opaline Green

3. CHEMICALS 3a Acid, Alkali, and all other corrosive contents i.e.

corrosive to the person except toxic lines Grey Yellow

3b. Toxic Lines Grey Tangerine

4. FIRE WATER LINES & FIRE FIGHTING EQUIPMENT Red Gloss -

5a. Fired Heaters, Heat Exchangers, Storage Tanks, Vessels (Except Chemicals)

< 120 C - Grey > 120 C - Aluminum

5b. Fired Heaters, Heat Exchangers, Storage Tanks, Vessels (Chemicals)

< 120 C - Grey > 120 C - Aluminum

Yellow/ Tangerine

6. INSULATED LINE! EQUIPMENT Aluminum. -

7. CHLORINE STORAGE White

8. MOVING EQUIPMENT

8a. Pumps, Comp, Turbines, stirrers, Blowers, Rotary air locks etc.

Mushroom gloss

8b. Motors & their field mounted switch qear Tangerine Gloss

9. AIRLINE &OUTSIDE INSTRUMENT SYSTEMS Black


X:\std\leveliv\L_SS_001.doc 10-11-10 12:25 PM

Page 1 of 7

JACOBS H&G

PIPING STANDARD SPECIFICATION

PROCUREMENT OF STEEL PIPES

DOCUMENT NO : L SS 001

PREVIOUS DOC. NO. : BSS-12-161/1

Rev No. Issue Date Pages Rev Description Prepared By

Checked By

Approved By

0 20 Aug. 2002 7 Issue for Use SST BSD RVM

JACOBS H&G LTD PIPING STANDARD SPECIFICATIONS L SS 001 DATE : 20 Aug. 2002 PROCUREMENT OF STEEL PIPES PAGE: 2 OF 7 REVISION NO: 0


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 DEFINITIONS 4.0 GENERAL 5.0 RELATED DOCUMENTATION (REFERENCES) 6.0 RECORDS 7.0 ATTACHMENTS / APPENDICES



1.0 PURPOSE

The purpose of this Standard Specification is to establish the requirements for procurement of Steel pipes.

2.0 SCOPE

The scope of the Standard Specification is to define the requirements of various pipes that the suppliers have to comply with. This Specification doesn’t cover high yield materials such as API 5L X_.

3.0 DEFINITIONS

ANSI: American National Standards institute ASME: American Society of Mechanical Engineers ASTM: American Society for Testing materials API: American Petroleum Institute MSS-SP Manufacturer’s Standard Society-Standard Practice BSI: British Standards Institution BIS: Bureau of Indian Standards IBR: Indian Boiler Regulations

4.0 GENERAL

This specification, together with the Purchase requisition / Order, all documents referenced in the Requisition/ Order and the Company’s / Client’s conditions of order covers the requirements of the supply of steel pipes listed below a) Carbon Steel b) Alloy Steel c) Austenitic Stainless Steel d) Galvanised Iron (G.I)

4.1 Conflicting Requirements 4.1.1 Any conflict between requirement of this specification, Purchase Data sheets and related Documents

shall be referred back to the Company for Approval, at the Bid stage.

4.2 Supplier’s Alternatives

4.2.1 Supplier’s shall submit the specification of the alternative for approval at the bid stage, in case the supplier wishes to supply equivalent / suitable alternative. Alternatives will not be accepted during supply stage.

4.3 Materials and Manufacture 4.3.1 Materials, dimensions and Manufacturing process of the Pipes shall be in accordance with the

Codes / Standards mentioned in the purchase requisition/ Order. 4.3.2 Pipes shall be supplied in Single / Double random lengths unless otherwise specified in the Data sheets.



4.4 Specific Requirements 4.4.1 Austenitic Stainless Steel items shall be furnished in the heat –treated condition. 4.4.2 All H grades shall be furnished in solution- treated conditions. 4.4.3 Double Long Seam is allowed for sizes 36” and larger. 4.4.4 Unless specifically exempted, welded pipes shall be acceptable only with longitudinal weld made

employing automatic welding. 4.5 Intergranular Corrosion Test (IGC Test) 4.5.1 Where IGC test is specified it shall be in accordance with ASTM A262, Practice E. 4.6 Special Requirements 4.6.1 NACE-MR-01-75 shall be followed for Pipes falling under NACE category. 4.6.2 For Hydrogen and other demanding services, Vendor shall include all special quality checks

and inspection in the quality Plans. 4.6.3 Special Tests would be applicable for items falling under cryogenic conditions. 4.7 End Finish 4.7.1 Unless otherwise specified end preparation of pipes shall be as follows

a) ½” to 1 ½” : Plain ends b) 2” and above : Bevelled ends c) Galvanized Pipes : Threaded and coupled Ends (T&C)

4.7.2 Wherever bevelled ends are specified it shall confirm to ASME B16.25. Threaded ends shall be as per ASME B1.20.1

4.8 Pipes falling under the purview of IBR 4.8.1 Spirally welded Pipes shall not be supplied for Steam service falling under the purview of IBR. All

Pipes falling under the purview of IBR shall be shall bear the inspection punch of IBR Inspector and shall be supplied with Form III A.

4.8.2 Pipes supplied to API 5L Specification shall not be cold expanded. 4.9 Workmanship, Finish and Appearance 4.9.1 All pipes shall be cleanly finished and when visually inspected shall be free from defects /

imperfections such as cracks, surface flaws, laminations etc. 4.9.2 The repair of defects shall be carried out as per the codes/ standards specified in the data

sheets. 4.9.3 All pipes shall be clean of rust, foreign materials, scales, oil and grease. Pipes shall be

provided with a suitable protective coating. Where Pipes are to be galvanized the zinc coating shall be as per codes/ standards.

4.9.4 Pipes supplied for Oxygen / Chlorine services, shall be chemically cleaned.



4.10 Tests 4.10.1 The following tests shall be carried out on the materials / Finished Items as prescribed in

applicable codes / standards.

a) Visual Examination b) Chemical composition/ Product analysis c) Mechanical Tests

i) Tensile Test ii) Flattening Tests iii) Bend Tests

d) Hydrostatic test e) Other NDT tests

4.11 Product Marking 4.11.1 Product marking shall include Heat Number and all other information as per Codes/

Standards. 4.11.2 For identification of materials at site, the following colour marking schedule given in 4.11.4

shall be used. 4.11.3 Colour / Ink used for marking shall not contain harmful metal or metal salts that causes

corrosive attack either ordinarily or in service. 4.11.4 Stainless Steel Pipes and Galvanised pipes do not require colour coding. 4.11.5 Colour Marking Schedule

Material Specification Colour Code IS 1239 White One Strip IS 3589 Black One Strip ASTM A 53 Gr. A/ B Orange One Strip ASTM A 106 Gr. A/ B/ C Green One Strip ASTM A 333 Gr.1/ 6 Brown One Strip API 5L Gr. A/ B Yellow One Strip ASTM A 335 Gr. P1 Black & Green One Strip each ASTM A 335 Gr. P5 Black & Red One Strip each ASTM A 335 Gr. P11 Black & Black One Strip each ASTM A 335 Gr. P22 Black & White One Strip each

4.11.6 Colour Code Strip shall be as follows

1 ½” and Smaller Colour code rings every 1.5 metres. apart 2” and Larger broad line (s) (min. ½” width painted along the

length of the pipe).



4.12 Inspection 4.12.1 Unless otherwise specified in the purchase order, it is the responsibility of the producer/

supplier to perform all inspection requirements specified in the Codes/ standards/ Data sheets. The Company / client shall have the right to perform any inspection and tests set forth in the specification.

4.12.2 Inspection and Test necessary to confirm that the products meet the requirements of the

standards, Specifications and of the Purchase Order shall be carried out in the Vendors Plant by the Vendors specially trained Personnel.

4.12.3 Products that are to the specifications shall be guaranteed by inspection certificate,

conformity certificate, Material certificate, test certificates etc. 4.12.4 All inspection activities shall be listed in the quality plan. This quality plan shall be submitted

for approval. 4.12.5 PMI (Positive Material Identification) by alloy analyser to be carried out where specified. 4.13 Extent of inspection and witnessing by Client/ Consultant/ Third Party 4.13.1 Extent of witness inspection shall be minimum 20% of the lot. However, extent of witness

inspection shall be increased where Vendor’s performance is not satisfactory. Inspection and witnessing rate for all the points listed in the quality plan shall be as follows :

Pipe Sizes Sampling

1½” and smaller 10% 2” to 10” 25% 12” and above 100% 4.14 Documentation 4.14.1 Certificate of Conformity: The Vendor shall submit a certificate of conformity with the

standards specified in the Purchase order. 4.14.2 Materials Certificate: The Vendor shall submit all material certificates pertaining to the results

of chemical analysis, mechanical tests, Non destructive tests and Acceptance certificates, carried out in accordance with the requirements of the codes/ standards, specified in the purchase order.

4.15 Acceptance 4.15.1 Inspection department shall not release the materials unless all the required certificates are

submitted and approved.

4.16 Preparation, Packing and Forwarding 4.16.1 All pipes shall be dry, clean and free of moisture, dirt, and loose foreign materials. 4.16.2 All pipes shall be protected from rust, corrosion and any mechanical damage during

transportation, shipment and storage. 4.16.3 Rust preventive coats shall be applied on machined surfaces, which is not harmful to the

material, welding etc. Coating shall be easily removable with a petroleum solvent.



4.16.4 Suitable End protectors shall be provided and they shall be properly secured and tightly

attached. 5.0 RELATED DOCUMENTATION (REFERENCES ) 5.1 ASME B 16.25 : Butt welding Ends 5.2 ASME B 36.10 : Welded and Seamless Wrought Steel Pipe 5.3 ASME B 36.19 : Stainless Steel Pipe 5.4 ASME B1.20.1 : Pipe Threads- General Purpose (Inch) 5.5 API : American Petroleum Institute 5.6 IBR : Indian Boiler Regulations.

6.0 RECORDS 6.1 Supplier shall compile a Test report manual, comprising of all Test reports, Inspection reports,

Acceptance report, inspection release certificate and shall submit along with the supplies. 7.0 ATTACHMENTS / APPENDICES Refer ‘Table of Contents’

X:\std\leveliv\LSS002.doc 10-11-10 12:26 PM

Page 1 of 7

JACOBS H&G


PROCUREMENT OF STEEL PIPE FITTINGS

DOCUMENT NO: L SS 002



Checked By

Approved By

0 4 Sept. 2002 7 Issue for Use SST BSD RVM

JACOBS H&G LTD PIPING STANDARD SPECIFICATION L SS 002 DATE : 4 Sept. 2002 PROCUREMENT OF STEEL PIPE FITTINGS PAGE: 2 OF 7 REVISION NO: 0


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 DEFINITIONS 4.0 GENERAL 4.1 CONFLICTING REQUIREMENTS 4.2 SUPPLIER’S ALTERNATIVES 4.3 MATERIALS AND MANUFACTURE 4.4 SPECIFIC REQUIREMENTS 4.5 INTERGRANULAR CORROSION TEST (IGC TEST) 4.6 SPECIAL REQUIREMENTS 4.7 END FINISH 4.8 FITTINGS FALLING UNDER THE PURVIEW OF IBR 4.9 WORKMANSHIP, FINISH AND APPEARANCE 4.10 TESTS 4.11 PRODUCT MARKING 4.12 INSPECTION 4.13 EXTENT OF INSPECTION AND WITNESSING BY CLIENT / CONSULTANT/ THIRD

PARTY 4.14 DOCUMENTATION 4.15 ACCEPTANCE 4.16 PREPARATION, PACKING AND FORWARDING 5.0 RELATED DOCUMENTATION ( REFERENCES ) 6.0 RECORDS 7.0 ATTACHMENTS / APPENDICES



1.0 PURPOSE The purpose of this Standard Specification is to establish the methods for procurement of

Steel butt welding, socket welding and screwed fittings. 2.0 SCOPE The scope of the Standard Specification is to define the methods and requirements for

procurement of Steel butt welding, socket welding and screwed fittings. 3.0 DEFINITIONS

ANSI: American National Standards institute ASME: American Society of Mechanical Engineers ASTM: American Society for Testing materials API: American Petroleum Institute MSS-SP Manufacturer’s Standard Society-Standard Specification BSI: British Standards Institution BIS: Bureau of Indian Standards IBR: Indian Boiler Regulations

4.0 GENERAL

This specification, together with the Purchase requisition / Order, all documents referenced in the Requisition/ Order and the Company’s / Client’s conditions of order cover the requirements of the supply of steel butt welding, socket welding and screwed fittings listed below: a) Carbon Steel b) Alloy Steel c) Austenitic Stainless Steel d) Galvanised Iron (G.I)

4.1 CONFLICTING REQUIREMENTS 4.1.1 Any conflict between requirement of this specification and Purchase Data sheets and related

Documents shall be referred back to the Company for Approval, at the Bid stage.

4.2 SUPPLIER’S ALTERNATIVES


4.3 MATERIALS AND MANUFACTURE 4.3.1 Materials, dimensions and Manufacturing process of the Fittings shall be in accordance with the Codes

/ Standards mentioned in the purchase requisition/ Order.



4.4 SPECIFIC REQUIREMENTS 4.4.1 Austenitic Stainless Steel items shall be furnished in the heat-treated condition. 4.4.2 All H grades shall be furnished in solution- treated conditions. 4.5 INTERGRANULAR CORROSION TEST (IGC TEST) 4.5.1 Where IGC test is specified it shall be in accordance with ASTM A262, Practice E.

4.6 SPECIAL REQUIREMENTS

4.6.1 NACE-MR-01-75 shall be followed for Fittings falling under NACE category. 4.6.2 For Hydrogen and other demanding services Vendor shall include all special quality checks

and inspection in the quality Plans. 4.6.3 Special Tests would be applicable for items falling under cryogenic conditions. 4.7 END FINISH 4.7.1 Unless otherwise specified end preparation of Fittings shall be as follows

a) ½” to 1 ½” : Socket welding Ends b) 2” and above : Bevelled ends c) Galvanized fittings : Threaded (Male)

4.7.2 Wherever bevelled ends are specified it shall confirm to ASME B16.25. Threaded ends shall be as per ASME B1.20.1. Wherever Socket weld, Screwed ends are specified, it shall confirm to ASME B 16.11

4.8 FITTINGS FALLING UNDER THE PURVIEW OF IBR 4.8.1 All Steel fittings, falling under the purview of IBR shall be shall bear the inspection punch of IBR

Inspector and shall be supplied with Form III C. 4.9 WORKMANSHIP, FINISH AND APPEARANCE 4.9.1 All fittings shall be cleanly finished and when visually inspected shall be free from defects /


sheets. 4.9.3 All fittings shall be clean of rust, foreign materials, scales, oil and grease. Fittings shall be

provided with a suitable protective coating. Where fittings are to be galvanized the zinc coating shall be as per codes/ standards.

4.9.4 Fittings supplied for Oxygen / Chlorine services, shall be chemically cleaned. 4.10 TESTS



4.10.1 The following tests shall be carried out on the materials / Finished Items as prescribed in

applicable codes / standards. a) Visual Examination b) Chemical composition / Product analysis c) Mechanical Tests


d) Hydrostatic Tests e) NDT tests

4.11 PRODUCT MARKING 4.11.1 Product marking shall include Heat Number and all other information as per Codes/

Standards. 4.11.2 For identification of materials at site the following colour marking schedule given in 4.11.4

shall be used. 4.11.3 Colour / Ink used for marking shall not contain harmful metal or metal salts that causes

corrosive attack either ordinarily or in service. 4.11.4 Stainless Steel and Galvanised items do not require colour coding 4.11.5 Colour Marking Schedule Material Specification Colour Code IS 1239 (Part II) White One Strip ASTM A 234 Gr. WPB/ WPC Orange One Strip ASTM A 234 Gr. WP1 Green One Strip ASTM A 234 Gr. WP11/12 Cl.2 Black & Red One Strip each ASTM A 234 Gr. WP5/WP9/11/12 Cl.1 Black & White One Strip each ASTM A 420 Gr. WPL6/9/3/8 Yellow One Strip 4.12 INSPECTION 4.12.1 Unless otherwise specified in the purchase order, it is the responsibility of the producer /





conformity certificate, Material certificate, test certificates etc.



4.12.4 All inspection activities shall be listed in the quality plan. This quality plan shall be submitted for approval.

4.12.5 PMI (Positive Material Identification) by alloy analyser to be carried out where specified. 4.13 EXTENT OF INSPECTION AND WITNESSING BY CLIENT/ CONSULTANT/ THIRD PARTY 4.13.1 Inspection and witnessing rate for the all points listed in the quality plan shall be as follows Pipe Sizes Sampling

1½” and smaller 10% 2” to 10” 25% 12” and above 100% 4.14 DOCUMENTATION 4.14.1 Certificate of Conformity: The Vendor shall submit a certificate of conformity with the



4.15 ACCEPTANCE 4.15.1 Inspection department shall not release the materials unless all the required certificates are


4.16 PREPARATION, PACKING AND FORWARDING 4.16.1 All items shall be dry, clean and free of moisture, dirt, and loose foreign materials. 4.16.2 All items shall be protected from rust, corrosion and any mechanical damage during


material, welding etc. Coating shall be easily removable with a petroleum solvent. 4.16.4 Suitable end protectors shall be provided and they shall be properly secured and tightly

attached. 5.0 RELATED DOCUMENTATION (REFERENCES ) 5.1 ASME B 16.25 : Butt welding Ends 5.2 ASME B 36.10 : Welded and Seamless Wrought Pipe



5.3 ASME B 36.19 : Stainless Steel Pipe 5.4 ASME B1.20.1 : Pipe Threads-General purpose (Inch) 5.5 ASME B 16.9 : Factory-made Wrought Steel Butt welding Fittings 5.6 ASME B 16.11 : Forged Fittings Socket Welding and Threaded 5.7 MSS-SP-43 : Wrought Stainless Steel Butt -welding Fittings 5.8 IBR : Indian Boiler Regulations.

6.0 RECORDS

Supplier shall compile a Test report manual comprising of all test reports, Inspection reports, Acceptance reports and submit the same along with the supplies.

7.0 ATTACHMENTS / APPENDICES Refer ‘Table of Contents’


Page 1 of 6

JACOBS H&G


PROCUREMENT OF STEEL FLANGES, SPADES AND SPACERS


PREVIOUS DOC. NO. :

Rev No. Issue Date Pages Rev Description Prepared

By Checked

By Approved

By


JACOBS H&G LTD PIPING STANDARD SPECIFICATION L SS 003 DATE : 4 Sept. 2002 PROCUREMENT OF STEEL FLANGES, SPADES AND SPACERS PAGE: 2 OF 6 REVISION NO: 0


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 DEFINITIONS 4.0 GENERAL 4.1 CONFLICTING REQUIREMENTS 4.2 SUPPLIER’S ALTERNATIVES 4.3 MATERIALS AND MANUFACTURE 4.4 SPECIFIC REQUIREMENTS 4.5 INTERGRANULAR CORROSION TEST (IGC TEST) 4.6 SPECIAL REQUIREMENTS 4.7 FLANGES, SPADES AND SPACERS FALLING UNDER THE PURVIEW OF IBR 4.8 FACE FINISH 4.9 WORKMANSHIP, FINISH AND APPEARANCE 4.10 TESTS 4.11 PRODUCT MARKING 4.12 INSPECTION 4.13 EXTENT OF INSPECTION AND WITNESSING BY CLIENT / CONSULTANT/ THIRD

PARTY 4.14 DOCUMENTATION 4.15 ACCEPTANCE 4.16 PREPARATION, PACKING AND FORWARDING 5.0 RELATED DOCUMENTATION (REFERENCES) 6.0 RECORDS 7.0 ATTACHMENTS / APPENDICES



1.0 PURPOSE The purpose of this Standard Specification is to establish the requirements for procurement of

Steel flanges, spades and spacers. 2.0 SCOPE The scope of the Standard Specification is to define the requirements of various flanges,

spades and spacers, that the suppliers have to comply with. 3.0 DEFINITIONS

ANSI: American National Standards institute ASME: American Society of Mechanical Engineers ASTM: American Society for Testing materials API: American Petroleum Institute AWWA: American Water Works Association MSS-SP: Manufacturer’s Standard Society- Standard Specification BSI: British Standards Institution BIS: Bureau of Indian Standards IBR: Indian Boiler Regulations

4.0 GENERAL

This specification, together with the Purchase requisition / Order, all documents referenced in the Requisition/ Order and the Company’s / Client’s conditions of order covers the requirements of the supply of steel flanges, spades and spacers listed below a) Carbon Steel b) Alloy Steel c) Austenitic Stainless Steel d) Galvanised Iron (G.I)

4.1 CONFLICTING REQUIREMENTS 4.1.1 Any conflict between requirement of this specification, Purchase Data sheets and related Documents




4.3 MATERIALS AND MANUFACTURE 4.3.1 Materials, dimensions and Manufacturing process of the flanges, spades and spacers shall be in

accordance with the Codes / Standards mentioned in the purchase requisition/ Order. 4.4 SPECIFIC REQUIREMENTS 4.4.1 Austenitic Stainless Steel items shall be furnished in the heat treated condition.



