SPECIFICATION PREFACE SHEET

DEPARTMENT:

Engineering / Piping

SHEET

AREA: Grundartangi Reduction Plant

OF 21

SPEC No: 00/04/TS001

REV: C3

STANDARD TECHNICAL
SPECIFICATION
FOR

MECHANICAL
PIPING AND FITTINGS

This Standard Technical Specification is subject to change without prior notice. The
most current issue will at all times be located on the Nordural web site,
www.nordural.is.
REV

BY

DATE

CHKD

APPROVED

C1

FH

20.09.1999

GP/SbG

C2

BK

19.02.2003

TMS

TMS

C2

C3

EFB/GG/G

07.06.2004

EFB

Issued for Construction

First issue

NORURL ENGINEERING

00-80-30-TS001

REVISIONS

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STANDARD TECHNICAL SPECIFICATION

NA-00/04/TS001

NORDIC ALUMINUM

CONTENTS
1

GENERAL DESIGN AND INSTALLATION STANDARDS....................................................................................................... 4

1.1

SCOPE ....................................................................................................................................... 4

1.2

REFERENCES........................................................................................................................... 4

1.3

GENERAL SPECIFICATION...................................................................................................... 5

1.4

GENERAL STANDARDS OF WORKMANSHIP ........................................................................ 6

1.5

FABRICATION ........................................................................................................................... 7

1.6

TOLERANCES ON FABRICATED PIPEWORK ........................................................................ 7

1.7

FIELD BENDS............................................................................................................................ 8

1.8

FREEDOM FROM RUST AND OTHER FOREIGN MATTER ................................................... 8

1.9

PLUGGING................................................................................................................................. 8

1.10 TESTING .................................................................................................................................... 8

1.11 BALANCING............................................................................................................................... 9
1.12 IDENTIFICATION....................................................................................................................... 9
1.13 VALVE LABELS & CHARTS ...................................................................................................... 9
1.14 DIFFERENTIAL SETTLEMENT ................................................................................................. 9
1.15 SCREWED PIPEWORK........................................................................................................... 10
1.16 FITTINGS ................................................................................................................................. 10
1.17 FLANGED JOINTS................................................................................................................... 10
1.18 ERECTION ............................................................................................................................... 10
1.19 SURFACE TREATMENT AND PAINTING .............................................................................. 10
2

WELDING OF PIPE AND FITTINGS ...................................................................................................................................... 11

2.1

SCOPE ..................................................................................................................................... 11

2.2

GENERAL ................................................................................................................................ 11

2.3

FILLER METAL BRANDS AND SPECIFICATIONS ................................................................ 11

2.4

PREPARATION OF PIPE ENDS FOR WELDING................................................................... 11

2.5

ALIGNMENT............................................................................................................................. 11

2.6

WELDING & INSPECTION ...................................................................................................... 11

2.7

DEFECTS................................................................................................................................. 12

2.8

QUALIFICATION OF WELDERS AND PROCEDURE ............................................................ 12

PIPES AND FITTINGS, STANDARDS ................................................................................................................................... 13

3.1

PIPES ....................................................................................................................................... 13

3.2

VALVES.................................................................................................................................... 14

3.3

FLANGES................................................................................................................................. 15

3.4

BOLTS FOR FLANGED CONNECTIONS ............................................................................... 15

3.5

GASKETS................................................................................................................................. 15

3.6

BUTT WELDED FITTINGS ...................................................................................................... 15

3.7

STEEL THREADED FITTINGS................................................................................................ 15

PIPE SYSTEM TESTING ........................................................................................................................................................ 16

4.1

TESTING .................................................................................................................................. 16

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4.2

FLUSHING / CLEANING.......................................................................................................... 16

4.3

SAFETY VALVES .................................................................................................................... 16

THERMAL INSULATION ........................................................................................................................................................ 17

5.1

GENERAL ................................................................................................................................ 17

5.2

SCOPE OF WORK................................................................................................................... 17

5.3

INSULATING MATERIALS ...................................................................................................... 17

5.4

PIPING INSULATION............................................................................................................... 17

5.5

INSTALLATION OF TYPE A PIPING INSULATION .............................................................. 18

5.6

INSTALLATION OF TYPE B PIPING INSULATION .............................................................. 19

5.7

TANKS AND EQUIPMENT ...................................................................................................... 19

5.8

INSULATION SUNDRIES ........................................................................................................ 19

5.9

HEAT TRACING....................................................................................................................... 19

PROTECTION OF PIPING UNDERGROUND ........................................................................................................................ 20

6.1

SCOPE ..................................................................................................................................... 20

6.2

PRIMING .................................................................................................................................. 20

6.3

APPLICATION OF TAPE ......................................................................................................... 20

6.4

HANDLING ............................................................................................................................... 20

6.5

TESTING .................................................................................................................................. 20

6.6

REPAIRS.................................................................................................................................. 20

6.7

LAYING PROTECTED PIPE.................................................................................................... 21

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GENERAL DESIGN AND INSTALLATION STANDARDS

1.1

SCOPE

1.1.1

The following specifications give the minimum requirements and standards for
material and workmanship, method of working, testing and identification for
mechanical piping and fittings.