4.4.2 All H grades shall be furnished in solution- treated conditions. 4.5 INTERGRANULAR CORROSION TEST (IGC TEST)

4.5.1 Where IGC test is specified it shall be in accordance with ASTM A262, Practice E.


4.6.1 NACE-MR-01-75 shall be followed for flanges, spades and spacers falling under NACE category.

4.6.2 For Hydrogen and other demanding services Vendor shall include all special quality checks

and inspection in the quality Plans. 4.6.3 Special Tests would be applicable for items falling under cryogenic conditions. 4.7 FLANGES, SPADES AND SPACERS FALLING UNDER THE PURVIEW OF IBR 4.7.1 All flanges, spades and spacers falling under the purview of IBR shall be shall bear the inspection

punch of IBR Inspector and shall be supplied with Form III C. 4.8 FACE FINISH 4.8.1 Unless otherwise specified in the data sheets the face finishing shall be as follows

a) Stock Finish : (250- 1000 AARH) 6.3- 25.4 Ra b) Serrated Finish : (250- 500 AARH) 6.3- 12.7 Ra c) Smooth Finish : (125- 250 AARH) 3.2- 6.3 Ra d) Extra Smooth Finish: ( 32- 63 AARH) 0.8- 1.6 Ra

4.9 WORKMANSHIP, FINISH AND APPEARANCE 4.9.1 All flanges, spades and spacers shall be cleanly finished and when visually inspected shall be

free from defects / imperfections such as cracks, surface flaws, laminations etc. 4.9.2 The repair of defects shall be carried out as per the codes/ standards specified in the data

sheets. 4.9.3 All flanges, spades and spacers shall be clean of rust, foreign materials, scales, oil and

grease. flanges, spades and spacers shall be provided with a suitable protective coating. Where Pipes are to be galvanized the zinc coating shall be as per codes/ standards.

4.9.4 Flanges, spades and spacers supplied for Oxygen / Chlorine services, shall be chemically

cleaned. 4.10 TESTS 4.10.1 The following tests shall be carried out on the materials / Finished Items as prescribed in


a) Visual Examination



b) Chemical composition/ Product analysis c) Other NDT tests


Standards. 4.11.2 Colour / Ink used for marking shall not contain harmful metal or metal salts that causes

corrosive attack either ordinarily or in service. 4.12 INSPECTION 4.12.1 Unless otherwise specified in the purchase order, it is the responsibility of the producer/






for approval. 4.12.5 PMI (Positive Material Identification) by alloy analyser to be carried out where specified. 4.13 EXTENT OF INSPECTION AND WITNESSING BY CLIENT/ CONSULTANT/ THIRD PARTY 4.13.1 Inspection and witnessing rate for the all points listed in the quality plan shall be as follows: Flange Sizes Sampling 1½” and smaller 10% 2” to 10” 25% 12” and above 100% 4.14 DOCUMENTATION 4.14.1 Certificate of Conformity: The Vendor shall submit a certificate of conformity with the






submitted and approved. 4.16 PREPARATION, PACKING AND FORWARDING 4.16.1 All items shall be dry, clean and free of moisture, dirt, and loose foreign materials. 4.16.2 All items shall be protected from rust, corrosion and any mechanical damage during


material, welding etc. Coating shall be easily removable with a petroleum solvent. 4.16.4 Suitable end protectors shall be provided and they shall be properly secured and tightly

attached. 5.0 RELATED DOCUMENTATION (REFERENCES ) 5.1 ASME B 16.5 : Steel Pipe Flanges and Flanged fittings 5.2 ASME B 16.47 : Large diameter Steel Flanges (NPS 26” Through NPS 60”) 5.3 API 605 : Large Diameter Carbon Steel Flanges 5.4 MSS-SP-44 : Steel Pipe Line Flanges 5.5 AWWA C-207 : Steel Pip[e Flanges for Water Works 4”-144” 5.6 BS 1560 : Circular flanges for Pipes, valves and fittings 5.7 BS 3293 : Carbon steel flanges (Over 24” Nominal size) for Petroleum Industry

5.8 BS 4504 Section 3.1: Circular flanges for Pipes, valves and fittings 5.9 ASME B1.20.1 : Pipe Threads, General Purpose (Inch) 5.10 IBR : Indian Boiler Regulations.

6.0 RECORDS

Supplier shall compile a Test report manual, comprising of all Test reports, Inspection reports, Acceptance report and shall submit along with the supplies.



Page 1 of 6

JACOBS H&G


PROCUREMENT FOR STEEL FLANGES, GASKETS


PREVIOUS DOC. NO. :


By Checked

By Approved

By


JACOBS H&G LTD PIPING STANDARD SPECIFICATION L SS 004 DATE : 4 Sept. 2002 PROCUREMENT FOR STEEL FLANGES, GASKETS PAGE: 2 OF 6 REVISION NO: 0


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 DEFINITIONS 4.0 GENERAL 4.1 GENERAL 4.2 DEFINITION OF “GASKET” 4.3 CONFLICTING REQUIREMENTS 4.4 SUPPLIER’S ALTERNATIVES 4.5 MATERIALS AND MANUFACTURE 4.6 SPECIAL REQUIREMENTS 4.7 WORKMANSHIP, FINISH AND APPEARANCE 4.8 TESTS 4.9 PRODUCT MARKING 4.10 INSPECTION 4.11 EXTEND OF INSPECTION AND WITNESSING BY CLIENT / CONSULTANT / THIRD





gaskets for Steel flanges, spades and spacers, Valves and fittings. 2.0 SCOPE The scope of the Standard Specification is to define the requirements of gaskets for flanges,

spades and spacers, Valves and fittings that the suppliers have to comply with. 3.0 DEFINITIONS

ANSI: American National Standards institute ASME: American Society of Mechanical Engineers ASTM: American Society for Testing materials API: American Petroleum Institute AWWA: American Water Works Association MSS-SP Manufacturer’s Standard Society- Standard Specification BSI: British Standards Institution BIS: Bureau of Indian Standards IBR: Indian Boiler Regulations

4.0 GENERAL 4.1 This specification, together with the Purchase requisition / Order, all documents referenced in

the Requisition/ Order and the Company’s / Client’s conditions of order covers the requirements of the supply of Gaskets for steel flanges, spades and spacers, Valves and fittings.

4.2 The term “Gasket” includes compressed fibre Gaskets, Spiral wound Gaskets, Octagonal ring

Gaskets, double -jacketed and non-metallic Gaskets. Use of Asbestos material in any form is unacceptable as per company’s HSE guidelines.


shall be referred back to the Company for Approval, at the Bid stage. 4.4 SUPPLIER’S ALTERNATIVES 4.4.1 Supplier’s shall submit the specification of the alternative for approval at the bid stage, in case the

supplier wishes to supply equivalent / suitable alternative. Alternatives will not be accepted during supply stage.

4.5 MATERIALS AND MANUFACTURE 4.5.1 Materials, dimensions and Manufacturing process of the flanges, spades and spacers shall be in

accordance with the Codes / Standards mentioned in the purchase requisition/ Order.



4.6 SPECIAL REQUIREMENTS 4.6.1 NACE-MR-01-75 shall be followed items falling under NACE category. 4.6.2 For Hydrogen and other demanding services Vendor shall include all special quality checks

and inspection in the quality Plans. 4.6.3 Special Tests would be applicable for items falling under cryogenic conditions. 4.7 WORKMANSHIP, FINISH AND APPEARANCE 4.7.1 All gaskets shall be cleanly finished and when visually inspected shall be free from defects /


sheets. 4.7.3 All gaskets shall be clean of rust, foreign materials, scales, oil and grease. flanges, spades

and spacers shall be provided with a suitable protective coating. Where Pipes are to be galvanized the zinc coating shall be as per codes/ standards.

4.8 TESTS 4.8.1 The following tests shall be carried out on the materials / Finished Items as prescribed in

applicable codes / standards. a) Visual Examination b) Chemical composition/ Product analysis c) Other NDT tests









for approval.



4.10.5 PMI (Positive Material Identification) by alloy analyser to be carried out where specified. 4.11 EXTEND OF INSPECTION AND WITNESSING BY CLIENT/ CONSULTANT/ THIRD PARTY 4.11.1 Inspection and witnessing rate for the all points listed in the quality plan shall be as follows Gasket Sizes Sampling 1 ½” and smaller 10% 2” to 10” 25% 12” and above 100% 4.12 DOCUMENTATION 4.12.1 Certificate of Conformity: The Vendor shall submit a certificate of conformity with the






material, welding etc. Coating shall be easily removable with a petroleum solvent. 5.0 RELATED DOCUMENTATION (REFERENCES ) 5.1 ASME B 16.5 : Steel Pipe Flanges and Flanged fittings 5.2 ASME B 16.47 : Large diameter Steel Flanges (NPS 26” Through NPS 60”) 5.3 API 605 : Large Diameter Carbon Steel Flanges 5.4 MSS-SP-44 : Steel Pipe Line Flanges 5.5 AWWA C-207 : Steel Pip[e Flanges for Water Works 4”-144” 5.6 BS 1560 : Circular flanges for Pipes, valves and fittings



5.7 BS 3293 : Carbon steel flanges (Over 24” Nominal size) for Petroleum Industry

5.8 BS 4504 Section 3.1: Circular flanges for Pipes, valves and fittings 5.9 ASME B1.20.1 : Pipe Threads, General Purpose (Inch) 5.10 IBR : Indian Boiler Regulations. .

6.0 RECORDS




Page 1 of 6

JACOBS H&G


PROCUREMENT OF STEEL FLANGE, BOLTING MATERIALS


PREVIOUS DOC. NO. :


By Checked

By Approved

By

0 7 Oct. 2002 6 Issue for Use SST BSD RVM

JACOBS H&G LTD PIPING STANDARD SPECIFICATION L SS 005 DATE : 5 Oct. 2002 PROCUREMENT OF STEEL FLANGE, BOLTING MATERIALS PAGE: 2 OF 6 REVISION NO: 0


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 DEFINITIONS 4.0 GENERAL 4.1 GENERAL 4.2 DEFINITION OF “BOLTING MATERIAL” 4.3 CONFLICTING REQUIREMENTS 4.4 SUPPLER’S ALTERNATIVES 4.5 MATERIALS AND MANUFACTURER 4.6 SPECIAL REQUIREMENTS 4.7 ORKMANSHIP, FINISH AND APPEARANCE 4.8 TESTS 4.9 PRODUCT MARKING 4.10 INSPECTION 4.11 EXTEND OF INSPECTION AND WITNESSING BY CLIENT / CONSULTANT / THIRD





Bolting materials for Steel flanges, Valves and fittings. 2.0 SCOPE The scope of the Standard Specification is to define the requirements of Bolting materials for

flanges, valves and fittings, that the suppliers have to comply with. 3.0 DEFINITIONS

ANSI: American National Standards institute ASME: American Society of Mechanical Engineers ASTM: American Society for Testing materials API: American Petroleum Institute AWWA: American water works Association MSS-SP Manufacturer’s Standard Specification BSI: British Standards Institution BIS: Bureau of Indian Standards IBR: Indian Boiler Regulations

4.0 GENERAL 4.1 This specification, together with the Purchase requisition / Order, all documents referenced in

the Requisition/ Order and the Company’s / Client’s conditions of order covers the requirements of the supply of Bolting material for steel flanges, Valves and fittings. a) Carbon Steel b) Alloy Steel

4.2 The term “Bolting material” includes Hexagonal headed full threaded/ partly threaded machined bolts

with washers and nut, Full length threaded studs with washers and two nuts and hexagonal headed full length threaded jack screws.





4.5 MATERIALS AND MANUFACTURE 4.5.1 Materials, dimensions and Manufacturing process of the bolting materials shall be in accordance with

the Codes / Standards mentioned in the purchase requisition/ Order.




4.6.1 NACE-MR-01-75 shall be followed items falling under NACE category. 4.6.2 For Hydrogen and other demanding services Vendor shall include all special quality checks

and inspection in the quality Plans. 4.6.3 Special Tests would be applicable for items falling under cryogenic conditions. 4.7 WORKMANSHIP, FINISH AND APPEARANCE 4.7.1 All bolting materials shall be cleanly finished and when visually inspected shall be free from

defects / imperfections such as cracks, surface flaws, laminations etc. 4.7.2 The repair of defects shall be carried out as per the codes/ standards specified in the data

sheets. 4.7.3 All bolting materials shall be clean of rust, foreign materials, scales, oil and grease. flanges,

spades and spacers shall be provided with a suitable protective coating. Where bolts are to be galvanized the zinc coating / cadmium coated, it shall be as per codes/ standards.

4.8 TESTS 4.8.1 The following tests shall be carried out on the materials / Finished Items as prescribed in

applicable codes / standards. a) Visual Examination b) Chemical composition/ Product analysis c) Other NDT tests









for approval.



4.11 EXTEND OF INSPECTION AND WITNESSING BY CLIENT/ CONSULTANT/ THIRD PARTY 4.11.1 Inspection and witnessing rate for the all points listed in the quality plan shall be decided at

the time of placement of firm purchase order. 4.12 DOCUMENTATION 4.12.1 Certificate of Conformity: The Vendor shall submit a certificate of conformity with the






material, welding etc. Coating shall be easily removable with a petroleum solvent. 5.0 RELATED DOCUMENTATION (REFERENCES ) 5.1 ASME B 16.5 : Steel Pipe Flanges and Flanged fittings 5.2 ASME B 16.47 : Large diameter Steel Flanges (NPS 26” Through NPS 60”) 5.3 API 605 : Large Diameter Carbon Steel Flanges 5.4 MSS-SP-44 : Steel Pipe Line Flanges 5.5 AWWA C-207 : Steel Pipe Flanges for Water Works 4”-144” 5.6 BS 1560 : Circular flanges for Pipes, valves and fittings 5.7 BS 3293 : Carbon steel flanges (Over 24” Nominal size) for Petroleum Industry 5.8 BS 4504 Section 3.1: Circular flanges for Pipes, valves and fittings 5.9 ASME B1.1 : Unified Inch Screw Threads



5.10 ASME B 18.2.1 &

B 18.2.2 : Square or Hexagonal headed Bolts & Nuts 5.11 IBR : Indian Boiler Regulations.

6.0 RECORDS




Page 1 of 8

JACOBS H&G


PROCUREMENT OF METALLIC EXPANSION JOINTS


PREVIOUS DOC. NO. : None


Checked By

Approved By


JACOBS H&G LTD PIPING STANDARD SPECIFICATION L SS 006 DATE : 7 Octt. 2002 PROCUREMENT OF PAGE: 2 OF 8 METALLIC EXPANSION JOINTS REVISION NO: 0


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 DEFINITIONS 4.0 METHODS 4.1 DESIGN 4.2 FABRICATION 4.3 TESTING AND INSPECTION 4.4 4.5 4.6 VACCUM TEST 4.7 SPRING RATE TEST 4.8 MATERIAL TEST 4.9 LIFE CYCLE TEST 4.10 SUPPLEMENTARY WORL EXAMINATION 4.11 WITNESSING OF TEST 4.12 MARKING – COMPANY’S IDENTIFICATION 4.13 PROTECTION, PACKING AND TRANSPORTATION 5.0 RELATED DOCUMENTATION ( REFERENCES ) 6.0 RECORDS 7.0 ATTACHMENTS / APPENDICES 7.1 DATASHEET FORMAT FOR BELLOWS 7.2 CHECK SHEET FOR BELLOWS



1.0 PURPOSE The purpose of this Standard Specification is to establish methods for procurement of metallic

expansion joints used in piping systems. 2.0 SCOPE

This Standard Specification defines the methods for the intended purpose of procurement, design, supply of metallic expansion joints. Expansion joints used in Equipments, Vessel shells, Heat Exchanger shells are not included in the scope of this Standard Specification.

3.0 DEFINITIONS Vendor / Supplier / Manufacturer: Successful Bidder Company : Jacobs H&G Pvt. Ltd.

EJMA : Expansion Joints Manufacturer’s Associate Inc. ASME : American Society for Mechanical Engineers.

4.0 GENERAL 4.1 DESIGN 4.1.1 Design of expansion joints shall be as per EJMA and ASME Standards and Codes. 4.1.2 Any conflicting requirements between this Standard Specification and related specification data sheets,

shall be immediately referred to the company for classification, prior to design, supply / procurement of materials.

4.1.3 Where a Vendor / Supplier finds a suitable alternative to that specified, without comprising on the

working conditions, quality and other requirements specified in the data sheets, shall submit the alternative in writing to the company for approval at the Bid stage.

4.1.4 When straight 18/8 stainless steels are used titanium stabilised is preferred for operating temperatures

of 7000C (13000F) and above. Unstabilised steels are acceptable if the carbon content is restricted to 0.04% max.

4.1.5 External sleeves or shrouds shall be removable to allow internal inspection. 4.1.6 Steam out connections will be required for same services, this will be noted on the data sheets. Such

connections shall be provided at suitable locations except on convolutions of the thin expansion joints. 4.1.7 Internal sleeves or liners shall not be designed to function as internal axial guides in axial movement

expansion joints. 4.1.8 When internal sleeves are required the supplier shall mark permanently on the unit, the direction of

flow. 4.1.9 Presettling of expansion joints is not acceptable unless, otherwise specified in the data sheets. 4.1.10 Spring rate indicated in the data sheets are maximum values. Vendors shall keep the values below the

specified values. In case it is not possible, the same shall be referred to the Company for approval. 4.1.11 Expansion joints that are working under vacuum conditions, shall be designed as per EJMA clause C.4

Bellows design – Circular expansion joints; considering the effects of “external pressure”. For such



expansion joints pressure thrust absorbing member (Tie-rods /Limit rods / Hinges / Gimbals) shall be evaluated for an internally pressurised system. However the effects of compression loading on slender member (viz. Long tie rods / limit rods) must be considered.

4.1.12 Number of tie-rods, lugs, their sizes shall be decided by the Manufacturer / Supplier / Vendor taking

into consideration all aspects of adequacy from the point of strength of the expansion joint for its proper working during operating conditions.

4.1.13 Wherever limit rods / tie rods are specified for the expansion joints, due consideration in Design /

Manufacturing shall be given for the pressure thrust and pipe loads. 4.1.14 Wherever Butt welded ends for expansion joints are specified along with limiting tie-rods,

manufacturer shall design the thickness of the pipe piece, so as to withstand forces and moments transferred to the pipe. The pipe schedule / thickness specified in the data sheet is for the main piping. The same thickness shall not be used before proper design checks. Pipe Butt weld ends shall be as per ASME B 16.25.

4.1.15 Wherever flanged end connections are specified, the manufacturer shall provide flanges to ASME B

16.5 unless otherwise specified. 4.2 FABRICATION 4.2.1 Welding of dissimilar material directly on end pipe piece or intermediate spool price of the

expansion joint shall be carried out only after providing a proper pad plate. 4.3 TESTING & INSPECTION 4.3.1 Vendor shall submit his quality assurance plan for approval. Vendor shall proceed for

fabrication only after getting approval of the same. 4.3.2 Vendor shall submit all heat treatment procedures when asked for. 4.3.3 Following tests shall be carried out as per the requirements laid down by EJMA and ASME

a. Visual Dimensional Test b. Leak Test (optional), if leakage rate is specified.

4.3.4 Non-Destructive Testing

a. Radiographic Examination ( spot examination, min.) b. Liquid Penetration Examination

4.3.5 Pressure Test

The test pressure shall be as per the value mentioned in the Technical Data Sheets, giving due consideration to temperature connection factor as per EJMA.

4.3.6 The following guidelines shall be followed for pressure testing of various types of expansion joints.

a. Axial expansion joints (without limit rod) : Axial expansion joints shall be tested

hydrostatically, with ends fixed (restrained) properly by means of rigid fixtures, so that the pressure thrust during testing can be absorbed by the restraints, without causing any deformation at the constructions of the expansion joints.



b. Axial Expansion Joints (with limit rods) / Lateral Expansion Joints (with tie rods) / Expansion Joints (with Hinges / Gimbals) : During the pressure testing of the above type of expansion joints, the ends shall be blanked, but shall not be held between fixed restraint. If required expansion joints can be suitably guided for maintaining its alignment during testing.

4.4 Expansion joints shall be tested in such a way that the tie rods, limit rods, Hinges / Gimbals

are also subjected to the internal loading due to pressure thrust. This method of hydrostatic testing will indicate the presence of leakage, if any. This will also verify structural integrity of the item being tested as well as the stability of the expansion joints.

4.5 Large expansion joints shall be provided with additional supports to take care of water load

during hydrostatic testing. 4.6 VACUUM TEST 4.6.1 When full vacuum test is asked for, the expansion joint, shall be subjected to test at 730 mm

of flange vacuum. All testing arrangement shall be same as mentioned in clauses 4.3. 4.7 SPRING RATE TEST 4.7.1 Spring rate mentioned in the data sheet is the maximum. Vendor shall consider this in the

design. In case if not possible to provide the required spring rate, Vendor shall submit the calculation.

4.7.2 Axial spring rate test shall be performed on all types of expansion joints. 4.8 MATERIAL TEST 4.8.1 Mechanical tests, chemical analysis test on materials, which become a permanent part of the

expansion bellow shall be carried out.

4.9 LIFE CYCLE TEST 4.9.1 Vendor shall guarantee the working of the expansion joints for 7000 life cycles. 4.10 SUPPLEMENTARY WELD EXAMINATIONS 4.10.1 Any supplementary weld inspection and test, will be specified in the data sheet. 4.11 WITNESSING OF TEST 4.11.1 This activity shall be clearly identified in the Vendor’s quality plan and the same shall be

submitted for approval. 4.11.2 All test identified for witnessing in the quality plan shall be witnessed by the Company’s

inspector / Client’s inspector / Third party inspector. 4.12 MARKING – COMPANY’S IDENTIFICATION



4.12.1 The Company’s identification shall be the project no., the item tag no. / S.M. no. given in the

datasheet. 4.12.2 Each expansion joint shall be provided with a non-corrosive metal tag by embossing the

Company’s identification. 4.12.3 Each expansion joint must be permanently marked with the flow direction wherever

appropriate. 4.13 PROTECTION, PACKING AND TRANSPORTATION 4.13.1 Generally, high alloy or stainless steel portion of the expansion joint shall be free of paint of

any kind. 4.13.2 All assemblies shall be protected against corrosion and mechanical damage. 4.13.3 All joints shall be clearly labelled with picture and notes for proper handling. 4.13.4 Should any expansion joint contain defects which are revealed during shop fabrication,

installation or whilst under normal test conditions, they will be rejected and a detailed report submitted to the supplier, who shall immediately replace them with bellows complying with the specification.

4.13.5 Should any expansion joint or delivery be found damaged or in any way not in compliance

with the terms of this specification, they will be rejected and a derailed report submitted to the Vendor who shall immediately replace them with sand bellows complying with the specification.

5.0 RELATED DOCUMENTATION (REFERENCES )

EJMA Std. : Expansion Joint Manufacturer’s Association Inc. ASME Sec. VIII Div. : American Society Mechanical Engineers.

6.0 RECORDS Vendor shall compile all stage wise test certificates, certified approvals, from design stage

upto delivery. The same shall be submitted in a file item wise. Vendor shall update all his engineering documents to “As-Built” stage for submission.




ATTACHMENT 7.1

DATA SHEET FOR METALLIC EXPANSION JOINTS

12

3a3b3c45

6a6b6c7a7b7c7d8a8b8c8d8e9a9b9c9d9e

10a10b10c10d10e111213

14a14b14c15a15b15c16

17a17b17c17d17e17f17g

192021

21a21b21c21d21e21f21g21h

Appd. By DateDateDate Chkd.byRev. No. Prpd. ByData Sheet for Metallic Expansion Joints

Data Sheet No. UU-VVVV-XX/ L.YY/ZZZZ/A_ProjectClient

QtySheet 1 of __

lateral (kg/mm)Angular ( kg/mm/deg.)

Temperature

S.M. No.Project No. BC-VVVV

Axial (kg/mm)

Materials of Construction CoverPipe SpecificationFlange Specification

Rods (Tie/ Limit/ Control)

overall (mm)

Design Pressure (Kg/cm2g)

I.D (In.)

Flange Standard : ASTM B16.5/ BS_____/ Din______

Spring Rate Limitations

Thickness (In.)

Max./ Min. (0C)Installation (0C)

Fluid InformationMedium Gas/ LiquidVelocity (m/ sec)Flow Direction

Nominal Size/I.D/ O.D (In./ mm)Expansion Joint Type

Design (0C)Test Pressure (kg/cm2g)

No. of CyclesAxial Compression (mm)Axial Extension (mm)Lateral (mm)Angular (deg.)No. of CyclesBellowsLiners

Outside Dia. (In.)

Pantographic LinkageAnchor Base (Main/ Intermediate)

Dimensional LimitationsInside Dia. (In.)

Installation Position: Horizontal / Vertical

Attach.

Design Code RequirementsQuality Assurance Requirements

Bellows Weld NDE

Long Seam

Vibration Amplitude/ Frequency

FacingO.D (In.)

Spec

ial F

lang

e D

esig

n

No. Of Holes

Sin

gle

Exp

n.

Join

t

Sin

gle

Exp

n.

Join

t W/ T

ie

Rod

s

Dou

ble

Exp

n.

Join

t w/

inte

rmed

iate

A

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r

Uni

vers

al E

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Jo

int w

/ove

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tie ro

d

Uni

vers

al E

xpn.

Jo

int w

/sho

rt tie

ro

d

Pre

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ed E

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Pre

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Inlin

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ress

ure

bala

nced

Exp

n.

Join

t

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tG

imba

l Exp

n.

Join

t

Uni

vers

al

Pen

togr

aphi

c E

xpn.

Joi

ntOperating Fluctuations

Pipe NDE

Partial Data Requirements

Axial Compression (mm)Axial Extension (mm)Lateral (mm)Angular (deg.)

Size of HolesHole Orientation

B.C.Diameter(In.)

Maximum Installation Movement

Maximum Design Movements

Axial Compression (mm)Axial Extension (mm)Lateral (mm)Angular (deg.)

Form No. f1-L006.xls Applicable Work Instruction L SD 006

JACOBS H&G

f1-L006.xls, Rev. 0

Note : Please double click on icon to display document



ATTACHMENT 7.2

CHECK SHEET FOR BELLOWS

DOC. No. SHEETDRG. No.APPD. BY

Project No. CHKD. BYProject Location PRPD. BYProject Title DATEClient REV.

GENERAL

Welding Details shownFlange Deails shown

Data Sheet completed by vendorTag No. Checked

Unit weight shownLine No. shown

Deviations from data sheet Identified and informed vendor

DRAWINGS

Internal sleeve details shownProtective cover details shown

Tie rods/ Limit rods/ lugs/ brackets/ Hinges/ gimbals Details shown

Convolution details shown

Material of Construction as per Data sheet, if not alternate acceptable

Test Pressure +ve and/ or vac.

DESIGN CALCULATIONS

Design Pressure +ve and/ or vac.

Overall and individual Dimensions of the bellow and other parts shown

Design TemperatureAxial/ lateral movementsAxial/ lateral / angular sprinf ratesDesign Life cycles

Fatigue LifeColumn instabilityAxial Spring rate

Membrane Stress due to internal pressure

Membrane/ Bending Stress due to deflection

Angular spring rateTie rods and Lug design

Lateral Spring rate

External pressure (Vacuum) design

Stress outputs checked for bellows

STRESS

Isometric checked

Supports (Anchors/ guides etc) checked from isometrics

Not AcceptableYES NO Remarks1

PIPINGCHECKLIST FOR BELLOWS

A 0

JACOBS H&G

f2-L006.xls, Rev. 0

Note : Please double click on icon to display document


Page 1 of 4

JACOBS H&G


TEST CERTIFICATE REQUIREMENTS FOR PIPING ITEMS AND COMPONENTS


PREVIOUS DOC. NO. :


By Checked

By Approved

By


JACOBS H&G LTD PIPING STANDARD SPECIFICATION L SS 007 DATE : 7 Oct. 2002 TEST CERTIFICATE REQUIREMENTS FOR PAGE: 2 OF 4 PIPING ITEMS AND COMPONENTS REVISION NO: 0


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 DEFINITIONS 4.0 GENERAL 4.1 CONFLICTING REQUIREMENTS 4.2 CERTIFICATES 4.3 SUPPLY OF CERTIFICATES 4.4 DOCUMENTATION 4.5 ACCEPTANCE 5.0 RELATED DOCUMENTATION (REFERENCES) 6.0 RECORDS 7.0 ATTACHMENTS / APPENDICES



1.0 PURPOSE

The purpose of this Standard Specification is to establish the type of certificates that Manufacturers/Vendors/ Suppliers have to submit for Piping items and components

2.0 SCOPE

The scope of the Standard Specification is to define the requirements of various types of Test certificates and guarantee certificates that are to be submitted for Piping items and components generally designed in accordance to various National and International Standards.

3.0 DEFINITIONS

ANSI: American National Standards institute ASME: American Society of Mechanical Engineers ASTM: American Society for Testing materials API: American Petroleum Institute MSS-SP Manufacturer’s Standard Specification BSI: British Standards Institution BIS: Bureau of Indian Standards IBR: Indian Boiler Regulations

4.0 GENERAL

This specification, together with the Purchase requisition / Order, all documents referenced in the Requisition/ Order and the Company’s / Client’s conditions of order covers the requirements of various certificates that are to be submitted for the Piping items and components listed below: a) Pipes b) Fittings c) Flanges d) Valves e) Bolting f) Gaskets g) Special Piping Components



4.2 CERTIFICATES

4.2.1 Type ‘A’ - (General Compliance): A formal Manufacturers / Suppliers guarantee certificate, certifying that components and items forming components all fully comply with the specifications and requirements stated in the purchase order and that, where applicable, radiographic and other non-destructive examinations have been satisfactorily applied.



4.2.2 Type ‘B’ – (Certified Chemical Analysis, Mechanical & Heat Treatment): A certified statement from Manufacturers / Suppliers giving the results of chemical analysis tests, mechanical tests and heat treatment carried out in compliance with specifications and requirements of the purchase order. Also, where applicable, confirmation that radiographic and other non-destructive examinations have been satisfactorily applied.

4.2.3 Type ‘C’ – (Certified pressure Tests): A certified statement from Manufacturers / Suppliers

giving the results of Pressure test ( e.g. Hydrostatic tests, Pneumatic tests etc.,) carried out in compliance with specifications and requirements of the purchase order.

4.3 SUPPLY OF CERTIFICATES 4.3.1 The type and quantities of certificates required shall be as mentioned in the Vendor

Document Requirements. (Refer to Attachment 7.5 of SOP 108) 4.4 DOCUMENTATION 4.4.1 Certificate of Conformity: The Vendor shall submit a certificate of conformity with the

standards specified in the Purchase order. 4.4.2 Materials Certificate: The Vendor shall submit all material certificates pertaining to the

results of chemical analysis, mechanical tests, Non destructive tests and Acceptance certificates, carried out in accordance with the requirements of the codes/ standards, specified in the purchase order.


submitted and approved. 5.0 RELATED DOCUMENTATION (REFERENCES )

LSS 001: Procurement of Steel Pipes LSS 002: Procurement of Steel Pipe Fittings LSS 003: Procurement of Steel Flanges, Spades and Spacers LSS 004: Procurement of Steel Flange, Gaskets LSS 005: Procurement of Steel Flange, Bolting Material LSS 006: Procurement of Metallic Expansion Joints

6.0 RECORDS Supplier shall compile a Test report manual, comprising of all Test reports, Inspection reports,

Acceptance report and shall submit along with the supplies. 7.0 ATTACHMENTS / APPENDICES Refer ‘Table of Contents’


Page 1 of 6

JACOBS H&G


PROCUREMENT OF SUPPORTS




Checked By

Approved By

0 24 Sep, 2002 6 Issue for Use SST BSD RVM

JACOBS H&G LTD PIPING STANDARD SPECIFICATIONS L SS 009 DATE : 24 SEP, 2002 PROCUREMENT OF PIPE SUPPORTS PAGE: 2 OF 6 REVISION NO: 0


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 DEFINITIONS 4.0 GENERAL 5.0 RELATED DOCUMENTATION ( REFERENCES ) 6.0 RECORDS 7.0 ATTACHMENTS / APPENDICES INDEX AND ATTACHMENTS OF PIPING SUPPORT STANDARDS



1.0 PURPOSE

The purpose of this Standard Specification is to establish the requirements for procurement of Pipe Supports, which are of mainly bought items.

2.0 SCOPE

The scope of the Standard Specification is to define the requirements of fabrication and supply of Pipe supports (Bought Items only), which suppliers have to comply with.

3.0 DEFINITIONS

ANSI: American National Standards institute ASME: American Society of Mechanical Engineers ASTM: American Society for Testing materials API: American Petroleum Institute MSS-SP Manufacturer’s Standard Society-Standard Practice BSI: British Standards Institution BIS: Bureau of Indian Standards IBR: Indian Boiler Regulations

4.0 GENERAL

This specification, together with the Purchase requisition / Order, all documents referenced in the Requisition/ Order and the Company’s / Client’s conditions of order covers the requirements of the supply of Pipe Supports listed below: a) Carbon Steel b) Alloy Steel c) Austenitic Stainless Steel d) Galvanised Iron (G.I)





4.3 MATERIALS AND MANUFACTURE 4.3.1 Materials, dimensions and Manufacturing process of the Pipes shall be in accordance with the

Codes / Standards mentioned in the purchase requisition/ Order. 4.4 INTERGRANULAR CORROSION TEST (IGC TEST) 4.4.1 Where IGC test is specified it shall be in accordance with ASTM A262, Practice E.



4.5 SPECIAL REQUIREMENTS 4.5.1 For Hydrogen and other demanding services Vendor shall include all special quality checks

and inspection in the quality Plans. 4.5.2 Special Tests would be applicable for items falling under cryogenic conditions. 4.5.3 Wherever bevelled ends are specified it shall confirm to ASME B16.25. Threaded ends shall be as per

ASME B1.20.1 4.6 WORKMANSHIP, FINISH AND APPEARANCE 4.6.1 All supports shall be cleanly finished and when visually inspected shall be free from defects /


sheets. 4.6.3 All supports shall be clean of rust, foreign materials, scales, oil and grease. Supports shall be

provided with a suitable protective coating. Where supports are to be galvanized the zinc coating shall be as per codes/ standards.

4.6.4 Fabrication of Support hanger rods, eye bolts and clamps shall not by welding. 4.7 TESTS 4.7.1 The following tests shall be carried out on the materials / Finished Items as prescribed in


a) Visual Examination b) Chemical composition/ Product analysis c) Mechanical Tests


d) Other NDT tests 4.8 TESTING & SETTING OF SPRING SUPPORT UNITS 4.8.1 Spring Units shall be tested by loading each unit with the installed load and then by either

decreasing to the operating load. The actual spring extension or compression shall be checked against the net deflection given on the spring data sheet.

4.8.2 After testing, the unit shall be pre-set at installed load as given in the spring data sheet. 4.8.3 Any deviation to the spring ’K’ value mentioned in the data sheet shall be intimated

accordingly for approval. Spring units have different ‘K” values shall not be despatched till approval is availed.

4.8.4 Spring units shall be marked with instructions regarding installation, operation and protection

of the spring during Hydrostatic testing.











for approval. 4.11 EXTENT OF INSPECTION AND WITNESSING BY CLIENT/ CONSULTANT/ THIRD PARTY 4.11.1 Inspection and witnessing rate for all the points shall be listed in the quality plan.

4.12 DOCUMENTATION 4.12.1 Certificate of Conformity: The Vendor shall submit a certificate of conformity with the





4.14 PREPARATION, PACKING AND FORWARDING 4.14.1 All items shall be dry, clean and free of moisture, dirt, and loose foreign materials. 4.14.2 All items shall be protected from rust, corrosion and any mechanical damage during


material, welding etc. Coating shall be easily removable with a petroleum solvent.



4.14.4 Suitable End protectors shall be provided and they shall be properly secured and tightly

attached. 5.0 RELATED DOCUMENTATION (REFERENCES ) 5.1 ASME B 16.25 : Butt welding Ends 5.2 ASME B 36.10 : Welded and Seamless Wrought Steel Pipe 5.3 ASME B 36.19 : Stainless Steel Pipe 5.4 ASME B1.20.1 : Pipe Threads- General Purpose (Inch) 5.5 API : American Petroleum Institute 5.6 IBR : Indian Boiler Regulations. 5.7 MSS-SP : Manufacturer’s Standard Society Standard Specification

6.0 RECORDS 6.1 Supplier shall compile a Test report manual, comprising of all Test reports, Inspection reports,

Acceptance report and shall submit along with the supplies. 7.0 ATTACHMENTS / APPENDICES Refer ‘Table of Contents’

\\nmumfil01\construction\44 mm 2800 mrpl\mechanical works\tender\section no. 3 technical documentation\zss003.doc 08/17/2009 15:23

Page 1 of 13

STANDARD SPECIFICATIONS FOR

EQUIPMENT ERECTION

DOCUMENT NO : Z SS 003


Rev.No. Issue Date Pages Rev Description Prepared

By

Checked

By

Approved

By

0 02.11.2001 13 Issue for use. MRAK CLS AGG

1 2 August 2004 13 Cover page revised ALB SGR AGG

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DATE: 2 August 2004 SPECIFICATION NUMBER: Z SS 003 PAGE: 2 OF 13 STANDARD SPECIFICATION FOR EQUIPMENT ERECTION REVISION NO: 1

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TABLE OF CONTENTS 1.0 PURPOSE (INTRODUCTION)

2.0 SCOPE

3.0 ERECTION OF STATIC EQUIPMENT 4.0 ERECTION OF ROTARY EQUIPMENT AND MACHINERIES 5.0 SPECIAL INSTRUCTIONS TO CONTRACTOR

6.0 DELIVERY STORAGE AND CUSTODY OF EQUIPMENTS / MACHINERIES

7.0 HANDLING, TRANSPORTING AND ERECTION 8.0 GROUTING

9.0 FINAL CHECKING AND FINISHING

10.0 TRIAL RUNS OF EQUIPMENT AND MACHINERY 11.0 OWNERS / CONSULTANTS SCOPE OF SUPPLY

12.0 CONTRACTORS SCOPE OF SUPPLY

13.0 SYSTEM TEST / START-UP (PRECOMMISSIONING)

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SPECIFICATION NUMBER: Z SS 003 DATE: 2 August 2004 STANDARD SPECIFICATION FOR EQUIPMENT ERECTION PAGE: 3 OF 13 REVISION NO: 1

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1.0 PURPOSE (INTRODUCTION)

The purpose of this specification is to define the Construction requirements of equipment erection.

2.0 SCOPE

2.1 This specification supplements the applicable code requirements / data sheets / drawings and specifications for fabrication, erection, inspection, testing, commissioning of equipments.

2.2 Engineering drawings/ specifications data sheets shall take precedence over this specification if there are any conflicting clauses.

3.0 ERECTION OF STATIC EQUIPMENTS 3.1 SCOPE OF WORK 3.1.1 The work under this specification covers transportation of vessels, exchangers, heaters,

drums, condensers, tanks filters, etc., from Owners stores / storage point, erection on foundation furnished by Owner, leveling, aligning and grouting including assembly and fixing of other internal / external fittings and completing the vessels, exchangers, filters, drums etc., in all respects for commissioning the plant all as per drawings, documents and specifications and as per instructions of the Owner.

The Contractor shall study related equipment layout, steel structural drawing, piping layout,

foundation drawing, underground piping and equipment drawing before starting any installation work. Grouting of equipment and machineries shall be carried out by the Contractor.

3.1.2 Approximate total weights are given in the schedule of rates. Approximate empty weight, elevation at which the vessels, columns etc., are to be erected are given in the equipment list to the extent possible. Rigging procedures / installation schemes for all major lifts and all other equipment maximum crane capacity shall be submitted by the Contractor to the Owner for approval prior to installation of equipment. However, approval to rigging procedure proposed by the Contractor shall not relieve the Contractor from his responsibility.

3.1.3 For details of equipments refer relevant project equipment list. 3.2 ERECTION

3.2.1 Before taking up the equipment for erection, the Contractor shall check the orientation of the nozzles, centre lines, elevations, length and position of anchor bolts spacing and size of bolt pockets on foundation, the diameter of anchor bolting and diameter of bolt hole in the equipment base plate with respect to piping and other applicable drawings and also with physical measurement of the equipment wherever required, and discrepancies if any shall be brought to the notice of Owner. Providing enlarging of the holes on the brackets and / or skirts of the equipment during installation shall be carried out by the Contractor at no extra cost to the Owner. Prior to installation of equipment on foundations that top of concrete foundation shall be thoroughly cleaned with air, water and dried.

3.2.2 Normally all concrete pedestals shall have bolt holes pockets as required. However, where opening for introduction of grouting materials has not been provided by Owner, the Contractor shall drill the required holes at approved rates before installation of equipment. Location and dimensions of foundations shall be checked with respect to general layout plans, civil floor layouts and other drawings well in advance before starting of actual erection work. The size, number and locations of foundation bolt pocket or holding down bolt holes shall be checked in advance by the Contractor and discrepancy if any, shall be brought to the notice of the Owner. Foreign matter if any, in the foundation bolt pocket, shall be completely removed by the Contractor. The rough foundation surface shall be chipped 5-6mm or more and the packers

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which need to lay in advance shall be levelled at the same level. Blue matching will be carried out wherever required at no extra cost by the Contractor.

3.2.3 When the Contractor intends to carry out installation work by using truck crane, chain block, or

by any other lifting devices the following to be checked thoroughly before erection.

i. Rated load, working radius. Hoisting from height and safety factor of truck crane. ii. Conditions of ground for safe planning work. iii. Chain block used for installation shall withstand overloading and slant slinging to a

certain degree. iv. Strength of beams and girders on which chain block is hung.

When the equipment to be installed on the steel structure, necessary arrangements shall be

made with frame builders so that beams, floors, railings, etc., are built in a removable way if so required or built after the installation of the equipment. It shall be recommended that the beams for swing stoppers of long equipment are installed to match setting holes of the equipment after installation and centering.

3.3 LEVELING, CENTERING AND ALIGNMENTS 3.3.1 The Contractor shall select and provide size and number of packets / shims and insert them

on both sides of each foundation bolt and at such places where load is expected. More than three layers of packers shall not be used. For line adjustment, shims shall be used. Packers shall be black steel plate free from surface scales, unevenness, injurious burrs etc. Wherever possible flat packers shall be used. The leveling and centering should be done by using two taper packers which shall be ultimately fastened together by tack welding. Shims and packers shall be spaced to enable mortar filling in the bolt hole without trouble. All equipment shall be properly levelled and plumbed where manufacturer has provided levelling pads or marks the same shall be used as a guide.

3.3.2 Centering / alignment of al vertical equipment like towers, vessels, heat exchangers (vertical

type) which are taller than 6M in height shall be done with the help of theodolite. Centers shall be measured at more than two points on the top and bottom with transits at two positions forming 90

0 approximately. The center line shall be 10mm wide and shall be marked by the

equipment manufacturer. Alignment / centering of small equipment shall be done with the help of bob weights. Accuracy for centering shall be as under.

i. For towers containing trays - within + 0.5mm per 1M. ii. For vessels and heat exchangers - within + 1mm per 1M.

However, in case of special / critical equipment’s, manufacturers / owners recommendations

should be followed. Horizontal equipment like vessels, heat exchangers (horizontal type) etc., leveling shall be

measured with water level on the datum point (punched) at both ends of the equipments. Where no datum points are available, leveling shall be measured by placing of 1/10 accuracy on the nozzle (largest diameter preferable) of the equipment. All horizontal vessels shall be checked for level across machined face of nozzle flange with precision level.

In case where nozzle is of small diameter of inclined and cannot be used for measuring the

level by use of a level, the canter line of equipment shall be measured with theodolite. Alignment / leveling of equipment with agitators shall be done with great care. Unless

otherwise specified the accuracy shall be 5/100 to 10/100 on the rotary shaft.

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It will be Contractors responsibility for marking arrangements for all measuring instruments to

be used for centering and leveling purpose shall be as but not limited to transit, Y level, level gauge (accuracy 1/10 - 1/100) bob, scale etc.

The Contractor shall also carry out the assembly, erection, leveling and alignment of all types

of trays, downcomers, and seal pans, wieplates, baffles, demisters, and other internal fittings. Work shall be carried out as per manufacturers standard / specification which shall be made available to the contractor at the time of erection.

Tolerances on assembly of internals like demisters, and other parts shall be specified by

manufacturers / Owner. All proprietary equipment shall be installed as per equipment layout and nozzle orientation

issued by the Owner and considering manufacturers manuals, installation instruction, catalogues / drawings and as per any specific directions of the Owner. Some of the equipment and machineries may be supplied in dismantled condition.