................In this Document the following words and expressions shall have the meaning
hereby assigned to them except where the context otherwise requires:
................Engineer: The Owner or any person or organisation employed or engaged at any
time by the Owner and authorised by the Owner, in writing, from time to time to act
on behalf of the Owner in the execution of the items covered by this Document, in
whole or in any part, for any or all purposes provided in this Technical
Specification.
................Owner:
Norurl hf (Nordic Aluminum Corporation Ltd.), an independent legal
entity owned by Century Aluminum.

1.2

REFERENCES

1.2.1

The following table lists standards referenced to in this specification.

00/03/TS001

Standard technical specification for surface treatment and painting

EN 287

Approval testing of welders - Fusion welding

EN 288

Specification and approval of welding procedures for metallic

materials

EN ISO 5817

Welding. Fusion-welded joints in steel, nickel, titanium and their

alloys (beam welding excluded). Quality levels for imperfections

EN ISO 9692-1

Welding and allied processes. Recommendations for joint

preparation Part 1: Manual metal-arc welding, gas shielded metalarc welding, gas welding, TIG welding and beam welding of steels

EN 1011-1

Welding. Recommendations for welding of metallic materials.

General guidance for arc welding

EN 1011-2

Welding. Recommendations for welding of metallic materials. Arc

welding of ferritic steels

EN 1011-3

Welding. Recommendations for welding of metallic materials. Arc

welding of stainless steels
Quality requirements for welding. Fusion welding of metallic
materials. Standard quality requirements

EN 729-3
ISO 7-1

Pipe threads where pressure-tight joints are made on the threads

ISO 898-1

Mechanical properties of fasteners made of carbon steel and alloy

steel -- Part 1: Bolts, screws and studs

ISO 898-2

Mechanical properties of fasteners -- Part 2: Nuts with specified

proof load values -- Coarse thread

EN 10216-1

NORURL

Seamless steel tubes for pressure purposes - Technical delivery

conditions - Part 1: Non-alloy steel tubes with specified room
temperature properties

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DIN 2441

Steel tubes; heavy-weight suitable for screwing

DIN 2528

Steel flanges; Technical delivery conditions

DIN 2605-2

Butt welding fittings; elbows part 2: full correlation of utilization

DIN 2609

Steel butt-welding pipe fittings; technical delivery conditions

DIN 2615-2

Steel butt-welding pipe fittings; Tees for use at full service pressure

DIN 2616-2

Steel butt-welding pipe fittings; Reducers for use at full service

pressure

EN 1092-1

Flanges and their joints - Circular flanges for pipes, valves, fittings
and accessories, PN designated - Part 1: Steel flanges

EN 10241

Steel threaded pipe fittings

DIN 2999
EN 10025

Whitworth pipe threads for threaded pipes and fittings; parallel

internal threads
Hot rolled products of non-alloy structural steels - Technical delivery
conditions

EN 10204

Metallic products - Types of inspection documents

ANSI B16.5

Pipe flanges and flanged fittings

ANSI B16.9

Factory made wrought steel butt-welding fittings

ANSI B16.11

Forged fittings, socket welding and threaded

ASTM A105
ASTM A181

Specification for carbon steel forgings for piping applications

Specification for carbon steel forgings, for general-purpose piping

ASTM A234

Standard Specification for Piping Fittings of Wrought Carbon Steel

and Alloy Steel for Moderate and Elevated Temperatures

API 5L

American Petroleum Institute: Specification for Line Pipe

BS 6351

Electric surface heating

1.3

GENERAL SPECIFICATION

1.3.1

Piping shall be routed to provide a neat and economical layout. It shall be

adequately supported and secured against vibration. All metal pipelines entering
or leaving plant areas/potrooms shall be fitted with insulating flanges using tufnol
or equal insulating washers, gaskets and bolt sleeves. Pipelines are to be earthed
to the main earthing system. Brackets shall be installed on every expansion bellow
for electrical equal potential connection.

1.3.2

The bottom of all lines where supported are not to be less than 150 mm above
grade.

1.3.3

Trench piping shall have the bottom of the pipe at least 250 mm above the floor of
the trench. Flange clearance 150 mm below trench cover and 75 mm from trench
wall.

1.3.4

Clearances for piping and equipment shall be as follows:

Above roads

5,5 m

Around compressors

1,2 m

Above Grade in Operating Areas

3,0 m

Piping, vertical from road except at crossing

3,0 m

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1.3.5

Maintenance access: All valves, relief valves, control valves and instruments shall
be located, where possible, so that they can be operated and serviced from grade.
If this is not possible, alternative valve operating devices shall be employed in
accordance with the approval of the Engineer.

1.3.6

Equipment piping: All piping attached to equipment, particularly equipment with

rotating parts shall be adequately supported to prevent excessive loading on the
equipment. Drop out pipe spools shall be provided in pump and compressor
suction piping together with temporary basket type strainer or filter.

1.3.7

Gas and air piping shall be designed for good line drainage. Drain valves and
traps shall be situated at low points for condensate removal. Branch connections
are to be taken from top of headers with the branch block valve in horizontal run at
the high point. On compressed air piping, the branch block valve can be on the
vertical run at a lower point.

1.3.8

Compressed air utility points, (except in potrooms where different requirements

shall apply), shall be provided for maintenance tool operation. The Engineer shall
approve the number of such points. Each point shall have a 25 mm (1") ND
(Nominal Diameter) valve and suitable quick coupling, subject to Engineers
approval.