The Contractor shall :

a) Check contents with packing list. b) Check for any damage. c) Check for any abnormality d) Check for rusting or corrosion e) Check for protectors, reinforcing material etc., which must beretained till end of erection.

Should there be any damage or discrepancy the Contractor shall immediately inform the

Owner for taking necessary action. Exchanger shall be set at level and square so that pipe connections can be made without

strain. While setting on foundation bolts, bolts of one end shall be kept loose to allow free expansion of shell. Slotted holes are provided in supports to achieve this.

All items of equipment shall be properly oriented and the fabricated parts and connections

should be installed as indicated on the drawings. Equipment to be installed on steel structural frame shall be levelled by use of shims, packers and wedges.

Equipment to be installed on concrete foundations shall be placed on the foundations together

with the base plate and the bolts connecting the equipment to the base plate slackened. The base plate shall be leveled on concrete foundations by putting wedges between the base

plate and concrete foundations initially and subsequently replacing the wedges with concrete grout. All the wedges shall be removed after the concrete grout is set. Equipments shall be placed level on the base plate and bolts connecting the equipment and base plate tightened. If necessary inserting shims in between. Setting of anchor bolts shall be checked with the latest revision of manufacturers drawings / or other applicable drawings.

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4.0 ERECTION OF ROTARY EQUIPMENT AND MACHINERIES 4.1 SCOPE OF WORK The work under this specification covers transportation of machinery / equipment etc., from

Owners stores / storage point to worksite, assembling of sub-assemblies / parts, erection on foundation furnished by Owner, leveling, aligning and grouting, of equipment for trial runs, carrying out no load trial runs as per instructions of Owner and handover in fit condition for the start up of the plant.

Defects due to Contractors fault noticed ruing trail runs shall be rectified by him. Schedule of

quantities given at the end of this chapter indicate approximate number dimensions and weights of the equipments.

The work shall in all respect be carried out in accordance with good present day engineering

practice and to the satisfaction of Owner. The Contractor shall study the respective specification given in this document for the work which he is required to carry out in this plant. The Contractor shall also study the related equipment layout, steel structure, piping layout foundation drawing, underground piping and equipment drawing before starting installation work.

4.2 ERECTION AND ALIGNMENT 4.2.1 Erection / alignment of all machineries shall be carried out by experienced fitters and

technicians. Contractor shall employ experienced erection supervisors and crews who have done similar type of jobs.

4.2.2 Proper sequence for assembly erection / installation and trial runs shall be adhered to in

accordance with drawings, catalogue and manufacturers instruction. 4.2.3 Couplings of machinery received with drive in assembled condition, shall be removed by the

Contractor, if required and alignment shall be checked. Realignment if required shall be done before recoupling. In case where the drive unit and driven unit arrive separately, they are to be assembled at site, wherever necessary the Contractor shall mark and drill holes including tapping the box plate for fixing motors, fixing of coupling on shaft, if necessary file / scrap the keys and key ways for fixing coupling on shafts, dowelling including providing dowel pins for retaining the alignment of machineries. All operations mentioned in this para shall be carried out by the Contractor within the unit rates quoted by him. However, Owner shall provide the machining facility if required.

4.2.4 Cooling water flushing and other piping connections connected with equipment / machineries

and its ancillaries shall be installed by the Contractor as per drawing, specification and instruction of Owner.

4.2.5 Items such as sight glasses, level gauges, etc., shall be installed by the Contractor as part of

equipment erection work and no separate payment will be made for the same. 4.2.6 After initial alignment the equipment shall be properly grouted. Grouting shall be carried out

as per the specification and insurrection of Owner. Shims shall be taken out and cavity formed shall be grouted wherever grout holes are provided in the base plates, grout shall be filled through them also.

4.2.7 To ensure that piping connections do not induce any undue stresses on the equipment, the

alignment shall be checked by the Contractor again, after the piping has been connected. After making necessary corrections on the piping, if any, realignment shall be done by the Contractor and he will ensure that no undue stresses are induced in the equipment.

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5.0 SPECIAL INSTRUCTIONS TO CONTRACTOR Contractor in addition to general specifications for erection as outlined in 3.0 & 4.0 shall follow

the following special instructions. 5.1 PUMPS, BLOWERS ETC. 5.1.1 Pumps shall be supplied to the Contractor for erection either completely assembled, coupled

to the drive and both mounted on a common based plate or in three individual parts as pump assembly, motor and base plate, or as pump assembly and motor mounted on separate base plate. The pumps shall be erected on foundation given by Owner and levelled with shims and wedges with the help of precision levels and other instruments. The pump and the driver and reducing gear, if any, shall be then coupled and centering / alignment.

Initially centering shall be done and centering shall be made by placing a level of 1/10

accuracy on the pump base or nozzle. Grouting of foundation bolts to be done after temporary centering. 5.1.2 First Centering First centering shall be done after the anchor is fixed. Shaft center deflection and inclination

shall be measured at four point on the top, bottom. Left and right side by way of turning, the coupling in single or both with dial gauge or clearance gauge etc.

After the first centering is over the space between the base and foundation shall be grouted. 5.1.3 Second Centering Second centering / final alignment shall be done after all piping connections are done. The

alignment and tolerance for alignment shall be maintained as specified in the manufacturers instruction manual. Shims and wedges where required will be arranged by Contractor.

The Contractor has to rectify, if any misalignment which might be observed after trial run of

pump with water. 5.1.4 All auxiliaries like lube oil system, filters, cooling water systems, and other piping connections

shall be supplied alongwith the pump in fabricated condition. If the piping are not received in fabricated condition then the Contractor shall have to fabricate the same form material issued by Owner and finally to be installed by the Contractor as per manufacturers instruction and instructions of Owner. The payment will be made as per piping schedule of rates.

5.2 EJECTORS Ejectors shall be delivered in assembled or sub-assembled condition and shall be installed in

accordance with manufacturers drawing, specification and instruction of Owner. The nozzles and diffusers shall be fixed on the associated piping as per arrangement drawings and shall be properly aligned.

5.3 COMPRESSORS Compressors shall be delivered to the Contractor in sub-assembled condition. The

compressor and the whole equipment shall be grouted after obtaining approval from Owner. If the compressor is received in knock down condition, the Contractor has to assemble and fit various parts of the compressor as per instruction of Owner and manufacturers instruction.

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The Contractor shall carry out the following as part of his work without any extra cost :

a) Placing the compressor on foundation after assembly with the motor. b) Leveling the entire unit. c) Rough alignment of motor. d) Grouting after the leveling and alignments are checked by Manufacturers

representative and Owner. e) Rechecking of alignment after the grout is set. f) If, necessary, Contractor has to open compressor cover and cleaning of Rotor,

Impellers, Seals and Bearings to be carried out. g) After cleaning and checking the compressor to be closed up. h) Gear box to be cleaned and alignment of gear box to compressor to be carried out. i) The manufacturer shall supply after coolers, prefilters, after filters separately. The

Contractor has to carry out erection, alignment and grouting of these equipment.

j) Piping connection such as water, steam, cooling water, other inlet and outlet connections, connections to coolers are made. Tolerance for alignment shall be maintained as specified in the manufacturers instruction manual. To ensure that piping connections do not induce any undue stresses on the equipment, the alignment shall be checked by the Contractor again after, the piping has been connected. Any rectification / correction necessary for proper alignment shall be done by the Contractor.

k) All auxiliaries and other piping will be supplied with the compressor in prefabricated

condition and shall be installed by the Contractor. If the piping are not supplied in fabricated condition, then the Contractor has to fabricate the piping as required with the material issued by Owner. Installation of piping will be paid as per Piping schedule of rates.

l) After pipings are connected, the Contractor shall check the alignment finally after

coupling the entire train i.e. motor, gear box and compressor. After this, trial run to be carried out and bearing temperature etc., to be noted and after this again alignment to be checked. If any defects are there, Contractor has to rectify the defects immediately.

The contractor shall study the layout drawings for compressors and other such machineries with their auxiliaries, controls, defining scope of supply and shall connect the gas steam and utility piping instruments and oil pipings as per manufacturers manual drawing specification and instruction of owner and manufacturers representative.

5.4 PACKAGE UNITS Units shall be supplied by the manufacturers as a package unit. The Contractor shall have to

erect the unit on the foundation prepared by Owner. In general all accessories connected with the unit will be installed by the manufacturer in the package unit. In case if the Contractor is required to carry out installation of any items as part of the package unit the same shall have to be carried out by the Contractor and will be paid on weight basis alongwith the units. The Contractor shall have to make all necessary facilities and fulfill the requirements for erection of the unit on the foundation.

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5.5 AGITATORS/ CONVEYORS/ ELEVATORS These items may be supplied in sub-assembled condition. However, if it is received in

assembled condition, it has to be dismantled to the extent it is required and shall be erected at no extra cost. Erection of motor, gear box, etc., to be carried out separately. Contractor shall align Motor, Gear box etc., separately then couple with each other. This again final alignment to be carried out including assembly of structure, belts etc.

6.0 DELIVERY STORAGE AND CUSTODY OF EQUIPMENTS / MACHINERIES The Contractor shall unpack, inspect, check the quantity extent of damage and rust if any of

the equipment and accessories supplied to him at the time of taking delivery in presence of Owner.

The Owner shall not be liable for any claims or complaints whatsoever in respect of quality

and quantity or condition of said materials once the Contractor has taken delivery thereof. However, Owner shall keep the accessories which are not directly necessary for installation. 7.0 HANDLING, TRANSPORTING AND ERECTION The Contractor shall be responsible for handling and transporting the items of equipment/

machineries from wherever stored at site by Owner, to the point of installation. The Contractor shall be responsible for organizing the lifting of the equipment / machineries in the proper sequence, so that orderly progress of the work is ensured and access routes for erecting the vessels, columns, heat exchangers, and other machineries etc., care should be taken not to damage nozzles, instruments, connections, structurals, clips etc.

Lifting tackles, slings and shackles before use at site must be tested by an approved agency,

and a certificate to that effect shall be produced by the Contractor. These certificates shall be maintained at site. Lifting tackle shall be visually inspected before use and shall be sent for re-testing by the Contractor if any doubt is expressed by the Owner, about its worthiness. Under no circumstances the Contractor shall use a defective or doubtful appliance.

The following shall be followed by the Contractor during transport, handling and lifting of the

equipment / machinery.

i. Use suitable capacity crane / truck lifting tackle, lifting beam / hoist. ii. Obtain prior permission of the Owner for using building or structure for slinging. iii. Use wire rope as per IS 1835 or stronger for thimbles. iv. Apply thimbles to lifting lugs taking into account center of gravity of the equipment.

Never use other parts of the equipment except the lifting lugs. v. When no lifting lugs are provided, take measures to be prevent slippage in

consultation with the Owner. In case slip preventing device is not available, attach a wire to prevent slippage.

vi. Avoid swinging motion of the equipment while lifting. vii. Use stay wire to prevent over turning.

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8.0 GROUTING

For equipment installed on concrete foundations, the Contractor shall fill mortar / concrete under the base plate as soon as possible after final tightening foundation bolts. Mortar shall be used for smaller equipment and concrete shall be used for bigger equipment. The surface of the concrete shall be thoroughly scraped, all waste material and dirt shall be removed, also all oil, grease, paint from the surfaces of the base plates (supports, lugs etc.) which are to be in contact with grout shall be cleaned. The top surface of the foundation shall be chipped if necessary to maintain the required elevations of equipment as per drawings at no extra cost. The concrete foundation shall be thoroughly wetted and kept wet for 24 hours before grouting. Cement slurry shall be brushed into the concrete surface immediately before placing the grout.

8.1 GROUTING OF POCKETS

The grouting shall be done with cement water in proportion of one part of Portland cement plus one part of sand and one part of grit (maximum size 6mm). Adequate quantity of water shall be added. In case where anchor bolts with sleeves are provided it shall be the responsibility of the Contractor to keep them clean particularly threaded portion of bolts shall be greased to protect them from damage. Grout shall be gradually poured in the pockets without disturbing the holding down bolts, and shall be tamped with a steel rod for proper compactions. For initial grouting all foundation bolt holes shall be filled to a height of 75mm to 100mm below top. After initial set has taken place cure with water by filling the holes to the top for seven days. After 7 to 10 days of initial grouting all foundation bolts shall be pulled up tight and if necessary checked with Capstan gauge reading.

8.2 GROUTING UNDER BASE PLATES AND MACHINE BASES

Before final grouting of base plates and machine bases all water should be removed from pockets. Grouting shall be done as per specification and instruction of Owner and manufacturers representative. The following mortar mixing ratio to be followed at the time of preparation of grout.

MIXING RATIO BY WEIGHT 01. Mortar Mix A Mix B Cement - 1 1 Non Shrink grout - 1 0 Sand - 1 1 Gravel - 0 0 Water - (0.4 - 0.5) 02. Concrete Cement - 1 1 Non Shrink grout - 1 0 Sand - 1 1 Gravel - 1.5 1.5 Water - (0.4 - 0.5) Note : Mix A - Mix with Non-Shrink Grout Mix B - Mix without Non-Shrink Grout To be adjusted at site for workability as per local conditions.

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It shall be worked in and compacted so that the inside space under the base plate and around the anchor bolts is thoroughly filled with the dense grout. Care should be taken that no air bubbles are left inside the grout. The grout shall be cured for a minimum of 7 days wetting the exposed areas. The shim plates and pockets under the base should be left undisturbed while grouting is undertaken. Thickness of grout shall be as per the drawings but in no case the thickness of grout shall be less than 25mm. Ordinary “SHRINKOMP” developed by the Research & Development Division of M/s. A.C.C. Ltd., or other equivalent Non-shrinking grout, approved by the Owner shall be used for grouting purpose in case of critical equipment like towers, compressors, turbines, centrifuges, D.G. sets and other such like items and ordinary grout shall be used for grouting purpose in case of non-critical equipment. All required precautions as per prevalent procedures not standard engineering practices will be followed while carrying out the grouting. The grouting shall be done exactly as per manufacturers specification.

9.0 FINAL CHECKING AND FINISHING

Equipment such as thermowells, trays, demister pads, grills etc., shall be properly installed by the Contractor after proper installation of the equipment. In case structural steel cleats are required to be welded and / or modified on the equipment, the same will be carried out by the Contractor at no extra cost to the Owner. Minor access ladder and platforms when supplied by the vessel fabricator shall also be fixed by the Contractor. Packing materials which shall be supplied by the Owner, shall be properly loaded in the equipment buy the Contractor wherever required. Final alignment for machinery, shall be done after piping connections are made. Tolerances for alignment shall be as specified by the vendors / suppliers, specification and Owner. Contractors should ensure that they do not induce any stress on the machinery. Care shall be taken to avoid undue strains or distortion of equipment caused by uneven bearing on foundations or equipment under operating condition, units such as pumps, fans, compressors, etc., shall be checked for proper alignment of driver.

All shafts shall be checked for freeness, alignment and freedom of rotation, cooling water, flushing exhaust air and other piping connections with the main equipment and auxiliaries shall be installed as per the drawings specifications and manufacturers instructions. All accessories and fittings either shipped lose or removed from main equipment during erection shall be kept tagged separately and installed after completion of erection / installation of the main equipment. All flanged connections and openings shall be kept blank with plugs / covers to prevent entry of foreign matter and shall be removed while making connections to the respective piping or other associated components. All the instruments like pressure gauges, temperature indicators etc., forming part of equipment supplied by a vendor shall be installed after the main equipment is installed as a part of the main equipment. Safety valves with manifolds / distant piece, if any, shall be installed by the Contractor. Setting of safety valves will, however be carried out by the other agency. But the Contractor shall remove the safety valves for calibration as and when instructed by Owner and reinstall the same after calibration including to and fro transportation within plant premises at no extra cost to the Owner.

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All equipment shall be thoroughly cleaned, oiled and greased and presented for inspection to the Owner before placing in for operation. A list of all oils and lubricants to be used as stipulated in the manufacturers instruction manuals shall be supplied to the contractor by the Owner. While filling lubricants and oils, care shall be taken that they conform to manufacturers recommendations. The required quantities of oils and lubricants shall be supplied by the Owner.

10.0 TRIAL RUNS OF EQUIPMENT AND MACHINERY 10.1 Any construction defects shall be intimated to Owner before startup. Before trial runs all

protection devices and guards shall be installed and equipment shall be checked for free movement by hand rotation. All foundation bolts and alignment shall be checked before starting the trial run.

10.2 Unless indicated to the contrary all the machinery will be subjected to trial runs for a period of

72 hours continuous. Contractor has to decouple and turn over to other agencies doing electrical work for testing and no load running of motors. After satisfactory completion of test the Contractor shall recouple the motors to the machinery and recheck the alignment. The trial shall start only after this is completed. In all, Contractor has to carry out coupling and decoupling twice. If it is required to do more than twice then Contractor shall be paid on manday rate basis.

10.3 During the trial run period the Contractor shall provide necessary skilled personnel round the

clock as required. Any defect noticed during the run and after the trial run shall be made good by the Contractor at his own cost if that part of the work is done by the Contractor and if it is otherwise then the Contractor shall be paid extra. Skilled personnel and worker required for this purpose shall be supplied by the Contractor.

10.4 Where the initial running of items of equipment is carried out with gland packings wherever

necessary the gland packing shall be replaced by mechanical seal. During the trial runs, reading of bearing temperature, cooling water inlet and outlet temperature, lube oil temperature, output pressure etc., shall be recorded by the Contractor.

11.0 OWNERS / CONSULTANTS SCOPE OF SUPPLY 11.1 Owner shall supply the equipment in assembled, package unit, or in condition received from

the supplier. 11.2 Owner shall provide necessary foundations for the equipment. 11.3 Owner shall provide necessary foundations bolts and nuts for erection of equipment.

However, please refer qualifications of this item under item 12.5 under Contractors scope of supply.

11.4 Owner/ Consultant shall provide drawings and necessary instructions required for installation

of equipment machinery. Besides above information, instruction manual and other literature wherever furnished by manufacturer will be made available only for consultation of the Contractor. The Contractor shall on completion of job return all the documents and drawings supplied to him.

11.5 Owner/ Consultant shall provide assistance from manufacturers representative wherever

applicable.

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11.6 Owner shall supply ordinary Portland cement for grouting, if available on special request from Contractor cost recoverable basis. Wherever cement is supplied to the contractor, the Owner / Consultant shall deduct the value of cement thus taken form the Owner from Contractors bills, at the prevalent rate.

11.7 Oil charges required for pump sumps, compressor crank, cases, bearing housings, gear

boxes, cylinder lubricators, flushing oil shall be provided by the Owner. However, please refer qualifications of this under 12.4 under Contractors scope of supply.

11.8 Owner shall provide free of cost at their direction and for duration of contract reasonable open

space common for equipment, piping, structural and other works given in this tender document.

12.0 CONTRACTORS SCOPE OF SUPPLY 12.1 Contractor shall arrange necessary skilled and unskilled labour, supervising staff, engineers,

stores personnel. The Contractor shall increase the strength of any of the above category of personnel as advised by Owner / Consultant.

12.2 The Contractor shall make his own arrangement of necessary erection and handling

equipment tools and tackles such as but not limited to cranes, winches, slings, shackles, test equipment, pressure gauges, dial gauges and other measuring tools welding sets, electric tools, oxyacetylene gas torches, electrical cables, drilling tapping machines, hydraulic test pumps, scaffolding materials etc., required for expeditious completion of work.

12.3 In cases wherein oil required for pump sumps, compressor crank cases, bearing housings,

gear boxes etc. are not available the contractor shall procure the same as per instructions and specifications of owner/ consultants. Non availability of lubricating/ cooling oil shall not be considered as a reason for delay in job completion. .

12.4 The Contractor shall arrange all consumable required for the purpose of erection. This will

include but not limited to straight and tapper packers, SS, CS, and brass shims (SS & CS) wedges, cement, sand, gravel, drill bits, tapping sets, hacksaw blades, fixes, scrappers, chisels, cotton waste, rags kerosene oil, grease, anti rust compound, wooden blocks, emery paper, grinding wheels, bolts & nuts required for supporting structures for equipment, platforms, walkways, ladders, etc.

12.5 All foundation bolts and H.D. bolts shall be supplied by the Owner free of cost. The Special

Conditions of Contract, Schedule of items will however superseded. This clause if the two are in variance.

13.0 SYSTEM TEST / START-UP (PRE-COMMISSIONING) During the phase of work the Contractor shall provide as part of his work any necessary

skilled personnel as required by Owner. Any defects noticed in the equipment shall be made good by the Contractor at his cost, if such defects are attributable to the Contractor.