1.3.9

Connections on piping for pressure instruments shall be 20 mm (") ND minimum

with 15 mm (") ND gate valve.

1.3.10

Vents and drains: All piping for fluid media (non gas) must have 15 mm (")
ND minimum high point vent. All piping must have 25 mm (1") ND minimum
low point drain. Such connections are to be fitted with valves and plugs.

1.3.11

Piping shall be generally designed in accordance with European standards. Other

standards may be used if approved.

1.3.12

The following piping sizes shall not be used:

32 mm

(1")

ND

45 mm

(1")

ND

65 mm

(2")

ND

90 mm

(3")

ND

115 mm

(4")

ND

125 mm

(5")

ND

1.3.13

At all times when air, water or gas are essential to the process requirements, the
design shall allow for ring main circuits or by-pass circuits to provide supply in
case of emergency or maintenance.

1.4

GENERAL STANDARDS OF WORKMANSHIP

1.4.1

All pipes shall be free from burrs, scale, rust, dirt or harmful substances.

1.4.2

All pipes shall be true to shape and full bore size.

1.4.3

Bushings are to be avoided where possible.

1.4.4

Joints shall not be positioned within building walls.

1.4.5

Eccentric reducers shall be used for changes in pipe diameter in horizontal

pipelines and concentric reducers for vertical pipelines. Utilising preformed bend
sections shall generally effect changes in direction.

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1.4.6

Long screw threads and connectors are not to be used.

1.4.7

All vertical pipes shall be plumb and all lines in the same direction shall be parallel
to each other.

1.4.8

During installation of all piping services, great care shall be taken to prevent any
foreign matter entering the pipes. All open ends shall be temporarily capped or
plugged with the appropriate pipefittings until the installation is completed.
Wooden plugs and the like shall not be used.

1.4.9

Transverse cuts in pipes shall be made with hacksaw or pipe cutting tool and all
cuts shall be square with the axis of the pipe. The use of hand oxy-acetylene
cutters on pipe will not be allowed. The ends of pipe when cut shall be well
reamed to give an unrestricted bore.

1.4.10

Upon completion welded joints shall be thoroughly cleaned with a stiff wire brush.
Screwed joints shall have all ends of jointing tape removed. Workmanship
throughout shall be of a high standard, and no caulking will be permitted.

1.4.11

Adequate space must be left between pipes in racks to give the necessary
clearance for flanges and the fitting of insulation.

1.4.12

Pipe supports are to be spaced such that the pipes do not sag when full of water
(usually used for hydraulic test). The following table lists maximum intervals
between pipe supports for compressed air piping.
PIPE SIZE (ND)

INTERVAL FOR
VERTICAL RUNS

INTERVAL FOR HORIZONTAL

RUNS

(m)

(m)

25

2,7

1,75

40

3,0

2,5

50

3,0

2,75

100

5,0

5,0

150

6,5

6,5

200

8,0

8,0

250

9,0

9,0

(mm)

1.5

FABRICATION

1.5.1

Qualified craftsmen must perform all welding. All welders and welding procedures
shall be currently qualified in accordance with specified standards.

1.6

TOLERANCES ON FABRICATED PIPEWORK

1.6.1

It is the Contractors responsibility to ensure that fabricated pipe work when

assembled will be in accordance with approved drawings and laid without undue
strain particularly where fixed to equipment. The selection of tolerances and/or
fixing flanges at site is the Contractor's responsibility. The following tolerances are
given as a guide to the standard expected.

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DESCRIPTION

TOLERANCES
Dimensions less
than 3 metres

Dimensions greater
than 3 metres

Face to face on flanges

1,5 mm

3 mm

Centre to centre of branches on manifolds

1,5 mm

3 mm

Centre of branch to face of flange on main

1,5 mm

3 mm

Centre of main to face of flange on branch

1,5 mm

3 mm

1.6.2

Branches and flanges shall be square with run of pipe. Flange faces shall be
square within 0,2 mm per 100 mm of flange diameter taken across the entire face.

1.6.3

Fabrication: Weld sizes, preparation, weld details and filler materials shall be in
accordance with specified welding standards.

1.7

FIELD BENDS

1.7.1

Field bends are not allowed.

1.8

FREEDOM FROM RUST AND OTHER FOREIGN MATTER

1.8.1

All pipes, valves and fittings shall be as far as possible thoroughly cleaned of rust
and other foreign matter before erection and pipe lines shall be flushed through
before being put into service.

1.9

PLUGGING

1.9.1

During installation, open ends of erected piping shall be temporarily blanked or

plugged by means of blank (blind) flanges, plates tack welded to the end of the
pipe or by plugs.

1.10

TESTING

1.10.1

Hydraulic tests, and performance tests on the Site under actual conditions on the
whole plant shall be carried out. As an alternative, hydraulic testing may be carried
out in shop on every fabricated pipe section. These sections then only need to be
leak tested with normal pressured compressed air after assembly.

1.10.2

Inspection on equipment during manufacture may be requested.

1.10.4

Satisfactory and acceptable hydraulic test means that appropriate pressures shall
be maintained for the period stated, after any defect has been repaired.

1.10.5

Certificates on any hydraulic test made at manufacturer's works and at the Site
shall be submitted.

1.10.6

All test certificates shall be signed and witnessed. All test certificates shall have
the following particulars thereon:

Apparatus or section under test.

Maker's number (if any).
Nature, duration and conditions of tests.
Results of test.
1.10.7

Radiography of butt welds is required where directed. Interpretation of spot

radiographs shall be in accordance with EN ISO 5817.

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1.11

BALANCING

1.11.1

Provision shall be made for carrying out all the required inspections, testing and
balancing of the systems to ensure that the system is handed over in good
working order and properly regulated.

1.11.2

In addition, a visit shall be made to the site two months before the end of the
maintenance period to check and, if necessary, re-adjust the balancing of the
systems.

1.12

IDENTIFICATION

1.12.1

All piped services shall be permanently identified by means of painted bands and
letters. Where the pipe diameter is not sufficient to allow the printing to be fully
visible, tags are to be used. The colour chosen for each pipeline shall be in
accordance with Standard Technical Specification for Surface treatment and
painting, 00/03/TS001, appendix 1.

1.12.2

Identification bands shall be applied adjacent to all valves, at intervals of not more
than 15 m along all pipe runs and on both sides of each wall or partition.

1.13

VALVE LABELS & CHARTS

1.13.1

Each item of plant or equipment shall be supplied complete with an identification

nameplate, clearly stating the manufacturer's name, plant number, date, together
with any other information that will assist future maintenance and the purchase of
spare parts. In the case of pumps, motors etc. the duty for which they are
designed and the maker's production number also shall be stated.

1.13.2

The nameplate of vessels which have been hydraulically tested shall state the test
pressure and the date of test.

1.13.3

In addition, each instrument or item of the switchgear shall be fitted with a similar
engraved metal label, secured by four brass set screws for which they shall be
drilled and tapped.

1.13.4

All valves in plant rooms shall have a label securely attached to the valve handle
or stem.

1.13.5

The label shall be rectangular in shape and of the size listed below. The label shall
be manufactured from 3 mm thick Laminated Plastic Traffolite or similar being
black-white- black in construction with the identification symbol engraved through
the black exposing the white inner skin.

1.13.6

The numbers on the valve labels shall refer to those on the record As fitted
drawings and the valve charts.
VALVE SIZE

LABEL SIZE

LETTERING

15 mm (1/2") to 50 mm (2")

35 mm (1 3/8") x 70 mm (2 3/4")

5 mm (3/16")

80 mm (3") to 100 mm (4")

57 mm (2 1/4") x 114 mm (4 1/2")

10 mm (3/8")

150 mm (6") & above

76 mm (3") x 152 mm (6")

13 mm (1/2")

1.14

DIFFERENTIAL SETTLEMENT

1.14.1

When settlement may be expected between items or equipment then sufficient

flexibility shall be provided in the connecting pipe work to prevent any excess
stresses being set up on the connected equipment.

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1.15

SCREWED PIPEWORK

1.15.1

Threads on pipes and equipment shall be protected during transit.

1.15.2

No screwed joints may be disclosed in the building structure and no pipe shall be
built into concrete or brickwork.

1.16

FITTINGS

1.16.1

All fittings shall be as specified for the relevant service.

1.16.2

Bushes are not to be used in tee branches and, where the sizes concerned are not
standard, the reduction in size is to be made by means of a nipple and reducing
socket.

1.16.3

Welding fittings shall suit the materials specified.

1.17

FLANGED JOINTS

1.17.1

Flanges shall be provided at all connections to plant and where necessary for
ease of maintenance.

1.17.2

For slip-on flanges whether welded by metal arc or oxy-acetylene methods, the
tube end shall be cut square and left back from the front face of the flange equal to
the wall thickness of the pipe plus 2 mm. The flanges shall be welded both at the
back and front and all surplus weld metal dressed off with a file, flush with the face
of the flange.

1.17.3

Care shall be taken to avoid distortion of the flange during welding.

1.17.4

Prefabricated blank (blind) flanges may be used, with a thickness not less than the
flange which it is to meet. Blank flanges shall be cut to a true circle with smooth
edges. Thickness shall be calculated for the duty.

1.17.5

Flanges shall be smooth machined from the full width across the face of the
flanges and on the edge but may be rough turned on the back. The two flanges
forming a joint shall be flush with each other when in position and all boltholes
shall be in correct alignment with those on the mating flanges.

1.17.6

Flanges shall be bolted up using hexagon headed ISO metric steel bolts and nuts.
One washer is to be fitted under each nut.

1.18

ERECTION

1.18.1

Piping is to be run strictly in accordance with the dimensions given on the

approved drawing.

1.19

SURFACE TREATMENT AND PAINTING

1.19.1

Surface treatment and painting is to be carried out in accordance with

00/03/TS001.

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WELDING OF PIPE AND FITTINGS

2.1

SCOPE

2.1.1

This section relates to the welding of pipe work and fittings.

2.2

GENERAL

2.2.1

All welding shall be performed in accordance with the relevant parts of EN 1011.
The contractor shall meet the requirement in EN 729-3, Standard quality
requirements

2.3

FILLER METAL BRANDS AND SPECIFICATIONS

2.3.1

Electrodes and welding material are subject to the Engineers approval.