ZSS004 Std Spec for Fabrication Erection of piping

Page 1 of 24


FABRICATION AND ERECTION OF PIPING

DOCUMENT NO: Z SS 004

PREVIOUS DOC. NO.: BSS-26-02/1


By

Checked

By

Approved

By

0 02.11.2001 14 Issue for use MRAK CLS AGG

1 25.07.2003 14 Issue for use RNK SGR AGG

2 30.09.2003 23 Design requirements added

BK AGG AGG

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DATE: 30 September 2004 SPECIFICATION NUMBER: Z SS 004 PAGE: 2 OF 24 STANDARD SPECIFICATION FOR REVISION NO: 2 FABRICATION AND ERECTION OF PIPING


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE

3.0 DEFINITIONS 4.0 GENERAL

4.1 TECHNICAL REQUIREMENTS 4.2 SCOPE OF WORK 4.3 APPLICABLE STANDARDS, CODES AND SPECIFICATIONS 4.4 PIPING MATERIAL CLASSIFICATION 4.5 DRAWING & SPECIFICATION 4.6 METHOD OF WORK 4.7 ALIGNMENT 4.8 FABRICATION 4.9 PREPARATION 4.10 FLANGE CONNECTIONS 4.11 BENDING, FORGING AND FORMING 4.12 THREADING 4.13 MITRE BENDS & FABRICATED REDUCERS 4.14 TOLERANCES 4.15 PREPARATION OF PIPE AND OTHER FITTINGS 4.16 INSPECTION OF FABRICATED PIPING 4.17 CLEANING OF PIPES 4.18 HEAT TREATMENT 4.19 WELDING 4.20 ERECTION 4.21 FLANGES 4.22 FITTING 4.23 VALVES AND ON-LINE FITTINGS 4.24 SUPPORTS, GUIDES AND ANCHORS 4.25 INSTRUMENTS 4.26 BOLTS & NUTS 4.27 STRAINERS 4.28 ASSEMBLY 4.29 FLANGE JOINTS WITH A GASKET 4.30 STRUCTURAL ATTACHMENTS 4.31 TREATMENT AFTER FABRICATION 4.32 FABRICATION PRIORITIES AND MATERIAL 4.33 INSPECTION 4.34 PROTECTION 4.35 PIECE MARKING 5.0 RELATED DOCUMENTATION (REFRENCES)

6.0 RECORDS 7.0 ATTACHMENTS / APPENDICES 7.1 TOLERANCES 7.2 BRANCH REINFORCEMENT 7.3 HEAT TREATMENT REQUIREMENTS

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SPECIFICATION NUMBER: Z SS 004 DATE: 30 September 2004 STANDARD SPECIFICATION FOR PAGE: 3 OF 24 FABRICATION AND ERECTION OF PIPING REVISION NO: 2


1.0 PURPOSE

The purpose of this specification is to define the pre-fabrication, Heat treatment, Inspection, Erection, construction and protection requirements of Carbon steel, Chromium Molybdenum, Carbon ½ MO. Pipe Work based generally on American National Standard Code for Pressure Piping.

2.0 SCOPE 2.1 This Specification does not apply to Low Pressure Ducting. 2.2 This specification supplements the applicable code requirements / data sheets / drawings and

specifications for fabrication, erection, inspection, testing of pipelines. 3.0 DEFINITIONS

Client/ Owner: The Company, which intends to put up the Plant/ It’s

nominated representative Consultant: The Company nominated by the Client/ Owner to carry out

Detailed Engineering / Construction Supervision. Contractor/ Fabricator: The successful bidder for Piping construction works. IBR Indian Boiler Regulations

4.0 GENERAL

4.1 TECHNICAL REQUIREMENTS 4.1.1 All Conflicts between the requirements of this specification, related Engineering documents/

Drawings/ Codes shall be immediately brought to the notice of the Construction Manager/ Engineer-in -charge or the Site Representative nominated by the company.

4.1.2 This specification is intended to cover the technical requirements for the execution of piping

fabrication and erection of entire piping work defined hereinafter. The work will include installation of inline instruments such as Control Valves, Orifice Flanges, Rotameter etc., and Impulse Piping up to 1st block valve.

4.1.3 The quantities of piping material listed in the Schedule of Rates are approximate and are

subject to variations. 4.2 SCOPE OF WORK 4.2.1 Contractor’s Scope of Work

a) Installation of piping system which shall include but not limited to pipes, pipe fittings, flanges, bolts, nuts, gaskets, inline fittings such as valves, strainers, traps, filters, thermo wells, orifice plates, safety valves, control valves, relief valves, pressure reducers, flame arrestors, sight glasses, rain hoods etc., and pipe supports at all elevations.

b) Testing and flushing / cleaning of all piping systems as per specification. c) Fabrication and erection of all support elements such as shoes, rollers, wooden

saddles, guides, stop / anchors, U-bolts, clamps, cradles, hangers, turn buckles, etc.,. d) Fabrication and erection of supporting fixtures, brackets, cantilever struts etc.,.

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e) Fabrication, excavation, laying, inspection, testing, flushing / cleaning, coating and wrapping and backfilling of underground piping, with all specials and fittings.

f) Fabrication and erection of pipe supports like shoe, saddle, guides, stops, Anchors,

clips, cradles, hangers, turn buckles, supporting fixtures, Bracket cantilevers, struts, Tee Posts, sway braces.

g) Erection of prefabricated spring supports to be supplied by the Owner, wherever

specified. h) Prefabrication of threaded and unthreaded nipples and Swage Nipples made from

pipes. i) Construction of 60 degrees and 30 degrees or other angle elbow by cutting 90

degrees and 45 degrees elbow supplied by Owner. j) Modification of piping that has been completed and / or is being fabricated. k) Fabrication of 90 degrees, 60 degrees, and 45 degrees mitre bends from pipes

supplied by Owner.

l) Fabrication of Stub-in / Stub-on connections with or without reinforcement. m) Pickling and passivation of S.S. Pipes, if required, after fabrication and before erection

or after erection as per specifications. n) Fabrication and installation of spool pieces with scrap pipes and plate flanges, in

place of valves and other on-line fittings wherever required, to continue erection of piping.

o) Any other items as required in the drawings / specifications to be fabricated from the

pipe material. p) Additional cleats for pipe supports to be welded with vessels and columns not stress

relieved. q) Radiography and / or heat treatment of weld wherever applicable.

4.3 APPLICABLE STANDARDS, CODES AND SPECIFICATIONS. Code of Petroleum Refinery Piping : ASME B31.3 Code of Procedure for Manual metal Arc Welding of mild steel : IS 823 Welding procedure specification, welders procedure, qualification tests and performance qualification tests. : ASME-Sec.IX Standard for welding pipe and related facilities : API Code 1104 Indian Boiler Regulations : IBR

All codes referred to shall be the latest editions. The contractor shall bear the cost of repairs, changes, replacement etc., due to non-compliance with the standards, codes and this contract or due to disregard of the instructions given by the Owner / Consultant.

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4.3.1 All piping systems shall be fabricated, installed, tested, flushed in accordance with this specification, piping specifications, general arrangements and other applicable drawings / standards and good engineering practice.

4.4 PIPING MATERIAL CLASSIFICATION 4.4.1 The complete piping system is broadly divided into various piping classes based on design

pressure, temperature and medium conveyed and the material of construction used in the piping. All the components used in a given pipeline shall be in conformity with the piping specifications assigned to it.

4.5 DRAWING & SPECIFICATION 4.5.1 Piping specifications, Engineering Line Diagrams, Piping General arrangement drawings,

Piping Isometrics, Equipment layout drawings, Supporting standards and other relevant drawings shall be furnished to the Contractor during the execution of the work.

4.5.2 The following drawings shall be supplied to the contractor.

i) FOR CARBON STEEL (NON IBR LINES):The contractor shall be supplied with construction drawing, General Arrangement drawings, P&IDs, Isometric Drawings, support standards, etc., for Carbon Steel Pipe 2”NB and Above. Preferred Routings for 1½”NB and below in General Arrangement Drawings.

ii) The contractor shall be supplied with isometric drawings for all sizes of stainless steel,

alloy steel and Composite isometric for IBR carbon steel pipe work. iii) The Owner / Consultant shall provide the Contractor standard pipe support and steam

trap assembly sketches and location. Further detailing / routing of the lines are contractors responsibility.

4.5.3 If any details specifically required for fabrication and erection are missing from the drawing

supplied by the Owner / Consultant, the contractor shall develop the same and submit to the Owner / Consultant for approval.

4.5.4 The Contractor shall bear the cost of repair, changes, replacements, etc., due to non-

compliance with the standards, codes, of this tender of due to disregard of instruction of Owner / Consultant.

4.5.5 Contractor shall prepare Sketches / Isometrics for field routed lines. 4.6 METHOD OF WORK 4.6.1 PREFABRICATION 4.6.2 The contractor shall fabricate all pipe work in conformity with the requirements of pertinent

general arrangement drawings, isometrics, piping specification and other specifications / documents. The piping layouts, isometric drawings and other documents specify the conditions of design, viz. Pressure ratings, clarifications, shape dimensions of pipe and piping components sufficient for fabrication. However, if necessary, the contractor shall prepare SHOP FABRICATION drawings, based on piping drawings and actual field measurements.

4.6.3 All Carbon steel piping 1½”NB and below are called as Field runs, unless otherwise

specifically Isometrics are issued, shall be fabricated, erected, supported and tested by the contractor in consultation with the Owner / Consultant.

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4.6.4 Where specific details of fabrication are not indicated on the drawings or not specified herein fabrication and erection shall be done in accordance with the code of Petroleum Refinery Piping ANSI B31.3 latest edition and INDIAN BOILER REGULATION of latest edition, as applicable.

4.6.5 Steam piping falling under jurisdiction of INDIAN BOILER REGULATIONS shall be fabricated

in accordance with the requirements of the applicable drawings, the latest edition of INDIAN BOILER REGULATIONS and to the entire satisfaction of local Boiler Inspector. Documents certifying the fabrication and testing of fabricated components of the piping system shall be obtained from the local Boiler Inspector in Form IIIA and IIIB of IBR by the contractor.

4.6.6 The contractor shall be responsible for working to the exact dimensions as shown on the

drawings irrespective of individual tolerance permissible. Where errors are / or omissions occur on the drawing with respect to site conditions, it shall be the contractors responsibility to notify the Owner/ Consultant prior to fabrication or erection.

4.7 ALIGNMENT 4.7.1 The pipes to be joined by welding shall be aligned correctly with the existing tolerance on

diameters, wall thickness and out of roundness. The same alignment shall be preserved during welding. Pipes with the higher wall thickness shall be internally machined / ground so that the adjoining surfaces are approximately flushed. No extra payment will be made for this purpose.

4.8 FABRICATION 4.8.1 GENERAL 4.8.2 Pipes shall be supplied with plain or beveled ends of random lengths (6.0 Mtrs) or double

random lengths (12.0 Mtrs) depending on the availability in the market. Wherever beveling is required as per welding procedure, contractor shall do the beveling at his own cost.

4.8.3 Longitudinal seam in seam-welded pipe shall be located so as to clear the pipe opening and

external attachments wherever possible. Longitudinal seems in adjoining courses shall be preferably at 180 degrees but a minimum distance of 150mm between seams, measured around pipe circumference shall be provided, where pipe size permits and external attachments wherever possible.

4.8.4 Sections of Pipes shall not be welded together for lengths below 3m(10ft.) and the number of

welds shall be kept minimum for longer lengths. 4.8.5 Materials found to be damaged or found to have defects shall not be used in fabrication

except that minor surface marks may be dressed up provided that the nominal wall or minimum wall thickness is not encroached upon after considering the manufacturing tolerances defined in the appropriate material or purchase specifications.

4.8.6 All pipe branches shall be 90 degrees unless otherwise indicated in the drawings. All changes

in direction of piping shall be 90 degrees / 45 degrees unless otherwise specified. The dimensions indicated in the drawings are true and contain no allowance for weld gaps. Gaskets less than 1/16” (1.5mm) are ignored in dimensional computations.

4.8.7 For laying out headers, tees, laterals, and other irregular details cutting templates shall be

used to ensure accurate cutting and proper fit-up. All cuttings shall follow the outline of the template.

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4.8.8 Branch connections shall be made by fabricated intersections, welded or screwed fittings, forged branch attachments, couplings or manifold extrusions as specified in the Piping material specifications/ Company’s drawings.

4.8.9 Fabrication details of special items; jacketed pipelines; multi-nozzle headers, extrusions, etc.,

will be specified on the purchase order, the contract Piping or in an addendum to this specification.

4.8.10 The contractor shall be responsible for working to the dimensions shown on drawings,

Isometrics and standards. The dimensions shown on the drawings/ Isometrics and those actually existing may not be matching for unknown reasons. To take care of these variations “FIELD WELDS” shall be provided in X, Y, Z directions during prefabrication stage. Extra length of 200 mm shall be provided at the field weld point over and above the dimension shown in the drawings/ Isometrics. During erection the pipe with extra length shall be suitable cut to obtain the actual dimension. Provision of field welds and cutting the extra length of pipe to achieve the actual length will not entertained as extra claim for the contractor.

4.8.11 Installation and protection of proprietary items, during fabrication shall be as per

Manufacturer’s instructions. 4.9 PREPARATION 4.9.1 PIPE JOINTS 4.9.2 Piping Material Specification specifies the type of Pipe joint for each piping class to be

adopted. In general, for Pipe sizes 2” NB and above, erection joints are Butt-Welded and maintenance joints are flanged. For Pipe sizes 1 ½” NB and below erection Joints are socket welded/ threaded, maintenance joints are flanged / with Unions.

4.9.3 Machined out bevels to form the welding groove are preferred in carbon steel pipe. However,

smooth, clean, slag-free, flames cut bevels are acceptable. In cases of alloy steel, S.S. Pipes weld bevels shall be generated with file or a grinder. Arc cutting in stainless steel pipe and alloy steel pipes is prohibited. “C” Cleats buttered on the edges with electrodes compatible with parent pipe is also acceptable.

4.9.4 Tack welds with full penetration shall be used and shall become the part of the finished weld.

Neither defective welds nor tack welds with lack of penetration are acceptable and shall be chipped / ground out.

4.9.5 If thermal cutting is used, at least 1.6mm thickness of the flame cut edge material shall be

dressed back to clean material. 4.9.6 Prior to welding, all fusion surfaces shall be free from foreign substances such as rust, loose

scale, slag, swarf, oil and grease etc., including any protective coating, for a distance of at least 25mm internally and externally back from the welding edges.

4.9.7 No joint within the distance of 20 pipe diameters upstream and 8 pipe diameters down stream

of orifice flange shall be allowed in straight running pipes. For other configurations of piping orifice flanges shall be located strictly as per drawings. In all cases, weld inside orifice flange shall be ground flush.

4.9.8 BRANCH CONNECTIONS

• All the branch connections, except where forged tees are required as per the specifications, shall be accomplished by pipe to pipe connections as per relevant code requirements and piping specification. Payment will be made for this as per the rates quoted in the respective table.

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• Fabricated intersections shall be of the “Set-On” type with the branch pipe prepared to suit a full penetration weld of a quality comparable to the girth welds.

• Branch reinforcement shall be of the type specified in the “BRANCH TABLE” of the Piping material specification.

• For reinforcement and non-reinforcement branch connections, the pipe longitudinal, girth and attachment welds be clear of the branch reinforcement perimeter, by a minimum of six times the header wall thickness.

• Forged branch attachments shall be of the type specified in the Piping material specification/ Isometrics and fitted accurately to the contours of the Pipes.

• Couplings and Half-couplings shall be accurately shaped and “SET-ON” to suit the contour of the run pipe. Those for”pressure taps” shall header drilled after welding.

• Reinforcement of branch connections of all piping systems if required shall be done in accordance with the requirements of the ANSI code for Petroleum Refinery, Piping B31.3 and the Indian Boiler Regulations wherever applicable. Payments will be made for this work based on unit rates quoted.

4.10 FLANGE CONNECTIONS 4.10.1 All flange facing shall be true and perpendicular to the axis of the pipe to which they are

attached. Flanges bolt holes shall be straddle to the normal centre lines unless different orientation shall be shown in the drawing to match the equipment connection etc., Tolerance in fabrication shall be as per relevant standards / execution drawings.

4.10.2 Flanged connections shall be used at connections to vessels and equipment and where required for ease of erection and maintenance unless otherwise stated.

4.10.3 Wherever spectacle blinds are to be provided as per drawings, drilling and tappings in the flanges will be done by the contractor before welding of the flanges with the pipe to facilitate installation and operation of the jackscrews.

4.11 BENDING, FORGING AND FORMING 4.11.1 Bends shall be used up to and including 40mm dia, pipe sizes where essentially required as

indicated in piping specifications. Carbon steel, alloy steel, stainless steel bends shall be cold bent to a radius of 5 times the nominal pipe diameter using formers or shoes which fit the desired contour of the pipe. The completed bend shall lie in one plane, have a smooth surface and shall be free from defects such as cracks, buckles, wrinkles, bulges, flat spot etc. They shall be true to dimensions. The flattering of a bend as measured by the difference between maximum and minimum diameters at any cross sections shall not exceed 5% and 3% of the nominal outside diameter for internal and external pressure respectively, wherever specified piping components shall be fabricated by hot or cold forming, rolling, forging, hammering etc., in any case, wall thickness after bending shall not be less than 87 ½ % of nominal wall thickness.

4.11.2 Proper account of spring back during bending shall be taken. Tolerance of angle of bend shall be + 1/2 degrees.

4.11.3 Hot forming shall be adopted with a temperature range consistent with material characteristics and post heat treatment shall be done wherever necessary as indicated in piping specifications. The rates quoted by the contractor for carbon steel, alloy steel and stainless steel piping of 40mm NB and below shall be inclusive of fabrication and erection of piping components as specified in drawings / specifications and or as required by the Owner / Consultant at site. Material for such fabrication shall be supplied by the Owner.

4.12 THREADING

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4.12.1 Threading of pipes shall be preferably done after bending, forging or heat treatment

operations. When this is impossible or very difficult to perform the threading may be done prior to such operations but precautions shall be taken to properly protect the threads from damage. Thread joints that are to be seal welded shall be made up dry (without using thread compound or tape). Unless otherwise stated, the threads shall be to IS 554 in case of G.I. Pipes and fittings. However, in other cases, it shall be NPT tapped and smooth to ANSI B2.1 unless otherwise mentioned in the material specification.

4.12.2 The threads shall be full length and free from defects. The threads on each joint of pipe shall

be carefully inspected and examined prior to installation. All threaded pipe joints (except those to be seal welded) shall be lubricated or tapped on the male and with thread joining component or P.T.F.E. tape acceptable to the Owner / Consultant. The contractor shall connect all joints of pipe into a screwed line sufficiently tight to withstand the test pressure specified.

4.12.3 On all threaded connections like vents, drains, couplings, etc., the threads shall be protected

from rusting by applying grease / oil when in open conditions. 4.12.4 While fixing the plugs / caps for pressure testing or otherwise the tightness of the joints shall

be ensure by using proper thread seal and suitable to the service temperature. Oil, grease and other sealing and protecting materials / consumables shall be supplied by the contractor at his cost. The rates quoted by the contractor shall be inclusive of threading and seal welding as required. Threaded connections wherever specified in drawings / documents or if required by the Owner / Consultant shall be seal welded by the contractor. Such thread joints shall be made up dry (without using thread compound or tape).

4.13 MITRE BENDS & FABRICATED REDUCERS 4.13.1 The specific application of welded mitre bends and fabricated reducers shall be governed by

the piping specification furnished to the Contractor. The radiographic requirements shall be as per the piping material specification for process and utility systems with the exception of steam piping falling under INDIAN BOILER REGULATIONS where radiographic requirement of IBR should be complied with.

4.13.2 The piping rates shall be inclusive of erection of mitre bends and fabricated reducers.

However, the contractor shall be paid separately for fabrication of mitre bends as per the rates quoted.

4.14 TOLERANCES 4.14.1 In addition to tolerances contained within the specified codes or standards, the following shall

also apply.

• For bending of pipes subjected to internal pressure, the difference between maximum and minimum outside diameters, at any cross section along the axis of bent portions of the pipe, shall NOT exceed 5% of the nominal outside diameter. The wall thickness of pipes after bending shall be not less than (Nominal wall thickness) x 87 ½ % (Minimum wall thickness).

4.14.2 All linear dimensions involved in relative position of branches, bases, flanges end, instrument

tappings and changed in directions, each to each other shall be maintained within + 3mm (1/8”).

4.14.3 In case of long lines this tolerance in linear dimension cannot be added that is the overall

dimension should be within + 3mm.

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4.14.4 All angular dimension of bends and branches shall be maintained within + 3mm. All angular dimension of bends and branches shall be maintained within + 1/4 degree.

4.14.5 Flange joint contact surfaces shall be flat and true as machined. Should warping take place

due to fabrication processes, the joint contact surfaces may be restored to their original accuracy, provided that the flange thickness dimensions are not reduced below the minimum required by the relevant ASME/ API/ MSS flange specification.

4.14.6 The rotation of flanges away from their axis shall be measured as indicated in Attachment

7.1. Tithe misalignment shall not exceed 1.5mm between diametrically opposed boltholes. 4.14.7 Alignment of flanges and branch welding ends measured as shown in Attachment 7.1. across

any diameter shall not deviate from the true position more than 1/32” per foot (2.5mm per metre) of diameter.

4.15 PREPARATION OF PIPE AND OTHER FITTINGS 4.15.1 Prior to aligning pipe for welding the ends of the pipe shall be machine bevelled. Bevel

dimensions shall be as per applicable codes / standards and piping specifications given to the contractor.

4.15.2 The bevelled ends of each joint of the pipe shall be thoroughly cleaned of paint, rust, mill

scale, dirt or other foreign materials to avoid defects in the completed welds. This shall be done by use of power driven wire brushing wheels or other methods approved by the consultants.

4.15.3 Any foreign matter or obstruction remaining inside the pipe shall be removed by appropriate

means. 4.15.4 Couplings and half couplings shall be accurately shaped and set on to suit the contour of the

run pipe, weldolets shall be fitted accurately to the contour of the run pipe. Pipe shall be properly supported and aligned by jigs or clamps as required in order to preclude extraneous loads and minimise strains during tacking.

4.15.5 Small tack weld i.e. between 1/2” (12.5mm) and 3/4” (18mm) in length penetrating to the

bottom of the groove may be used in fitting up. Tacks should be equally spaced as follows : For 2 1/2” pipe and smaller - 2 tacks For 3” to 12” pipe - 4 tacks For 14” and large pipe - 6 tacks Unless otherwise specified, all pipe to pipe joints shall be butt welds. 4.15.6 Pipe with a wall thickness of 1.4” (6mm) and greater shall not have internal mis-alignment of

pipe wall exceeding 1/16" (1.5mm). 4.15.7 Pipes with a wall thickness less than 1.4” (6mm) shall not have internal mis-alignment of pipe

wall exceeding 25% of pipe wall thickness. When mis-alignment is greater than the above component shall be aligned by drifting, rolling or machining in accordance with the code, ensuring that the nominal wall of minimum wall thickness is not encroached upon after considering the manufacturing tolerances defined in the appropriate material specifications.