2.3.2

Portable ovens shall be used to keep the electrodes dry. Electrodes with damaged
coating shall not be used.

2.4

PREPARATION OF PIPE ENDS FOR WELDING

2.4.1

The edges of pipes to be joined by welding shall be cleaned by grinding, filing or

brushing and when new preparation is necessary this shall be done by machine
oxy-acetylene cutting, manually operated and using a floating head. Joint
preparation of pipe and fittings shall be in accordance with EN ISO 29692.

2.5

ALIGNMENT

2.5.1

The ends of tube-to-tube, tube to fittings and tube to valves shall be aligned as
accurately as is practical within the existing commercial tolerances on tube
diameter, tube wall thickness and out-of-roundness. Alignment shall provide the
most favourable conditions for depositing the root bead. This alignment shall be
preserved during welding. In cases where ends of unequal internal diameter are
abutted and the internal mis-alignment exceeds 1,5 mm the tube wall shall be
lightly warmed and hammered by bronze headed hammers to bring the alignment
within 1,5 mm tolerance. Where there is unequal wall thickness exceeding 1,5 mm
the thicker section shall be internally trimmed to match bore to within 1,5 mm. For
fillet welding of shoes, brackets and supports, the members being joined shall fit
snugly. Where this is not possible owing to faulty material, preparation or fit-up, a
gap of no more than 3 mm is allowed, the limit of 3 mm is mandatory.

2.6

WELDING & INSPECTION

2.6.1

All welds shall be visually examined externally and internally, where possible, for
faults and irregularities and 10% of butt welds shall be radiographed. The weld
quality shall meet EN ISO 5817, Class C.

2.6.2

Butt weld reinforcement shall be uniform and not less than 1,5 mm nor more than
3 mm in height. Reinforcement shall merge smoothly into the tube or member
surface without undercut. All fillet welds as deposited on shoes, brackets and
supports shall be flat (mitre profile) or convex. The use of concave fillet welds shall
be avoided.

2.6.3

Fillet welds terminating at the ends or sides of parts of members shall be

continued round the corners of the joint for a distance of not less than twice the

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size of the weld. In particular this provision applies to fillet welds joining brackets
and similar connections that are not welded all round.
2.6.4

Care shall be taken to ensure that excessively large fillet welds which increase
internal stresses, are avoided.

2.7

DEFECTS

2.7.1

All cracks, non-fusion, lack of root penetration and excessive burn through area,
excessive slag and porosity, non-metallic voids and discontinuities shall be
removed by chipping, grinding, cutting with abrasive discs and/or oxy-acetylene
gouging when the defects exceed the standards of acceptability as required by EN
ISO 5817, Class C.

2.8

QUALIFICATION OF WELDERS AND PROCEDURE

2.8.1

Welders and welding procedures shall be qualified to EN 287 and EN 288.

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PIPES AND FITTINGS, STANDARDS

3.1

PIPES

3.1.1

Pipes are seamless steel pipes according to EN, DIN or API standards. Pipe sizes
15 ND through 40 ND are seamless, black or galvanized heavy wall carbon steel
pipes, suitable for screwing. Pipe sizes 50 ND through 250 ND are black, heavy
wall seamless or welded carbon steel pipes, suitable for welding.

3.1.2

Minimum pipe wall thickness and type for various pipe sizes and connection of
fittings are according to API, DIN 2441 and the table shown below. The table lists
pipe wall thickness for compressed air and potable water pipes:
Pipe size
(mm) ()

Wall thickness
DIN (mm)

Wall thickness
API (mm)

Type

Connection

15

(")

3,25

3,7 (SCH 80)

Seamless

Screwed

20

(")

3,25

3,9 (SCH 80)

Seamless

Screwed

25

(1)

4,05

4,5 (SCH 80)

Seamless

Screwed

40

(1)

4,05

5,1 (SCH 80)

Seamless

Screwed

50

(2)

3,6

3,9 (SCH 40)

Seamless/welded

Welded

80

(3")

4,5

5,5 (SCH 40)

Seamless/welded

Welded

100

(4")

5,0

6,0 (SCH 40)

Seamless/welded

Welded

150

(6")

5,6

7,1 (SCH 40)

Seamless/welded

Welded

200

(8")

8,0

8,2 (SCH 40)

Seamless/welded

Welded

250

(10)

8,0

9,3 (SCH 40)

Seamless/welded

Welded

Pipes for diesel fuel and fuel gas are the same as listed above except for 200 and
250 ND:

3.1.3

200

(8)

6,3

6,4 (SCH 20)

Seamless/welded

Welded

250

(10)

6,3

6,4 (SCH 20)

Seamless/welded

Welded

Piping material shall be to:

EN 10216-1

API 5L Grade B

3.1.4

Seamless steel tubes for pressure purposes - Technical

delivery conditions - Part 1: Non-alloy steel tubes with
specified room temperature properties
American Petroleum Institute: Specification for Line Pipe

Fittings material shall be to:

1.0432 DIN 2528

Steel flanges; materials

EN 10216

Seamless steel tubes for pressure purposes - Technical

delivery conditions - Part 1: Non-alloy steel tubes with
specified room temperature properties

ASTM A181 Grade 1 or 11

Standard specification for forgings, carbon steel, for

general-purpose piping

ASTM A105 Grade B

Standard specification for forgings, carbon steel, for

piping components

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Standard specification for piping fittings of wrought

carbon steel and alloy steel for moderate and elevated
temperatures

ASTM A234 GR WFB

All piping and fittings material used shall have inspection certificate to EN 10204.
3.1.5

All pipe threads referred to are as required by ISO R7/1 taper.