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4.16 INSPECTION OF FABRICATED PIPING 4.16.1 Pipe work that has been done shall be checked with the isometric drawings and other related

documents to verify that it is fabricated, complies with the dimensions and specifications. 4.16.2 Fabrication shall have dimensions falling within the tolerances defined earlier. 4.16.3 All welds shall be visually examined and shall also be subjected to radiographic inspection as

provided for in para Radiographic inspection thereof. Joints shall have proper weld penetration without undercuts, overlaps, or abrupt ridges or valleys. Visual defects such as cracks, pin holes incomplete fusion, etc., shall be removed and joints rewelded at contractors cost and particular case should be exercised in built welding of small diameter pipes and stainless steel pipes so as to prevent reduction of internal diameter at the joint beyond the limits specified below. The root pass of butt joints, regardless of techniques use shall be such that the projection of weld metal into the pipe bare shall not exceed specified limits indicated in standard codes and piping specifications.

4.17 CLEANING OF PIPES 4.17.1 On completion of fabrication, all pipes and fittings shall be cleaned inside and outside by a

suitable means (mechanically driven rotary cleaning tool, wire brush, compressed air, detergent etc.). Before erection to ensure that assembly is free from all loose foreign material such as scale, sand, weld spatter particles, cuttings chips etc.

4.17.2 All field fabricated piping shall also be cleaned at the completion of the fabrication. All burrs

welding icicles and weld spatter shall be removed by any suitable means (mechanical tools, wire brush etc.). The pipe interior shall be water flushed to eliminate cement mortar, sand, heavy oil films and loose scale etc., and ends shall be capped.

4.17.3 Both shop and field fabricated piping shall be blown with compressed air at the termination of

cleaning. The ends of complete section of pipe line shall be closed with suitable plugs, caps or other approved methods. All fabricated piping shall be protected against rust and corrosion pending erection, by the contractor at his own cost.

4.17.4 Cleaning requirements for special services, if any, shall be followed by the contractor as

specified in the piping specifications. 4.17.5 Pickling and passivation of S.S. pipes if required shall be carried out as specified in the

attached specifications. 4.18 HEAT TREATMENT 4.18.1 PRE-HEATING Piping joints shall be preheated before welding to the extent required for different types of

materials as per the requirement of standards / codes and specifications and also refer to Attachment 7.3

4.18.2 POSTWELD HEAT Welded joints shall be heat treated for the various types of steel as specified in the piping

specifications and also refer to Attachment 7.3 4.18.3 Flange seal surfaces must be protected against oxidation during Heat –Treatment. 4.18.4 All bends and other parts worked either cold or hot shall be heat treated as indicated in

Attachment 7.3

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4.18.5 In all cases maximum Brinell hardness values given in Attachment 7.3 shall not be exceeded. 4.19 WELDING 4.19.1 All welding shall be in accordance with the code and with any amendments or additional

requirements noted on drawings or within this specification. 4.19.2 All welding procedures and supporting qualifications to be used by the contractor shall be

presented to the company for written approval. 4.19.3 Welder qualification shall be in accordance with section IX of the ASME Boiler and Pressure

vessel code and shall be witnessed by the client/ company’s representative. In case of IBR piping welders & welding, procedure shall be subject to approval from IBR inspectorate.

4.19.4 Backing rings shall not be used without the approval of the company. 4.19.5 During welding, sections of pipe shall be adequately supported so that the joints are relieved

of any strain. 4.19.6 All welding shall be supervised and records maintained, identified with the individual welder

concerned. 4.19.7 Electrodes shall be stored , dried and utilized as per manufacturer’s recommendations. 4.20 ERECTION 4.20.1 For erection of piping, use of davits, welding of temporary supports on adjacent equipment /

structure, use of existing foundation or steel structure shall be allowed only after approval of Owner / Consultant. In each case maximum load and erection procedure shall be as direct by the Owner / Consultant.

4.20.2 The intent of prefabrication at the shop is to accelerate progress of pipe work and to minimize

work in the field. Such prefabrication should be based on approved isometrics and piping layouts furnished to the contractor. Field weld means position weld of prefabricated piece at site or near the plant. However, the contractor shall bear in mind that there can be variations in dimensions between those appearing in the isometrics and those actually occurring at the site due to minor variations in the location of equipments, inserts etc. Therefore field welds shall be decided by the contractor permitting preassembly to be installed without any modifications. The shop fabricated pieces shall be largest practicable size limited for easing transportation to site. In any case, no extra claims will be entertained on this score. After prefabrication, during intermediate storage pipe ends shall be sealed off. Before, sealing the ends, piping shall be cleaned inside to remove welding spatter and foreign debris (brush clean).

4.20.3 All piping shall be routed and located as shown in piping drawing keeping in view the piping

specifications. No deviations from the arrangement shown shall be permitted without the express consent of the Owner / Consultant.

4.20.4 All piping shall be straight and direct with requisite slopes provided to headers and jacketed

lines as indicated on drawings. Piping shall generally be routed parallel to or at right angles to the plant columns and beams and shall be neatly and evenly spaced as shown in drawings

4.20.5 Pipes shall be installed at elevations and dimensions indicated on piping drawings and the

contractor shall be fully responsible for accurately laying out the pipe work. Should changes be necessary at site in order to avoid interference, this shall be carried out by the contractor in consultation with the Owner / consultant at no extra cost.

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4.20.6 Steam lines shall be provided with steam traps at low points in general. Drains and vents shall be provided on all pipe lines at low and high points respectively as well as at locations necessary for pressure testing, even though the same may not have been shown in the piping drawings.

4.20.7 Installation of jack screws will be done by the Contractor. Jack screws will be issued by the

Owner 4.20.8 Lines requiring steam tracing shall be laid by the contractor in strict compliance to the

specification drawings and details provided. Payment for tracer lines will be made at the corresponding unit rates quoted separately.

4.20.9 Location and design of pipe supports shown in Construction drawing, general arrangement

drawings, support manuals should be strictly adhered to. Pipe supports have been designed and located to effectively sustain the piping system for weight and thermal effects. Erection and fabrication of supports i.e. restraints, such as guides steps, anchors must be made in such manner that they will not contribute to the over stressing of a line, while protecting a weaker or more sensitive sections of a line, while protecting a weaker or more sensitive component e.g. turbine, pump, compressor of approved nozzles. Supports other than these specified above shall be designed fabricated and erected by the contractor.

4.21 FLANGES 4.21.1 While fitting up mating flanges, care shall be exercised to properly align the pipes and to

check the flanges for stress, so that faces of the flanges can be pulled up together without inducing any stresses at the pipes and equipment nozzles. The bolt holes of the flanges in the vertical plane shall straddle the vertical centre line of the pipe in the erected position and for flanges in the horizontal plane the bolt holes shall straddle the plant north south axis unless otherwise indicated on the drawings.

4.21.2 Flanged connections at the pumps, turbines, compressors shall be made in such a way so as

not to induce any stresses due to misalignment excessive gaps etc. The final tightening shall be redone when the machines are aligned completely and specifically authorized by the Owner / Consultant. Temporary protective covers shall be provided at all flanged connections of pumps, compressors, turbines and other similar equipments until the piping is finally connected.

4.22 FITTING 4.22.1 Wherever cold spring is specified, the contractor shall maintain the necessary gap provided

for cold spring as indicated in the drawings. Before cold pulling two sections, Consultant / Owner must check the gap and confirmation in writing is to be obtained in this respect that gap provided is in accordance with the drawings.

4.22.2 Expansion loops shall be fabricated from pipe and prefabricated bends and installed by the

contractor from material supplied by Owner / Consultant. 4.22.3 Slopes specified for various lines in the drawings shall be maintained by the contractor. In

case the contractor unable to maintain the indicated slope, he shall check the sagging of pipe with a precision spirit level. Vents and drains are shown in the isometrics of each line and these are intended, during hydraulic test, for releasing the trapped air and draining out the test fluid after testing. Valved vents and drains are also shown wherever required. The contractor shall provide vents and drains connections even these are not shown in the drawings and are found necessary by the Consultant/ Owner. The details of the type of connections to be adopted shall be given to the contractor at the time of work.

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4.22.4 Avoid any metal to metal pressure contact between stainless or acid resistant steel and unalloyed steel, as such contact can cause corrosion damage.

4.22.5 When applying wire-rope slings, keep these chaffing against the item being handled by

interposing cushioning material. Take care during field assembly that structural members of unalloyed steel do not rub against stainless steel and acid resisting steel components.

If any piping components have to be held in vices, or similar clamping devices, cover the vice jaws or holding surfaces with work protectors of the same stainless steel or of lead or copper sheet.

4.22.6 After the piping is erected in final position, it shall be cleaned, tested for tightness and kept dry

wherever instructed as described in this specification. 4.23 VALVES AND ON-LINE FITTINGS 4.23.1 All on-line fittings such as valves, strainers, traps, filters, thermowells, safety valves, control

valves, pressure reducers, ejectors, flame arrestors, sight glasses, rainhoods etc., shall be installed as specified in the drawings. Valves should preferably be with stem pointing upwards or horizontal as directed. They shall be installed in such a manner that hand wheels, stem and motors will not obstruct platforms and walkways. Temporary spool pieces in place of any of the on-line fittings shall be provided. Should such items be not available at the time of erection / testing the spool pieces shall be replace with the appropriate fittings when the same is available.

4.23.2 In case of control valves spool pieces shall be provided in their place on pipelines at the time

of testing and flushing. The spool pieces, shall be removed and control valves shall be installed in their place before trial running and pre-commissioning. Fabrication installation and removal of spool pieces is in the contractors scope of work and no extra payment shall be made for the same.

4.23.3 All globe valves shall be installed with the fluid pressure acting on the bottom of the discs. Globe valves, check valves, control valves shall be installed in the correct sequence and

direction as shown in line diagrams and piping drawings. In case the direction of flow is not given in the valve body, the contractor shall check then and mark the correct direction on the valves prior to their installation.

4.24 SUPPORTS, GUIDES AND ANCHORS 4.24.1 Pipe supports shall be provided generally as per the standard piping support details shown in

drawings / pipe support manual, location and design of main pipe racks only are given in drawings. But, for certain critical piping, location and design of pipe supports are also given in piping drawing. The contractor shall strictly adhere to these details and provide proper pipe supports.

4.24.2 For the field run piping, the contractor shall locate suitable and adequate supports consistent

with the design and type supports used in the rest of the plant. 4.24.3 Additional supports may have to be provided at site where necessary to avoid sagging and / or

transmitting undue loads to interconnecting equipment. Discretion for providing all such additional support lies with the Owner / Consultant.

4.24.4 If temporary pipe supports are required during installation, the contractor shall provide the

same at no extra cost and remove the same on fixing of permanent supports.

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4.24.5 Welding on any piping, machinery or equipment for the purpose of pipe / valve support shall not be done unless otherwise indicated on drawings or written permission is obtained from the Owner/ Consultant.

4.24.6 Correct installation of supports at pumps and compressors is a must. The following points are

to be checked after installation with Owner / Consultant and necessary confirmation in writing is to be obtained in this respect.

i. Restraints installed properly. ii. Clearance as per support drawings. iii. Restraints strength adequate (visual) iv. Insulation (does not restrict thermal growth) v. Spring supports located as per support drawings, spring removed and cold load

setting checked. Interference and travel from cold to hot to be checked. 4.24.7 Lines shown with the pipe hangers shall be installed with hanger rods set at a slope in the

direction opposite to the pipe movement from the operation. No supports shoe/ cradle shall be offset unless shown specifically in the drawing. Spring supports shall be checked for the range of movement and adjusted if necessary to obtain correct positioning in the cold condition.

4.24.8 Fabrication and erection of supporting elements and structural fixtures wherever required and

as pointed out by the Owner / Consultant shall be carried out by the Contractor. 4.24.9 For fabrication of pipe supports, payment will be made separately as per unit rates quoted. 4.24.10 However, for spring hangers supplied by the owner, piping rates shall be inclusive of these

supports. 4.25 INSTRUMENTS 4.25.1 In case of instruments the limits of piping contractor are clearly shown in the drawings

provided (such as up to first block valve, nozzle and flanges taps, etc.). In addition to this, the contractor shall install all on-line instruments such as restriction orifices / orifice assemblies with first block valves venturies, control valves, flow integrators, positive displacement meters, with strainers, pressure relief / safety valve, rotameters, rots transmitters, etc. Though exact location is indicated on drawing for take off for temperature pressure flow level, sample connections etc. The contractor shall ensure correct orientations site in consultation with the Owner/ Consultant before starting final welding. Care shall be used a control valves, flow meters, etc., to avoid contamination with dust and foreign matters.

4.26 BOLTS & NUTS 4.26.1 During erection of the piping, the contractor shall use proper number and size of bolts and

nuts as per drawings and specifications. The contractor shall clean all bolts and nuts if required with rust removing compound and provide approved quality of grease mixed with graphite powder thoroughly on all the bolts and nuts to prevent rusting during storage of his stores, immediately after erection and when the flanged joints are opened and remade for any purpose including flushing, testing and alignment of equipment etc. The grease and graphite powder shall be supplied by the contractor within the rates for piping work.

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4.27 STRAINERS 4.27.1 The installation of the conical strainers between two flanges shall be part of piping erection

work and no separate payment will made for this work. 4.28 ASSEMBLY 4.28.1 The assembly of various piping components shall be done so that the completely erected

piping conforms to the requirements of the specification as wells as the arrangements and details shown in construction drawings.

4.28.2 All flanged pipe sections and flanged appurtenances shall be accurately lined up before

making up flanges in order to prevent any stresses from slinging or forcing the piping in to place by means of flange bolts. Flange facings shall be true and perpendicular to the axis of the pipe.

All bolts shall extend completely through their nuts but not more than 1/2”. All flange bolts connections shall be off - centre lines unless otherwise required. 4.29 FLANGE JOINTS WITH A GASKET 4.29.1 The following procedure shall be adopted when assembling

a) Brush off the flange surfaces. b) Align the flanges. c) Insert two or three aligning pins. d) Remove the gasket from the package, drop into its place. e) Cleaning bolts and nuts if required with rust removing compounds and grease with

graphite powder. f) Insert bolts into free holes and tighten. g) Replace aligning pins with bolts and nuts. h) Tighten all bolts evenly first on the quarter and then gradually in symmetrical pattern to

ensure equal torque on the bolts. 4.29.2 Full face drilled gaskets shall be used on all flat faced flanges unless specified otherwise.

During erection / installation of the piping, proper number and size of the nuts and bolts shall be fitted as per drawings and specifications. All flanged joints shall be so fitted that the gasket contacts faces bear uniformly on the gasket and then made up with relatively uniform bolt stress.

4.29.3 In case of Tie-in-joints the joint fit up will be checked and approved by Owner/ Consultant.

Root run will be checked by dye penetration testing. The joint will be fully radiographed and defects, if any will be rectified and re-radiographed. All these will be carried out at contractors cost. The tie-in-joints will not be tested hydrostatically.

4.30 STRUCTURAL ATTACHMENTS 4.30.1 Reinforcement pads for structural attachment shall be provided with an untapped hole of 6mm

diameter for venting, drilled prior to welding to header. Attachment welds shall be in accordance with 4.18 & 4.19

4.31 TREATMENT AFTER FABRICATION 4.31.1 Where pipe work is required to be lined, coated or given treatment of any kind after

fabrication, these operations will be subject of separate specification.

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4.32 FABRICATION PRIORITIES AND MATERIAL

4.32.1 Where contract requirements demand, the company will inform the contractor/ Fabricator of the fabrication priorities, which are subject to periodic revision and updating. The contractor/ fabricator shall provide a fabrication control system that is flexible enough to accommodate reasonable change in priority.

4.32.2 Optimisation on weight or work content shall not be factors of fabrication priority.

4.32.3 The company reserves the right to request the production of pipe spools where minor items of the materials are not available in time, e.g half couplings, full couplings, bosses, sockolets etc.

4.32.4 The contractor/ Fabricator shall be able to maintain production with these variations and absorb any double handling necessary.

4.33 INSPECTION

4.33.1 Pipe work shall be checked against the Engineering Drawings issued for construction and other related documents to verify that it complies with the company’s requirements, as fabricated.

4.33.2 Fabrication shall have dimensions falling within the tolerances defined elsewhere in this document.

4.33.3 All completed welds shall be visually examined for visible defects.

4.33.4 For non-destructive test requirements, reference should be made to the Annexure in piping material specification.

4.34 PROTECTION 4.34.1 The contractor/ fabricator shall ensure that all fabricated pipe work is protected against

corrosion and mechanical damage during storage, transportation and erection. 4.35 PIECE MARKING

4.35.1 All spool pieces shall be marked with proper identification for ease of assembly. Each spool shall be marked with the following, starting from the direction of flow arrow shown in the Isometrics/ drawings.

• Piece identification mark e.g. MK-1, MK-2 etc.,

• Line Number

• Isometric number

4.35.2 Hard stamping shall not be used as a method for marking pipe work. 5.0 RELATED DOCUMENTATION (REFERENCES)

Z SS 005 : Specification for Piping-Welding

Z SS 006 : Specifications for piping –flushing, testing and inspection

6.0 RECORDS

None

7.0 ATTACHMENTS/ APPENDICES

Refer to “Table of Contents”

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ATTACHMENT: 7.1

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ATTACHMENT: 7.2

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ATTACHMENT 7.3

1. THERMAL CUTTING

TABLE 1

PREHEAT TEMPERATURES FOR THERMAL CUTTING

MATERIAL Preheat Minimum o C

Carbon Steel See Notes below

1 Cr ½ Mo. 100, See Notes below 1 ¼ Cr ½ Mo. 100, See Notes below 2 ¼ Cr 1Mo. 150, See Notes below 5 Cr ½ Mo. 150, See Notes below

7 Cr ½ Mo. 150, See Notes below 9 Cr ½ Mo. 150, See Notes below Carbon ½ Mo. 100, See Notes below

Notes:

• Where carbon content is greater than 0.25% or wall thickness is greater than 19mm (¾ in.) a preheat of 80 degree C minimum shall be applied.

• Preheat shall be applied uniformly around pipe circumference prior to cutting.

• Treatment after thermal cutting

1. Remove all slag.

2. Oxide skin on weld preparation to be dressed back to clean metal by grinding, machining or filing.

2. COLD BENDING OR FORMING

TABLE 2

Materials Max bending Temp 0C

Heat treatment after Bending

Carbon steel 620 Note-1

1 ¼ Cr. ½ Mo. 650 None 2 ¼ Cr. 1Mo. 680 None 5 Cr. ½ Mo. 720 None Carbon ½ Mo. 650 None Austenitic Cr. Ni. 425 Note-2

Notes:

1. Cold bent carbon and low alloy steel pipes in all thicknesses shall be stress relieved when impact tested. All pipes intended for caustic, or any other service, likely to induce stress corrosion cracking, shall also be stress relieved (Table 5). This information will be defined in the contract specification.

2. Under certain circumstances e.g. when the fabrication is to be exposed to

conditions which promote stress- corrosion cracking, solution annealing at 1050- 1100

0 C should be considered.

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Definitions:

1. For ferritic steels, cold bending involves operations at temperatures below the lower critical point; the temperature limitations of Table 2 make allowances for safe margin below this temperature.

3. HOT BENDING OR FORMING

TABLE 3

Materials Hot bending Temp 0C Heat treatment after Bending

Carbon steel 850- 10500 C (N) 900 - 950

0C, Note 1

1 – 9 Cr. Mo. 900- 11000 C (N) 900 - 950

0C and (T), Note 2

Carbon ½ Mo. 900- 11000 C (N) 900 - 950

0C, Note 3

Austenitic Cr. Ni. 950- 11000 C Solution Annealing at 1050- 1100

0 C, Note 4

Notes:

1. Heat treatment may not be necessary. Precise requirements are defined in the

contract piping specification.

2. Normalise (N) and Temper (T) as defined in contract piping specification.

3. Normalise (N) as defined in the contract piping specification.

4. The complete item shall be normally be heat-treated. Local heating shall not be used except under special circumstances with Company approval.

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4. PREHEATING REQUIREMENTS FOR WELDING

TABLE 4

PRE-HEATING REQUIREMENTS FOR WELDING

Low Hydrogen Metal (Note 2) Non Low Hydrogen Metal (Note 2) Material Thickness (mm) Note 1 Minimum Pre-heat Thickness (mm) Note 1 Minimum Pre-heat

Greater than 30 800 C Greater than 20 80

0 C C.S Less than or equal

to 0.25% of Carbon Less than or equal to 30 100 C Less than or equal to 20 10

0 C

Greater than 12.5 1000 C Greater than 12.5 100

0 C C.S greater than 0.25%

of Carbon Less than or equal to 12.5 100 C Less than or equal to 12.5 10

0 C

Greater than 12.5 1000 C Note 3

Carbon ½ Mo. Less than or equal to 12.5 10

0 C Less than or equal to 12.5 100

0 C

Greater than 12.5 1500 C Note 3 1 Cr. ½ Mo.

1 ¼ Cr. ½ Mo Less than or equal to 12.5 1000 C Note 3

Greater than 12.5 2000 C Note 3 2 ¼ Cr. 1Mo.

3 Cr. 1Mo. Less than or equal to 12.5 1500 C Note 3

5 Cr. ½ Mo. 7 Cr. ½ Mo. 9 Cr. 1 Mo

ALL 2000 C Note 3

3 ½ Ni. 5 Ni. 9 Ni.

Consult Company Construction department

Notes:

1. Greater component thickness at weld joint.

2. Low hydrogen weld metal shall contain not more than 10 ml of diffusible hydrogen, per 100g of deposited weld metal (BS 639).

3. Only Low hydrogen weld metal shall be used.

5. POST WELD HEAT TREAMENT REQUIREMENTS

TABLE 5

Material Thickness Temperature Minutes of Soak

Time Maximum Hardness (Note 1)

(mm) 0 C

Per mm

Minimum Vickers Brinell

Less than or equal to 20 (Note 2)

Nil (Notes 2 & 3) Nil Nil 237 225 Carbon Steel

Greater than 20 580- 620 (Note 3) 2.5 30 237 225

1 Cr. ½ Mo. 1 ¼ Cr. ½ Mo

All (Note 5) 705- 740 (Notes3, 4 & 6) 5 120 237 225

2 ¼ Cr. 1Mo. 3 Cr. 1Mo.