3.1.6

Pipes for potable water and compressed air shall be hot dip galvanized. Pipes for
diesel fuel and fuel gas shall be black.

3.1.7

Specifications for HT (High Temperature) medium piping and valves etc. are to be
agreed with the HTM supplier before finalising. The Engineer is to be advised of
the final specification agreed.

3.1.8

The Engineer is to be advised of all pipe selections.

3.2

VALVES

3.2.1

Valve types have been selected to ensure that the total number of different types
used on the project is kept to a minimum. The table below gives the minimum
pressure rating for valves used for Engineering Services:
VALVE SIZE

PRESSURE RATING

CONNECTION

15 mm (") to 40 mm (1)

40 bar

Screwed

50 mm (2) to 250 mm (6)

16 bar

Flanged

3.2.2

Where applicable, valves shall be packed with Crane packing style 1066 or agreed
equivalent, unless this material is not suited for the duty.

3.2.3

Valves for Compressed air piping:

VALVE SIZE
ND

PRESSURE RATING

TYPE

CONNECTION

15 to 40

40 bar

Ball valve

Screwed

50 to 250

16 bar

Gate valve

Flanged

Ball valves shall be screwed, forged carbon steel body, stainless steel (316) ball
and trim, glass reinforced PTFE seats.
Gate valves shall be flanged, forged carbon steel body, trim 13% Cr, rising stem,
hand wheel operated.

3.2.4

Valves for Potable water piping:

VALVE SIZE
ND

PRESSURE RATING

TYPE

CONNECTION

15 to 40

40 bar

Ball valve

Screwed

50 to 200

16 bar

Gate valve

Flanged

Ball valves shall be screwed, carbon steel body, stainless steel (316) ball and trim,
glass reinforced PTFE seats.
Gate valves shall be flanged, forged carbon steel body, trim 13% Cr, rising stem,
wrench operated 50 to 150 ND and 200 ND gear operated.

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3.2.5

Valves for Diesel Fuel and Fuel gas piping:

VALVE SIZE
ND

PRESSURE
RATING

TYPE

OPERATION

CONNECTION

15 to 40

40 bar

Ball valve

Wrench

Screwed

50 to 150

16 bar

Ball valve

Wrench

Flanged

200 to 250

16 bar

Ball valve

Gear

Flanged

All valves for Diesel Fuel and Fuel Gas shall be ball valves, firesafe and antistatic
with cast steel body, stainless steel ball and trim, viton O ring and spring loaded
nylon seats.

3.3

FLANGES

3.3.1

Flanges (for pipes 50 mm and larger) shall be rated to 16 bar or ASME/ANSI

Class 150. Material is forged steel S 235 to EN 10025 and dimensions are to EN
1092-1 or ANSI B16.5. The EN flanges have greater bore than the pipes specified
in 3.1 PIPES. (See 2.7 ALIGNMENT for aligning unequal wall thickness.)
Slip-on flanges to ANSI B16.5 can also be used. Note, EN and ANSI flanges can
not and must not be used together in the same flanged connection.

3.4

BOLTS FOR FLANGED CONNECTIONS

3.4.1

Bolts are carbon steel bolts to ISO 898-1 class 8.8 with nuts to ISO 898-2 class 8.

3.5

GASKETS

3.5.1

Gaskets shall be ring, inside bolt circle, compresses asbestos free fibre 1,5 mm
thick. They shall be according to approved standards. Electrical insulation gaskets
shall be subject to Engineers acceptance.

3.5.2

Where directed, electrical insulating gasket sets, Maloney type E (or equivalent)
shall be used comprising of:
One central full faced, neoprene faced phenolic gasket.
One phenolic insulating sleeve per bolt.
Two laminated phenolic washers per bolt.
Two plated steel washers per bolt.

3.6

BUTT WELDED FITTINGS

3.6.1

Bends, branches and reducers, 50 mm and larger for welding: Material P 195 TR1
to EN 10216-1 (see DIN 2609, Butt welded fittings, technical delivery conditions)
and dimensions to DIN 2605-1 (wall thickness ("Wanddicke Reihe"): class 4,
construction: type ("Bauart") 3), DIN 2615-1 (wall thickness: class 4), DIN 2616-1
and 2 (wall thickness: class 4). In general, wall thickness shall suit pipe wall
thickness as far as possible.

3.7

STEEL THREADED FITTINGS

3.7.1

All threaded steel fittings shall be according to EN 10241, Threaded steel pipe
fittings. Cast iron or malleable fittings is not allowed for the Engineering Services.
Threads shall be according to DIN 2999, parallel.

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PIPE SYSTEM TESTING

4.1

TESTING

4.1.1

Pipelines shall be hydrostatically tested.

4.1.2

Gauges for hydrostatic testing shall be tested for accuracy. Test gauges shall be
installed as close as possible to the lowest point in the system being tested.

4.1.3

All vents and other connections which can serve as vents shall be open during
filling so that all air shall be vented prior to applying test pressure. All restrictions,
which interfere with filling, venting or draining, such as orifice plates shall not be
installed until testing is complete.

4.1.4

Test blanks shall be temporarily installed to isolate piping from equipment and
from other sections, which have a different test pressure.

4.1.5

The testing period shall have a minimum duration of 2 hours.

4.2

FLUSHING / CLEANING

4.2.1

All prefabricated piping shall be checked for cleanliness before erection and must
be free from all loose matter. All installed sections of piping (except for
compressed air) shall be thoroughly flushed with clean water. When sufficient
water is available, the velocity of the flushing water shall exceed the pipeline fluid
velocity.

4.2.2

Prior to flushing, all orifice plates, control valves, check valves, etc. are to be
removed from the system and replaced by temporary spools.

4.3

SAFETY VALVES

4.3.1

Safety valves are not to be installed until upon completion of the flushing and
testing.

4.3.2

Safety valves are to be reset at site to the correct popping and reseating
pressures.

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THERMAL INSULATION

5.1

GENERAL

5.1.1

Equipment and/or material covered by this specification is subject to the

enclosures referred to hereinafter. The Contractor shall be responsible for and
governed by all the requirements stated therein.

5.2

SCOPE OF WORK

5.2.1

This specification covers the general requirements for the supply, offloading and
erection of Thermal and Personnel Protection Insulation.

5.3

INSULATING MATERIALS

5.3.1

Insulating materials shall be one of the following:

a)

Resin Bonded Long Fibred Mineral Wool, with a minimum weight of

100 kg/m.

b)

Resin Bonded Glass Fibre with a minimum weight of 100 kg/m.

c)

Rigid foamed Polyurethane Block, with a nominal density of 30 kg/m (for

anti-sweat prevention only).

5.3.2

Insulating materials shall be suitable for operating temperatures of up to 400C in

respect of heat insulation (mineral wool and glass fibre), and for operating
temperatures of between 20C to 30C for anti-sweat insulation (Polyurethane
Block). The material shall be non-flammable and free from any substance, which
might lead to spontaneous combustion in the presence of air. It shall be
non-corrosive, wet or dry, odourless at operating temperatures and shall not
contain substances which initiate the growth of moulds or support vermins. It shall
not suffer permanent deterioration as a result of contact with moisture.

5.4

PIPING INSULATION

5.4.1

All piping, pipe fittings, valves and strainers to be insulated shall be insulated as
follows:

Insulation Type A
TEMPERATURE
APPLICATION

Up to 400C
Compressed Air
Hot water lines

MATERIAL

Mineral Wool or Glass Fibre

NOMINAL PIPE SIZE

INSULATION THICKNESS

25 mm (1") and under

20 mm (")

32 - 65 mm (1" to 2")

25 mm (1")

80 - 150 mm (3" to 6")

40 mm (1")

200 - 300 mm (8" to 12")

50 mm (2")

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Insulation Type B
TEMPERATURE

20C TO 30C

APPLICATION

Overhead Cold Water Lines

Anti-Sweat Protection

MATERIAL

Polyurethane Block, Mineral Wool

or Glass Fibre

NOMINAL PIPE SIZE

INSULATION THICKNESS

50 mm (2") and under

20 mm (")

Above 50 mm (2")

25 mm (1")

5.4.2

Pre-formed moulded sections shall be used whenever practical on pipes and

fittings. Moulded sections shall be mechanically robust and capable of being
transported and handled without undue breakage, and shall fit snugly with the
surface to be insulated. Plastic insulation shall only be used where the smallness
or intricacy of the unit makes the use of moulded sections impractical, and for
seam jointing. This material shall have the same insulating properties as the
moulded material.

5.5

INSTALLATION OF TYPE A PIPING INSULATION

5.5.1

Piping
a)

Insulation shall be applied by butting adjoining sections firmly together and pasting
canvas smoothly over the joints. Longitudinal and circumferential joints need not
be pointed with finishing cement. Longitudinal joints shall be staggered.

b)

All indoor pipe work shall be finished with 0,6 mm plain aluminium jacketing. The
aluminium jacketing shall be applied to all straight runs, bends, elbows, tees and
other fittings.

c)

Pipe work located outdoors shall be finished with 0,9 mm plain, or 0,6 corrugated
aluminium jacketing. The aluminium jacketing shall be applied to all straight runs,
bends, elbows, tees and other fittings. Suitable means of draining off condensation
are to be incorporated.

d)

All aluminium jacketing is to be fixed by the use of pop rivets or equal, and finished
work shall present neat and workmanlike appearance.

e)

All joints in the outdoor aluminium jacketing are to be permanently sealed for
weather protection by the use of an aluminium coloured vapour barrier sealer.

5.5.2

Valves and Fittings

a)

All valves, fittings and flanges shall be insulated with the same material, and to the
same thickness as the adjacent piping, and shall be finished in aluminium
sheeting.

b)

Insulation shall be stopped-off at a sufficient distance from all flanges to permit the
easy removal of bolts.

c)

All valves and flanged joints are to be insulated with purpose made aluminium
boxes lined with the insulating material. The lining is to be a compression fit over
the contours of the particular valves and flanges to be insulated. The boxes are to

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be made in two halves that shall be fixed by means of hinges and quick release
fasteners for ease of removal.
d)

The boxes on outdoor insulation are to be permanently sealed for weather

protection. The main joint shall be sealed by means of a neoprene rubber strip
permanently fixed to one side of the joint and arranged to give a compression
weather-tight seal on closure.

e)

All finished work shall present a neat and workmanlike appearance.