All 710- 750 (Notes3, 4 & 7) 5 120 253 241

5 Cr. ½ Mo. 7 Cr. ½ Mo. 9 Cr. 1 Mo

All 720- 760 (Note 3, 4) 5 120 253 241

3 ½ Ni. 5 Ni. 9 Ni.

Consult Company Construction Department

Carbon ½ Mo.

All (Note 6) 650- 680 (Notes 3, 4 & 5) 2.5 60 237 225

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Notes:

1. The method employed for hardness testing shall be of identifying peak hardness values, which occur in the heat-affected zone. Acceptable methods are the Vickers test preferably with a load of 10 Kg for laboratory evaluation of weld test pieces and portable dynamic tests for assessment of production welds.

2. Post weld treatment may be required on carbon steel and low temperature

carbon steel for process reasons, e.g. caustic or chloride service, regardless of wall thickness. Such requirements will be defined in the Piping specification.

3. i) Where a static furnace is used, the furnace temperature shall not exceed

4000 C when inserting the weldment.

ii) The heating rate shall not exceed the following

For pipes of thickness up to and including 25mm- 220

0 C per hour; for pipes

of thickness over 25mm- 220

0 C x (25

0 C /t) per hour, or 55

0 C whichever is

greater. iii) For pipes thickness t up to and including 25mm - 275 x (25

0 C /t) per hour or

550 C per hour, whichever is greater.

4. The cooling rate down to 4000 C shall not exceed the following:-

For Pipes of thickness t up to and including 25mm – 275

0 C per hour.

For pipes thickness t over 25mm - 275 x (25

0 C /t) per hour or 55

0 C per hour,

whichever is greater. 5. Post weld heat treatment is not required for thicknesses up to and including 12.5

mm providing the hardness in the weld and heat affected zone does not exceed 237 Vickers (225 Brinell).

6. Post weld heat treatment shall be carried out at 630

0 C - 670

0 C, when optimum

creep properties are required.

7. Post weld heat treatment shall be carried out at 6800 C - 720

0 C, when optimum

creep properties are required. In this case the minimum soaking time shall be 180 minutes regardless of thickness.

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8. DISSIMILAR METAL WELDS

TABLE 6

1ST

Base Metal 2nd

Base Metal Filler Material Pre-Heat Post Heat Notes

Carbon Steel C. ½ Mo. 1-3 Cr. Mo.

As for 2nd

Base metal

As for 2nd

Base metal

As for 2nd

Base metal

Note 1

Carbon Steel 5- 9 Cr. Mo. 2 ¼ Cr. Mo. As for 2

nd Base

metal As for 2

nd Base

metal Note 1 & 2

Carbon Steel Austenitic S.S E309

Inconel82/182 or Equiv.

As for 1st Base

metal Consult the company

-

Cr. Mo. Higher Cr. Mo. As for 2

nd Base

metal As for 2

nd Base

metal As for 2

nd Base

metal Notes 1 & 2

Cr. Mo. Carbon.½ Mo.

Austenitic S.S E309

Inconel82/182 or Equiv.

As for 1st Base

metal As for 2

nd Base

metal

1-3 Cr. Mo. As for 2

nd Base

metal As for 2

nd Base

metal As for 2

nd Base

metal Note 1

Carbon.½ Mo. 5- 9Cr. Mo. 2 ¼ Cr. Mo.

As for 2nd

Base metal

As for 2nd

Base metal

Note 1 & 2

Austenitic S.S C.S, C.½ Mo., Cr. Mo.

E309 Inconel82/182 or

Equiv.

As for 2nd

Base metal

Consult the Company Piping Group (piping shall consult FEG)

Austenitic S.S Another Austenitic S.S

As for 2nd

Base metal

None None

Notes:

1. When welding any of the Cr. Mo. Steels in situations where P.W.H.T is impractical and higher hardness values are likely occur, consideration shall be given to welding with INCONEL 82/ INCONEL 182.

2. When joining of steels widely variable compositions, such as:

Carbon steel/ 1Cr. ½ Mo./ 1 ¼ Cr. ½ Mo. Welding to 5Cr. ½ Mo./ 7Cr. ½ Mo./ 9Cr. 1Mo. Consideration shall be given to use of mutually compatible intermediate transition piece. Where such changes occur, the company construction Department shall be consulted.

ZSS005 Std Spec for Piping Welding

Page 1 of 1


PIPING - WELDING




By

Checked

By

Approved

By

0 02.11.2001 14 Issue for use MRAK CLS AGG

1 02.08.2004 14 Cover page revised ALB SGR AGG

JACOBS

DATE: 2 August 2004 SPECIFICATION NUMBER: Z SS 005 PAGE 2 OF 14 STANDARD SPECIFICATION FOR PIPING – WELDING REVISION NO: 1


TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE

3.0 INTRODUCTION

4.0 WELDING EQUIPMENT AND ACCESSORIES 5.0 WELDING PROCESS

6.0 WELDER'S QUALIFICATION AND PROCEDURE TESTS

7.0 WELDER'S SYMBOL 8.0 WELDING PROCEDURE

9.0 CLEANING OF WELD JOINTS

10.0 INSPECTION AND TESTING GENERAL 11.0 EXAMINATION METHODS AND REQUIREMENT

12.0 DEFECTS

13.0 WELDING CONSUMABLES

14.0 APPENDICES 14.1 APPENDIX I - WELDING SPECIFICATION CHART

JACOBS

SPECIFICATION NUMBER: Z SS 005 DATE: 2 August 2004 STANDARD SPECIFICATION FOR PIPING – WELDING PAGE 3 OF 14 REVISION NO: 1


1.0 PUPOSE

This purpose of this specifications is to define the construction requirements of welding for pipelines.

2.0 SCOPE 2.1 This specifications supplements the applicable code requirements / specifications / drawings

for fabrication, erection, inspection, testing of pipelines. 2.2 Engineering drawings/ codes/ standards shall take precedence over this specifications if there

are any conflicting clauses. 3.0 INTRODUCTION

The specification shall be adopted to all welded pipe joints of Carbon Steel and Stainless Steel piping system coming under the Plant. The welded pipe joints are defined as under:-

a) All line joints of the longitudinal and circumferential butt welded and socket welded

type. b) Split sleeve joints on certain S. S. Pipes. c) Attachments of castings, forging, flanges and other supporting attachments to pipes. d) Welded manifold headers and other sub-assemblies. e) Welded branch connections with or without reinforcing pads. f) Manufacture of welded / fabricated piping components. g) The attachment of smaller connections for vents, drains, drips and other instrument

tappings.

All welding, heat treatment, other ancillary welding equipment and the welding personnel shall be in accordance with the following accepted standards, codes and procedures, latest editions as applicable.

a) Code for Petroleum Refinery Piping - ANSI B31.3 b) Standard for Welding Pipes and other Related Facilities - API 1104 c) Welding Qualifications - ASME Sec. IX d) Code of Procedure for Metal and Welding of C.Steel - IS-823 e) The Indian Boiler Regulations - IBR In the event of any variation due to additional requirements over and above those that are obligatory as per codes, this specification shall be binding.

4.0 WELDING EQUIPMENT AND ACCESSORIES

All welding machines, line up clamps, levelling machines and other equipment’s used in connection with the welding work must be satisfactory and must be kept in good mechanical condition so as to produce sound welds. Only D.C. Motor generator welding sets or Rectifier Welding sets shall be used for welding on pipes.

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For TIG welding on stainless steel pipes high frequency units shall be used in conjunction with D.C. Motor generator welding sets or Rectifier Welding Sets.

5.0 WELDING PROCESS 5.1 No welding process or procedure shall be adopted without prior approval of the Owner /

Consultant. 5.2 All piping shall be welded using either the Shielded Metal Arc Welding (SMAW). Process or

the Gas Tungsten Arc Welding (GTAW) process or a combination of the two. 5.3 Oxy-acetylene brazing shall be used for brazing copper and copper alloys where used. Oxy-

acetylene soldering process shall be used for soldering bronze to C.S. and Cast Bronze to copper.

5.4 For welding of all grades of Steel and Nickel alloys by the GTAW process, a 2% Thoriated

Tungsten Electrode confirming to AWS a5, 12-69 EW TH - 2 classification shall be used. 5.5 Any other welding process, if proposed by the Contractor, shall require specific approval of

Owner / Consultant.. 5.6 A combination of different welding processes or a combination of electrodes of different

classes / makes could be employed for a particular joint only after duly qualifying the welding procedure to be adopted and obtaining the approval of Owner / Consultant.

6.0 WELDER'S QUALIFICATION AND PROCEDURE TESTS 6.1 WELDER'S QUALIFICATION

Any Welder who is entrusted with the performance of welding work shall passed the pipe Welder Test to ASME Section IX. Prior to his assignment in the field, the Welder shall weld a test specimen in a horizontal and vertical position or as directed by Owner / Consultant as per the requirement of ASME Section IX. API 1104 or other equivalent / applicable code as may be required and get himself qualified for welding on the job. Depending on the pipe welding shall be done on one or several pipes. For all welding coming under IBR, Welders shall be qualified by Boiler Inspectorate possessing IBR.

Certificate in addition to above shall only be employed. The Owner / Consultant shall witness the test and certify the qualifications of each welder separately. IBR Welders shall be approved by the Boiler Inspector before deployment on the Job. The test specimen shall be 100% radiographed. The test specimen 2.5 cm in width, shall be out from the pipe piece at right angles to weld. The test specimens shall be subjected to root bend, face bend, tests. These tests shall be arranged by the Contractor at his own cost but shall be witnessed by the Owner / Consultant. The manner of performing the test and the results required shall be in accordance with ASME Section IX, API - 1104 and ASME Boiler and Pressure Vessel Code as may be applicable.

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The contractor shall submit the Welders qualification test report in the standard format as required by Owner / Consultant. The Welder shall not be entrusted with any work until the test specimen has been fully evaluated and approved. If a Welder is found to perform a type of welding or in a position for which he is not qualified, he shall be debarred from doing further work. All such welds performed by an unqualified Welder shall be out and redone by a qualified welder at the expense of the Contractor.

6.2 Welding procedure qualification tests shall be carried out in accordance with job requirements

and the relevant requirements laid down in Section IX of ASME Boiler and Pressure Vessel code or other applicable codes and the job requirement. The Contractor shall submit the welding procedure to the Owner / Consultant who will check and approve the welding procedure and shall release the procedure for procedure qualification tests. Standard tests shall be performed in all cases. In addition to these standard tests. Tests like micro-examination, hardness tests, dye-penetration examination, charpy V notch and U notch impact tests, etc., shall be carried out on specimens depending on the type of base, materials, operating conditions and requirements laid down in specification. It shall be the responsibility of the Contractor to carry out all such tests free of charge. The procedure qualification test shall be carried out by the Contractor at his expenses.

It shall be the responsibility of the Contractor to carry out all the tests required to the satisfaction of the Owner / Consultant.

7.0 WELDER'S SYMBOL

After qualification, the Welder's symbol shall be confirmed and recorded in a list. This symbol (die stamp) shall be used for identifying all welds made by that welder. For thin-walled and alloy steel pipes, the welding superintendent may decide that the Symbol will be applied to the work piece by painting.

8.0 WELDING PROCEDURE 8.1 EDGE PREPARATION

The edges to be welded shall be prepared to meet the joint design requirement by any of the following methods given below: a) Carbon Steel

Gas cutting, machining or grinding methods shall be used. After gas cutting oxides shall be removed by chipping or grinding.

b) Low Alloy Steel Containing up to 2.5% Chromium

Gas cutting, machining or grinding methods shall be used. After gas cutting machining or grinding shall be carried out on the cut surfaces.

c) Stainless Steel

Plasma cutting, hacksaw cutting, machining or grinding methods shall be used. Plasma cutting out shall be machined or ground smooth.

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8.2 CLEANING

The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides, sand, earth and other foreign matters. The ends shall be completely dry before the welding commences.

8.3 ALIGNMENT

The pipe shall be aligned so that the longitudinal mill weld in the pipe is on the top 90 degrees of the pipe lines (except on vertical bends) and in such a way that the longitudinal Mill welds are staggered not less than 45 degrees. Elements to be joined by welding shall be aligned with the aid of internal or external centering facilities. Root opening and root gap shall depend on the root welding procedure and as per code specified. The welding butts as well as the surroundings must have a bright finish and be free of grease. For pipes of wall thickness 5 mm and above the ends to be welded shall be secured in position with the aid of couplers, yokes, and 'c' Clamps to maintain perfect alignment. Yokes shall be welded to the pipes with the electrodes suitable for welding the parent pipe material and shall be detached after the completion of weld, without causing any surface irregularities. Any irregularity caused on the pipe surface must be suitably repaired to the satisfaction of the Owner / Consultant. Tank welds, for maintaining the alignment, of pipe joints shall be made only by qualified welders. Since the tack welds become part of the final weldment they shall be executed carefully and shall be free from defects. Defective tack welds must be removed prior to the actual welding of the joints. Tack welds should be equally spaced - Minimum number of tacks shall be:

2 tacks - for 2 ½" dia, and smaller 4 tacks - for 3" to 12" pipe dia. 6 tacks - for 14" pipe dia, and larger 8.4 WEATHER CONDITIONS

The parts being welded and the welding personnel should be adequately protected from the rain and strong winds. In the absence of such a protection no welding shall be carried out. During field welding using CTAW process, particular care shall be exercised to prevent any air current affecting the welding process.

General Welding Requirements

a) Surfaces to be welded shall be free from paint, rust, oil, grease, dust or any other contamination.

b) Root passes shall be made with electrodes / filler wires recommended in the welding

specification chart and as approved in procedure test. The preferable size of the electrodes is 2.5 mm diameter (12 SWG) but in any case not greater than 3.15 mm (10 SWG).

c) Upward technique shall be adopted for welding pipes held fixed with its axis

horizontal.

JACOBS



d) The root pass of butt joints should be executed properly so as to achieve full penetration with complete fusion of the root edge without under cutting along the sides of the weld.

e) Welds shall be cleaned between passes to remove all traces of slag and flux before

successive beads or layers are deposited. The craters at the starting and stopping points of each individual bead shall be carefully examined and any defects shall be removed by grinding. Wire brushed used for cleaning stainless steel joints shall have stainless steel wires and the grinding wheels used for grinding stainless steel shall be of a suitable type. Separate grinding wheels and wire brushes should be used for Carbon steel and stainless steel.

f) Welding shall be continuous and uninterrupted during a pass. g) While the welding is in progress care should be taken to avoid any kind of movement

of the components. h) Fillet weld shall be made by shielded metal arc / CTAW welding process irrespective

of the thickness and class of piping. Fillet welds shall preferably be slightly convex and shall be free from undercutting and overlap at the tee of the weld.

i) Peening shall not be permitted. j) Dams used for conserving inert gas during purging, shall be removed after completion

of the welding and shall be accounted for. k) Joint shall be completed using the class of electrodes recommended in the welding

specification chart. l) Two weld beads shall not be started at the same point in different layer.

m) Butt joints shall be completed with a cover layer that would effect good fusion at the

joint edges and a gradual notch free surface. n) The welding shall be free from under cuts and other defects.

9.0 CLEANING OF WELD JOINTS

All weld joints shall be free from adherent weld spatters, slag, swarp, dirt or foreign matter. This can be achieved by brushing. For stainless steel, brushes with only stainless steel bristles shall be used.

10.0 INSPECTION AND TESTING GENERAL

a) Owner / Consultant shall have free access to all concerned areas, where the actual

work is being performed. b) Owner / Consultant shall be entitled to inspect at shop or field where prefabrication

and erection of pipe lines are being done with the following objectives:

i) To supervise the welding procedure qualification. ii) To supervise the welder performance qualification. iii) To check the conformance to relevant standards and suitability of various

welding equipment’s and the welding performance.

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iv) Any other checking / inspection work connected with Construction work. v) For welding of all grades of steel and nickel alloys by the GTAW process, a

2% Thoriated Tungsten electrode confirming to AWS AS 12-69 EWTH - 2 classification shall be used.

vi) Argon Gas Cylinder (Min. purity 99.95%) with regulator and flow meters. vii) Nitrogen Gas Cylinder (Min. purity 99.95%) with regulator and flow meter. viii) The power source shall consist of a meter generator welding set connected

with a high frequency unit or rectifier welding set connected with a high frequency set.

ix) Inspection of all welds shall be carried out as per ANSI and other relevant

applicable codes, latest edition. All finished welds shall be visually inspected for parallel and axial misalignment of the work, excessive reinforcement, concavity of welds shrinkage, cracks, inadequate penetration, un-repaired burn through under cuts, dimensions, of the weld, surface porosity and other surface defects.

INTERNAL WELD PROTRUSION ( INCLUDING PENETRATION BEAD ) Normal Pipe Size All Protrusion in mm Upto 1" NB 1.0 mm or 3% of pipe outside dia. whichever is less. Over 1" NB upto 2 ½" NB 1.5mm or less Over 2 ½" NB upto 10" NB 2.0mm or less Over 10" NB upto 18" NB 2.5mm or less Normal Pipe Size All Protrusion in mm i) Over 18" NB 3.0mm or less ii) Weld ripple irregularities 2.5mm or less iii) Lack of uniformity in Bead 2.5mm or less iv) Lack of uniformity of leg length 2.5mm or less v) Unevenness of Bead 2.5mm or less vi) Weld undercutting (Weld undercutting 2.5mm or less of 0.5mm or less shall be smoothly finished) vii) Overlaps 1.5mm or less viii) Bead Deflection 2.5mm or less

ix) Thickness of weld reinforcement

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Nominal Wall Thickness Upto 12mm 2.5mm or less Upto 12mm upto 25mm 3.0mm or less Upto 25mm upto 50mm 3.5mm or less Upto 50mm 4.0mm or less 10.1 SHIELDING AND PURGING

Purging at a flow of approx. 0.28. m³ / hr subjected to maximum of 1.4m³ / hr depending on diameter of pipe until 6 times the volume of the Section of piping between the dams has been replaced is usually adequate. In no case should the initial purge be for less than 10 Minutes.

10.2 After the initial purging is completed the flow of Backing gas during welding should be reduced

to a point where only a slight positive pressure prevails. For systems which have a small volume (up to 14 liters) to be purged during welding a gas flow rate of 0.14 m³ / hr is usually adequate. Systems of larger volume may require higher flow rates and these should be established at the procedure test. Purging is not required on socket type welded joints, provided it is ensured that oxidation does not take place in case of stainless steel material. Argon Gas shall be used for shielding purpose.

The rate of flow for shielding purposes shall be established in the procedure qualification. 10.3 The filler wire shall be of approved quality and test certificates for the batch production of filler

wire from the manufacturer shall be furnished by the Contractor to the Owner / Consultant for approval.

TIG Welding shall be done in stringer runs. 11.0 EXAMINATION METHODS AND REQUIREMENTS The type and extent of weld examination shall be as per the piping specification attached. 11.1 VISUAL EXAMINATION As a matter of principle the exterior of all weld joints must be examined visually and as far as

possible the interior also before starting any other examination. 11.2 RADIOGRAPHY EXAMINATION 11.2.1 The radiography examination shall be carried out in accordance with the piping specification. 11.2.2 The procedure and quality of radiography examination limits of acceptability, repair and

removal of defects etc., shall be as per API Standard 1104, ANSI 1331.3 and other applicable codes.

11.2.3 Where 10% radiography is called for, this shall be spread uniformly over all pipe diameters in

a particular system as follows: In diameter up to and including 500mm shall mean 10% of the joints in each pipe diameter

encountered.

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11.2.4 The radiographers employed shall be qualified as stipulated in the said codes and must be fully familiar with radiographic equipments and methods including safety procedure and thoroughly experienced in the field of radiographic work.

11.3 DYE PENETRATION TEST Liquid penetrant examination is a method of non destructive examination which for the

detection of discontinuities open to the surface in ferrous and non ferrous material which are non porous. Typical discontinuities detectable by this method are cracks, seams, laps, cold shuts and laminations.

11.3.1 Surface Preparation

a) In general satisfactory results may be obtained when the surface is in the as-welded,

as-rolled, as-cast, or as-forged condition. When the surface irregularities mask the indication of defects, grinding or machining of the surface will be required.

b) Prior to liquid penetrant examination, the surface to be tested and any adjacent area

within atleast 25mm of the surface to be tested shall be dry and free of any dirt, grease, lint, scale, welding flux, spatters, oil or any extraneous matter that would obscure surface openings or otherwise interfere with the test.

11.3.2 Drying

Drying of the surface to be tested, after steaming can be accomplished by normal evaporation.

11.3.3 Penetrant Application

a) The penetrant solution confirming to the code IS 3658 / 1966 shall be applied by dipping, brushing or spraying.

b) Penetration time is critical. In general, the finer and tighter the discontinuity, the longer

the penetration time should be. At temperature between, 16°C and 52°C, the penetration time shall be atleast 10 minutes, but this minimum time may have to be extended under certain conditions.

c) Penetrant shall not be allowed to become "tacky". If a long penetration is required,

fresh penetrant shall regularly be applied to the surface to ensure that the surface is wet at all times.

d) After the penetration time specified in the procedure has elapsed, any penetrant

remaining on the surface shall be removed. 11.3.4 Developing

a) The developer shall be applied as soon as possible after the penetrant removal

operation and the interval shall not exceed the time as specified in standard document and codes.

b) The developer is a suspension of powder in water or a volatile solvent and shall be

applied by dipping or spraying.

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11.3.5 Examination a) It is a good practice to observe the surface during the application of the developer in

order to detect the nature of certain indications, which might tend to bleed out profusely. Final interpretation however, shall be made after allowing the penetrant to bleed out for a minimum of seven (7) minutes to a maximum of thirty (30).

b) The developer should form a more or less uniform coating. Surface defects are

indicated by bleeding out of the penetrant, which is normally of a deep red colour. 11.4 ULTRASONIC TEST

The ultrasonic test may be performed, provided that the work pieces are of suitable material and wall thickness and that qualified personnel is available.