5.6

INSTALLATION OF TYPE B PIPING INSULATION

5.6.1

In all location where the dripping of moisture due to condensation on cold piping
would be a nuisance the lines shall be insulated with Polyurethane material.

5.6.2

Installation procedure shall be the same as for Type A piping insulation, except
that insulation shall be fixed with adhesive direct to the pipe work and all joints
shall be sealed with mastic to provide complete vapour seal. Indoor pipe work
shall be finished with 0,6 mm Aluminium Cladding and all joints shall be sealed by
the use of an aluminium coloured vapour barrier sealer.

5.6.3

Anti-sweat insulation may be used on overhead cold water lines in Offices and
maintenance buildings, and any additional areas as directed.

5.7

TANKS AND EQUIPMENT

5.7.1

Tanks and equipment requiring insulation shall be insulated with 50 mm (2") thick
Mineral Wool or Glass Fibre slabs, finished with 0,9 mm Aluminium Cladding
sheets. Insulation shall be securely attached by composite welding studs and
spring clip washers. All voids are to be filled before cladding. Sheets are to be held
in place by aluminium alloy screws into studs. Joints are to be sealed as in 5.4
PIPING INSULATION.

5.8

INSULATION SUNDRIES

5.8.1

Sizes of aluminium straps and seals shall be as follows:

10 0,5 mm for insulation smaller than 300 mm (12") ND
20 0,6 mm for insulation 300 mm (12") ND or larger.

5.8.2

Glass tape and glass cloth fabric shall be of the woven mesh type.

5.8.3

All finishing canvas shall be 0,25 kg cotton.

5.9

HEAT TRACING

5.9.1

Heat tracing used for freeze protection purposes shall be provided using the
electric conduction method. It shall conform to BS 6351 : Electric surface heating,
Parts 1, 2 and 3 latest edition and all relevant CENELEC EN Standards. Care shall
be taken that the thermal insulation applied is adequate for use with heat tracing
system.

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PROTECTION OF PIPING UNDERGROUND

PRIMER
WRAPPING

Protecto Wrap No.1170 or approved equivalent

Protecto Wrap No.200 AGT or approved equivalent

6.1

SCOPE

6.1.1

This specification covers the protection of Compressed Air, Water, and Gas, steel
piping buried underground, or in sleeves, certain piping in concrete and that laid in
concrete trenches that are to be subsequently sand filled.

6.2

PRIMING

6.2.1

Bare pipe shall be thoroughly wire brushed and all loose dust and rust, oil, grease
or other foreign matter removed.

6.2.2

After thoroughly stirring, the primer shall be applied to the cleaned pipe with a
clean brush to give an even coating and a rate of 5 litres per 13-14 m. The pipe
must be completely covered.

6.2.3

Only that amount of pipe should be covered that will not dry out before wrapping
can be applied.

6.3

APPLICATION OF TAPE

6.3.1

When the primer has reached a tacky state, remove draft paper backing and apply
the tape, wrapping spirally with a 50% overlap exerting an even tension to ensure
conformability. If primer dries before the wrapping is applied, the primer has to be
re-applied.

6.3.2

Sleepers supporting pipe shall be moved to permit continuous wrapping of pipe.

6.4

HANDLING

6.4.1

Particular care shall be taken in handling wrapped pipe. Sling belts at least 150
mm wide shall be used to lift pipes. Chains, ropes and wire ropes shall not be
used.

6.5

TESTING

6.5.1

Before lowering pipe into trench, or passing through sleeve, the wrapping shall be
tested with a suitable holiday detector with an output voltage of 10.000 volts. Any
faults revealed shall be immediately made good.

6.6

REPAIRS

6.6.1

In the event of a defect discovered from any reason, the wrapping on either side of
the defect is to be cut back, and one whole turn covering the defect removed.

6.6.2

The pipe so exposed, and half a wrapping width on either side shall be coated with
primer.

6.6.3

A length of new wrap shall be spirally wound over the freshly primed area and in
the same direction as before.

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6.7

LAYING PROTECTED PIPE

6.7.1

In the case of pipes to be laid in trenches, the pipe is to be carefully laid and the
trench shall be of the correct depth, trimmed if necessary with clean well
compacted soil or sand. All vegetable matter, rocks, stones or any sharp bodies
liable to penetrate the protective coating, shall be removed. Refer also to 6.4
HANDLING. Avoid strains, snags or scraping.

6.7.2

In the case of pipes laid in concrete trenches or in sleeves, the pipe shall be
adequately supported along its length. Where pipe is inserted into a sleeve, the
direction of wrapping shall be such that the exposed overlap edges face away
from the direction of insertion. The same care shall be exercised in handling the
wrapped pipe.

6.7.3

In the case of pipes laid in open ground, the bottom of the trench to just above the
top of the pipe shall be filled with sand, well tamped under and alongside the pipe.
The trench shall then be filled with selected granular material (sand); the 300 mm
immediately above the pipe shall be tamped in 150 mm layers and the remainder
of the backfill shall be tamped in layers not exceeding 200 mm.

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