12.0 DEFECTS Defects revealed by visual inspection as well as radiographic inspection and / or dye penetrant check of welds shall be repaired / rectified by the Contractor at his cost to the satisfaction of the Owner / Consultant. The repaired portion shall be re-examined by dye check and / or radiographically at no extra cost to the Owner. The repairs carried out shall meet the approval of the Owner / Consultant. For Weld Joints other than 10% radiography, 2 additional checks shall be carried out for each weld joint judged "Not applicable" and these shall be made on welds done by the welder who is responsible for defective workmanship at no extra cost to the Owner. A register of welding checks shall be maintained and continually updated by the Contractor, said register shall indicate the opinions expressed by the Owner on examining welding joints, welding to be repaired and the reference of welder who has performed the work. A register revised to the date of their last entry shall be consigned to the Owner at the end of work. All radiographic films submitted by the Contractor or the independent Agency carrying out the radiographic inspection of welds shall be the property of the Owner / Consultant. All cost and expenses involved in radiographic inspection including but not limited to the cost of labour, materials, equipment, tools and payments to the independent agency by the relevant item of the Schedule of Rates. Repeat radiography due to defective unclear and unsharp films or in repaired joints due to contractor's fault shall be carried out at Contractor's cost.

13.0 WELDING CONSUMABLES The welding consumables used shall meet requirements of the relevant codes and shall produce a deposit with, which is compatible in chemical analysis and similar in mechanical properties to the parent material. Only consumables which have received the prior approval of the Owner / Consultant shall be used.

SS Consumables max. Ferrite contents 6% permissible

max. Copper 0.2% permissible Before proceeding with welding, Contractor shall submit for approval to the Owner / Consultant type, brand and size for each batch of consumables for use in each class of piping.

JACOBS



Different grades of electrodes shall be completely separated. The Contractor shall have facilities available for storing electrodes at recommended temperatures where specified. The consumables shall be stored and handled at all times during construction so as to avoid damage to them and to the containers in which they are transported. Those in open containers shall be protected from excessive moisture changes. Electrodes, filler wires and fluxes that show signs of damage or deterioration shall not be used. Electrodes shall be stored in electrode storage ovens at 250°C - 300°F or as otherwise, recommended by manufacturer.

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DATE: 2 August 2004 SPECIFICATION NUMBER : Z SS 005 PAGE 13 OF 14 STANDARD SPECIFICATION FOR PIPING – WELDING REVISION NO.: 1


14.1 APPENDIX 1 WELDING SPECIFICATION CHART

Sr.

Material

P.

MOC Specification

Pipe size and

Welding process

Material

Type of

Purging

Shielding

Remarks

No. No. thickness Root Pass

Filler Pass

Root Pass Filler Pass Joints

1 Carbon Steel

P1 A 53 Gr. ‘B’ API 5L Gr.‘B’ A 285 Gr.‘C’ IS 1239 IS 2062

Pipe Size 2” & above with wall thickness upto 19mm

SMAW SMAW E 6010 E6013 BUTT WELD

NA

NA

2 Carbon Steel

P1 A 106 Gr.‘B’ A 105 A 216 Gr. WCB A 181

Pipe Size 2” & above with wall thickness above 19mm

SMAW SMAW E6010 / E7016 / E7018

E7016 / E7018

BUTT WELD

NA

NA

3 Carbon Steel

P1 A 53 Gr. ‘B’ API 5L Gr.‘B’, IS 1239, A 106 Gr. ‘B’, A 105

Pipe size 1½” and below irrespective of thickness

SMAW SMAW E7018 E7018 FILLET WELD

NA

NA

4 Carbon Steel

P1 As in Sr. No. 1&2 Pipe Size 2” & above with wall thickness upto 19mm

GTAW SMAW ER70S2 E7018 / E7016

BUTT WELD

NA

Argon

5 Stainless Steel

P8 A 312 TP 304 A 312 TP 304L

Pipe Size 2” & above with wall thickness upto 12mm

GTAW SMAW/GTAW

ER308/ ER308 L

E308L E308

BUTT WELD

Nitrogen Argon

6 Stainless Steel

P8 A 312 TP 304 A 312 TP 304L

All sizes thickness > 12mm

GTAW SMAW ER308/ ER308 L

E308-15/ E308-16

BUTT WELD

-Do-

-Do-

7 Stainless Steel

P8 A 312 TP 321 All size, All thickness

GTAW SMAW ER347 E347-15/ E347-16

BUTT WELD

Nitrogen Argon

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14.1 APPENDIX 1 WELDING SPECIFICATION CHART

Sr.

Material

P.

MOC Specification

Pipe size and

Welding process

Material

Type of

Purging

Shielding

Remarks

No. No. thickness Root Pass

Filler Pass

Root Pass Filler Pass Joints

8 Stainless Steel

P8 A 312 TP 316 A 312 TP 316L

All sizes, All thickness

GTAW GTAW/ SMAW

ER316L ER316

ER316 - L/ E316 - L

BUTT WELD

Nitrogen Argon

9 Low Alloy Steel

P1 A 333 Gr. 6 All sizes, All thickness

GTAW SMAW ER70 S 2 E7018-Al E8018-Cl

BUTT WELD

NA

Argon

10 Low Alloy Steel

P9B

A 333 Gr. 3 All sizes, All thickness

GTAW SMAW ER80SNi 3 E8016-C2 / E8018-C2

BUTT WELD

NA

Argon

11 Low Alloy Steel

P3 A 335 P1 All sizes GTAW SMAW ER80S D2 E7010A1 E7018A1

BUTT WELD

NA

Argon

12 Low Alloy Steel

P4 A 335 P 11 All sizes, All thickness

GTAW SMAW ER80S B2 E8018 B2 E8015 B2 E8016 B2

E8018 B2 L

BUTT WELD

NA

Argon

13 Low Alloy Steel

P5 A 335 P 22 All sizes, All thickness

GTAW SMAW ER90S B3 E8018 B2 E8015 B2 E8016 B2

E8016 B2L

BUTT WELD

NA

Argon

NA - Not Applicable. NOTE : This is for guidance only and actual site requirement shall be decided as per applicable codes.

ZSS006 Std Spec for Piping Flushing Testing Inspection

Page 1 of 9


PIPING – FLUSHING, TESTING AND INSPECTION




By

Checked

By

Approved

By

0 02.11.2001 9 Issue for use. MRAK CLS AGG

1 02.08.2004 9 Cover page revised ALB SGR AGG

JACOBS

SPECIFICATION NUMBER : Z SS 006 DATE: 2 August 2004 STANDARD SPECIFICATION FOR PIPING – PAGE 2 OF 9 FLUSHING, TESTING AND INSPECTION REVISION NO: 1


TABLE OF CONTENTS 1.0 PURPOSE

2.0 SCOPE

3.0 FLUSHING

4.0 GENERAL REQUIREMENTS OF TESTING 5.0 TEST FLUID

6.0 TEST PREPARATION

7.0 PROCEDURE FOR PRESSURE TESTING 8.0 TEST RECORD

JACOBS

DATE: 2 August 2004 SPECIFICATION NUMBER : Z SS 006 PAGE 3 OF 9 STANDARD SPECIFICATION FOR PIPING – REVISION NO: 1 FLUSHING, TESTING AND INSPECTION


1.0 PUPOSE The purpose of this specification is to define the construction requirements of flushing, testing

and inspection of pipelines. 2.0 SCOPE 2.1 This specifications supplements the applicable code requirements/ specifications/ standards

for fabrication, erection, inspection, testing of pipelines. 2.2 Engineering drawings/ codes/ standards shall take precedence over this specification if there

are any conflicting clauses. 3.0 FLUSHING 3.1 Flushing of all lines shall be done before pressure testing. 3.2 Flushing of all lines including IBR lines etc. shall be done in the presence and as per the

approval of the Owner / Consultant. 3.3 Flushing of pipe lines will be done by fresh potable water or dry compressed air wherever

water flushing is not desirable to clean the pipe of all dirt, debris or loose foreign materials. 3.4 The supply of compressed air for flushing will be Contractor's responsibility and it will be done

at his cost. 3.5 It will be Contractor's responsibility to provide pumping equipment, compressors, water / air

hoses with accessories etc., Wherever required, instruments such as pumps, pressure gauges, safety valves etc. spool pieces, temporary gaskets, tools and tackles and all other arrangements, equipment, materials and consumables etc. required as aids for completing the flushing as per the directions of the Owner / Consultant.

3.6 During flushing, care shall be taken for on line instruments as per clause of this specification. 3.7 The Contractor shall carry out all the activities required before, during and after the flushing

operation arising from the flushing requirement such as but not limited to the following : 3.7.1 Removing of valves, specials, distance pieces, on line instruments and any piping part before

flushing. The flanges to be broken for this purpose should be envisaged by the Contractor, approved by the Owner / Consultant and should be provided with temporary gaskets at the time of initial erection.

3.7.2 After flushing is completed and approved, the valves, distance pieces, piping specials etc.

shall be re-installed by the Contractor with permanent gaskets. However, flanges at equipment nozzles and other places where isolation is required during testing, only temporary gaskets will be provided.

3.7.3 Flushing will be continued till the inside of the pipe is fully cleaned to the satisfaction of the

Owner / Consultant. 3.7.4 For air flushing the line / system will be pressurised by the compressed air at the required

pressure. Then pressure will be released by quick opening of a valve already in line or installed temporarily for this purpose.

This procedure will be repeated as many times as required till inside of the pipe is fully

cleaned. The arrangement for raising and releasing the air pressure will be made by the Contractor as per the approval of the Owner / Consultant.

JACOBS



3.7.5 During the flushing, discharged water / air shall be drained to the place directed by the Owner/ Consultant. Care shall be taken during flushing so as not to damage / spoil other agencies work. As desired by the Owner / Consultant, proper temporary drainage for flushing of water shall be provided by the Contractor. Precautions shall also be taken to prevent entry of water / foreign particles in to equipment, electrics, motors, instruments, electrical installations etc. in the vicinity of lines being flushed.

3.7.6 In case where fluid inlet in to the pipe lines through connected equipment such as columns,

vessels, exchangers etc. is unavoidable this shall be done after having approval of the Owner / Consultant. However, equipment thus included in the circuit for the flushing shall be completely drained and dried with compressed air after flushing is completed.

3.7.7 Wherever required as per specification lines will be dried with air after flushing. 4.0 GENERAL REQUIREMENTS OF TESTING The intent of this specification is to provide a basis and guide for carrying out field testing of

piping to ensure leak tightness. This covers the general requirements for testing of piping after erection as specified by the

code of Petroleum Refinery Piping ANSI B.31.3. Chapter VI Inspection and Test - Latest Edition.

Upon completion of installation the piping system shall be inspected to ascertain that each of

the following points have been adhered to : i) Proper use of material. ii) Correct erection of line (in accordance with drawings). iii) Correct installation of (temporary) blind discs to be employed during testing. iv) The correct application of pre-established pressure.

v) Sectioning of the line in correspondence with these materials and / or equipment, which are not a part of the test.

With the exclusion of instrumentation, piping systems fabricated or assembled in the field shall

be test in the field, irrespective of whether or not that have been pressure tested prior to site welding or fabrication (Process and Utility piping system).

For the steam piping falling under Indian Boiler Regulation, testing shall be done as per latest

Indian Boiler Regulation. The test shall be performed in accordance with the requirements of local Boiler Inspector, prior to testing all lines shall be flushed as per procedure in clause thereof. All tests shall be completed to the satisfaction of the Owner / Consultant. On completion of the test the system shall be dried with compressed air at the pressure decided by the Owner / Consultant and made ready for operation. From all permanent strainers the screens mesh shall be removed before flushing is done.

After completion of flushing and testing, draining and drying of lines, the permanent strainers

screens shall be cleaned and re-installed. During flushing temporary strainers shall be retained. After flushing temporary strainers shall be removed, cleaned and re-installed before testing. All joints remaining untested during hydro-testing such as nozzles in columns, vessels, heat exchangers etc. shall be tested pneumatically after the hydrogenating is over. Pneumatic test pressure will be indicated by the Owner / Consultant and Contractor shall ensure that this test pressure is not exceeded any time during this test.

JACOBS



All tests shall be conducted as per the procedure outlined in this specification. Lines repaired by welding subsequent to the pressure test shall be retested after the repair at the same test pressure originally applied. However, the Owner / Consultant may waive such retest in case of minor addition or alteration by taking some precautionary measure to assure sound construction.

Following basis for preparation of process / utility loops shall be followed by the Contractor. The selection of piping systems for individual test will be based on the following : 1) Test Pressure required. 2) Maximum allowable pressure for the MOC of piping. Depending on the above requirement and based on Construction completed / on construction

progress, maximum length of piping shall be included for each test. Piping checks incorporating various lines to be tested at the same process shall be marked on the P&I diagram.

4.1 Systems / lines may be tested in sections to facilitate completion of work in that area or areas,

however, such sections so tested shall be capped out, tagged suitably and subsequently tested as a complete system prior to final acceptance. Such weld joints (untested) may be exempted from hydraulic testing by the Owner / Consultant subject to radiography approval of these joints.

4.2 Lines, which are directly, open to atmosphere such as vents, drains, safety valves, discharge

shall not be tested but all joints shall be visually inspected. Wherever necessary, as decided by the Owner / Consultant, such lines shall be tested by continuous flow of fluid to eliminate the possibility of blockage.

4.3 Instrumentation pressure impulse piping shall start beyond the first block valve located in the

process line. During the pressure test this isolation valve must be kept closed to prevent dirt or any foreign matter entering in to the instrument piping. Temperature impulse connections shall be blocked off by a blind flange or threaded plug to be provided by the Contractor.

4.4 Locally mounted indicating pressure gauge may be tested with the piping if the test pressure

does not exceed the scale range. However, the gauge shall be blocked off from the piping during cleaning and flushing. Where lines to which they are connected will receive a higher test pressure the gauge shall be isolated by closing the gauge isolation valve.

The Owner / Consultant shall be notified in advance by the Contractor of the testing sequence

/ programme to enable him to be present for witnessing the test. The Contractor shall be fully responsible for making all necessary arrangements with the local Boiler Inspector to witness the necessary tests applicable to steam lines falling under purview of Indian Boiler Regulations.

Required number of copies of test certificates in this respect shall be obtained in the relevant

forms of IBR and shall be furnished to the Owner / Consultant. 5.0 TEST FLUID Fresh potable water shall be used as the testing medium for the hydrostatic testing of piping

unless specified otherwise. Air shall be used as alternate medium wherever specified in the line list / specification and for drying the lines. In testing of stainless steel equipment and piping water containing more than 50 ppm of chloride shall not be used.

In case chloride content of water is less than 50 ppm. water used for hydrostatic testing of

S.S. equipment and / or piping should be drained completely as soon as test is approved.

JACOBS



Salty water shall never be used for hydrostatic testing under any circumstances. Pressure testing for certain specific lines will have to be carried out as per piping specifications.

6.0 TEST PREPARATION All equipment, materials, consumables, and services mentioned below but not limited to them,

required for carrying out pressure testing of piping shall be provided by the Contractor at his cost.

- Pump sets for pressurisation, air compressor etc. - Hoses for water and other test fluid if any, with accessories and adaptor flanges.

- Supply, fabrication and erection of temporary carbon steel piping valves, fittings specials etc.

- Pressure gauges, safety valves and all such instruments with necessary connections. - Temporary gaskets wherever required as per specifications and instructions of the

Owner. - Soap solution, grease, graphite, white lead, paints etc. all consumables. - Tools, Tackles, pipe wrenches, spanners etc. - All aids not specified here but required for carrying out pressure test of piping. 6.1 Before testing all piping shall be cleaned by fresh potable water or blown with compressed air

where water flushing is not desirable to make it free from dirt, loose scale, debris and other loose foreign material as per the details given in clause thereof. This should be completed wherever required prior to completion of final weld in order that visual inspection of interior is possible.

6.2 INSTRUMENTATION 6.2.1 Any restrictions which interfere with filling of draining such as orifice plates etc., shall not be

installed until flushing is completed. Till such time that orifice plate is installed orifice flanges shall be provided with temporary gaskets.

6.2.2 Control valves shall be first installed with temporary gaskets. Before flushing is started control

valves shall be removed and reinstalled after completion of flushing and testing with permanent gaskets. If for any reason control valve is retained in the line during tests, it shall be isolated by blinking off.

6.2.3 All safety valves and rotameters shall be installed only after flushing and testing is completed

successfully. 6.3 Wherever in the line any void is existing, due to any reasons, for absence of control valves,

safety valves, check valves etc.. it will be filled with temporary spools. 6.4 All joints welded, screwed or flanged shall be left exposed for the examination during the test.

Before pressurising the lines each weld joint shall be cleaned by wire brush to make it free from rust and any other foreign matter.

6.5 The test will be carried out with permanent gaskets installed unless otherwise specified herein

or instructed by the Owner.

JACOBS



6.6 Vents and drains at the highest and the lowest points in the piping systems shall be provided. 6.7 Pumps, blowers, compressors, in line instruments other equipment and piping specialities

shall be isolated during flushing and pressure testing by metallic blinds, blanks caps or plugs. 6.8 No pressure test shall be carried out against closed valve unless approved by the Owner /

Consultant. 6.9 Piping which is spring or counter weight supported shall be temporarily supported where the

weight of the test fluid would overload the supports. Retaining pins or spring supports shall be removed only after testing is completed and test

fluid is fully drained. 6.10 Piping systems subject to extended hydrostatic test period shall be provided with protective

device to relieve excess pressure due to the thermal expansion of the test fluid. 6.11 TEST PRESSURE GAUGES 6.11.1 All gauges used for field testing should be of the Bourdon type having a suitable range and

dial scale not less than 4 ½ diameter. Test pressure indication should fall between 40% to 80% of gauge scale range. Gauge shall be of good quality and shall be in first class working condition.

6.11.2 Prior to the start of test and periodically during the field test programme all test gauges shall

be calibrated using a standard Dead Weight gauge tester or other suitable approved testing apparatus. Any gauge showing incorrect zero reading, or error of more than + 2% of full scale range shall be discarded. The Owner / Consultant shall check the accuracy of water pressure gauge used for calibration. The Contractor shall furnish documentary proof of having calibrated each gauge / instrument to the satisfaction of the Owner / Consultant and shall maintain such records until completion of the project.

6.11.3 The pressure gauge shall be installed as close as possible to the lowest point of piping system

to be rested to avoid over stressing of any of the lower portion of the system. For longer lines and vertical lines two or more pressure gauges shall be installed at the locations decided by the Owner / Consultant. Over and above the pressure gauges installed in the system being tested, a pressure gauge will be installed on discharge of pumps or other pressurising source.

For lines containing check valves any of the following alternatives will be adopted for pressure

testing : i) Wherever possible pressurise up stream of valve. ii) Replace the valve by a temporary spool and reinstall the valve after testing.

iii) Provide blind on valve flanges and test the up streams and down streams of the line separately and remove the blind after testing, (in all the above mentioned cases wherever valves, flanges are required to make and break for testing, the Contractor shall provide temporary gaskets at the time of initial installation of check valves. Final gaskets will be provided only after completion of testing.)

7.0 PROCEDURE FOR PRESSURE TESTING 7.1 All pipe lines to be tested are shown in the piping specifications. The medium to be used and

test pressure to be applied is also indicated in the piping specifications provided to the Contractor for the performance of work.

JACOBS



7.2 TEST PRESSURE 7.2.1 The minimum hydrostatic / pneumatic test pressure shall be indicated in the piping

specifications or as per instructions of the Owner / Consultant. 7.2.2 The selection of the piping system for one individual test will be based on the following : - Test pressure required as per line list. - Maximum allowable pressure for the material of Construction of piping. Depending upon the above requirements and based on construction progress maximum

length of piping shall be included in each test. 7.3 PRESSURISING, INSPECTION APPROVAL 7.3.1 All vents and other connections used as vents shall be left open while filling the line with test

fluid for complete removal of air, in the lines for pressurising and depressurising the system temporary isolating valves shall be provided in valve vents, drains do not exist in the systems.

7.3.2 Pressure shall be applied only after the system / line is ready and approved by the Owner /

Consultant. 7.3.3 Pressure shall be applied by means of a suitable test pump of other pressure source which

shall be isolated from the system as soon as test pressure is reached and established the system.

7.3.4 The test pressure shall be retained long enough to facilitate inspection of the complete

system. Duration of the test in each case shall be fixed up by the Owner / Consultant but in no case it will be less than 2 hours. No leakage of any kind will be permissible. The glands of the valves in the system being tested shall be tightened by the Contractor, so as to stop / minimise the leakage, if any. In case leakage is not stopped after adequate tightening of the glands, the handwheel of such valves shall be painted red only on the rim to identify these valves for subsequent repair. The gland packing for replacement shall be supplied by the Owner.

The Contractor shall replace the gland packing on the valve and tighten it to make it leak

proof. Valve gland tightening and handwheel painting shall be done by the Contractor. 7.3.5 Care shall be taken to avoid increase in pressure due to temperature variation during the test. 7.3.6 After completion of hydrotest, the pressure shall be released gradually. All vents and drains

shall be kept open till the lines are fully drained. After draining, lines / systems shall be dried by air.

7.3.7 Pressure test shall be considered, complete only after approval by the Owner / Consultant.

Defects, if any noticed during testing shall be rectified immediately and retesting immediately and retesting of the system / line shall be done by the Contractor at his cost.

JACOBS



8.0 TEST RECORDS Records in triplicate shall be prepared and submitted by the Contractor for each system

(linewise) for the flushing and the pressure test done giving following details in the proforma approved by the Owner / Consultant.

- Date of flushing. - Date of test. - Identification of piping tested, i.e. line no., line diagram no., plant area etc. - Flushing medium used. - Test fluid used. - Minimum test pressure required and actual test pressure obtained. - Signature of the Contractor's representative. - Approval signature of the Consultant. - Approval signature of the Owner.