PIPINGSTANDARDS

 TABLE OF CONTENTS
S.No TOPICS PAGE NO.
i. Pipe 3
ii. Tubes 5
iii. Uses 6
iv Manufacture 6
v. Sizes of pipes 7
vi. Pipe schedule table 9
vii. NPS table 10
viii. Standards 15
ix. Traceability and positive material identification (PMI) 17
x. Fitting and valves 20
xi. List of standards for pipe and pipe fittings 20
xii. Butt welding fittings 23
xiii. Technical specification for erection of pipes 30
1. Scope 30
2. General 30
3. Welding and examination 30
4. Prefabrication 34
5. Assembly and erection 35
6. Inspection

 7. Testing 38

PROTOCOLS
Protocol for completion of works before doing hydro/pneumatic test 41
Protocol for hydro test / pneumatic test of pipe line 42
Protocol for commissioning of pipe line : putting liquid/gas 43

8. Records 46
9. Commissioning 47
10.Supplementary requirement for oxygen testing 48
11.Safety requirements for Fabrication and erection 53
12.Storage and erection instructions 54
13. Painting 55

Pipe (fluid conveyance)

A pipe is a tubular section or hollow cylinder usually but not necessarily of circular cross-section used mainly to
convey substances which can flow liquids and gases (fluids), slurries, powders, masses of small solids. It can
also be used for structural applications; hollow pipe is far stiffer per unit weight than solid members.

In common usage the words pipe and tube are usually interchangeable, but in industry and engineering, the terms
are uniquely defined. Depending on the applicable standard to which it is manufactured, pipe is generally
specified by a nominal diameter with a constant outside diameter (OD) and a schedule that defines the thickness.
Tube is most often specified by the OD and wall thickness, but may be specified by any two of OD, inside
diameter (ID), and wall thickness. Pipe is generally manufactured to one of several international and national
industrial standards. While similar standards exist for specific industry application tubing, tube is often made to
custom sizes and a broader range of diameters and tolerances.

Many industrial and government standards exist for the production of pipe and tubing. The term "tube" is also
commonly applied to non-cylindrical sections, i.e., square or rectangular tubing. In general, "pipe" is the more
common term in most of the world, whereas "tube" is more widely used in the United States.

Both "pipe" and "tube" imply a level of rigidity and permanence, whereas a hose (or hosepipe) is usually portable
and flexible. Pipe assemblies are almost always constructed with the use of fittings such as elbows, tees, and so
on, while tube may be formed or bent into custom configurations. For materials that are inflexible, cannot be
formed or where construction is governed by codes or standards, tube assemblies are also constructed with the use
of tube fittings.
4

Since the purpose with a pipe is the transport of fluids like water, oil and many other products, the most import
pipe property is the capacity, or in reality, the inside diameter of the pipe. The nominal diameter of a pipe is
therefore related to the inside diameter.

If we take a look at ASME/ANSI B 36.10 Welded and Seamless Wrought Steel Pipe, the inside diameter of a 2''
pipe schedule 40 is 2.067". The inside diameter of a schedule 80 pipe is 1.939". Both inside diameters are close to
2". The outside diameters for both schedules are 2.375".

Since the outside diameter of a single nominal pipe size is kept constant, the inside diameter of a pipe will depend
on the "schedule", or the thickness, of the pipe. The schedule and the actual thickness of a pipe will vary with size
of pipe.

It is common to identify pipes in inches by using NPS or "Nominal Pipe Size". The metric equivalent is called DN
or "diametre nominel". The metric designations conform to International Standards Organization (ISO) usage
and apply to all plumbing, natural gas, heating oil, and miscellaneous piping used in buildings. The use of NPS

does not conform to American Standard pipe designations where the term NPS means "National Pipe Thread
Straight".

Nominal Bore (NB) may be specified under British standards classifications along with schedule (wall
thickness).The tolerances are looser to pipes compared with tubes and they are often less expensive to produce.

Tubes
The nominal dimensions of tubes are based on the outside diameter. If we look at Copper Tubes - ASTM B88 the
outside diameter of a 2" pipe is 2.125", relatively close to 2".

The inside diameter of a tube will depend on the thickness of the tube. The thickness is often specified as a gauge.
If we look at Copper Tubes - ASTM B88 the wall thickness of 0.083"of a 2" pipe is gauge 14.

The tolerances are higher with tubes compared to pipes. Tubes are often more expensive to produce than pipes.

Uses
Domestic water systems
Pipelines transporting gas or liquid over long distances
Scaffolding
Structural steel
As components in mechanical systems such as:
o Rollers in conveyor belts
o Compactors (E.g.: steam rollers)
o Bearing casing
Casing for concrete pilings used in construction projects
High temperature or pressure manufacturing processes
The petroleum industry:
o Oil well casing
o Oil refinery equipment
Delivery of fluids, either gaseous or liquid, in a process plant from one point to another point in the process
Delivery of bulk solids, in a food or process plant from one point to another point in the process
The construction of high pressure storage vessels (note that large pressure vessels are constructed from plate,
not pipe owing to their wall thickness and size).

Manufacture
There are three processes for metallic pipe manufacture. Centrifugal casting of hot alloyed metal is one of the
most prominent process. Ductile iron pipes are generally manufactured in such a fashion. Seamless (SMLS) pipe

is formed by drawing a solid billet over a piercing rod to create the hollow shell. Seamless pipe withstands
pressure better than other types, and is often more easily available than welded pipe. Welded (also Electric
Resistance Welded ("ERW"), and Electric Fusion Welded ("EFW")) pipe is formed by rolling plate and welding
the seam. The weld flash can be removed from the outside or inside surfaces using a scarfing blade. The weld
zone can also be heat treated to make the seam less visible. Welded pipe often has tighter dimensional tolerances
than seamless, and can be cheaper if manufactured in the same quantities.

Large-diameter pipe (25 centimetres (10 in) or greater) may be ERW, EFW or Submerged Arc Welded
("SAW") pipe.

Tubing, either metal or plastic, is generally extruded.

Sizes
Pipe sizes can be confusing because the terminology may relate to historical dimensions. For example, a half-inch
iron pipe does not have any dimension that is a half inch. Initially, a half inch pipe did have an inner diameter of
0.5 inches (13 mm)but it also had thick walls. As technology improved, thinner walls became possible, but the
outside diameter stayed the same so it could mate with existing older pipe, increasing the inner diameter beyond
half an inch.

Pipe sizes are specified by a number of national and international standards, including API 5L, ANSI/ASME
B36.10M and B36.19M in the US, BS 1600 and BS EN 10255 in the United Kingdom and Europe.

There are two common methods for designating pipe outside diameter (OD). The North American method is
called NPS ("Nominal Pipe Size") and is based on inches (also frequently referred to as NB ("Nominal Bore")).

The European version is called DN ("Diametre Nominal" / "Nominal Diameter") and is based on millimetres.
Designating the outside diameter allows pipes of the same size to be fit together no matter what the wall thickness.

For pipe sizes less than NPS 14 inch (DN 350), both methods give a nominal value for the OD that is
rounded off and is not the same as the actual OD. For example, NPS 2 inch and DN 50 are the same pipe, but
the actual OD is 2.375 inches or 60.33 millimetres. The only way to obtain the actual OD is to look it up in a
reference table.

For pipe sizes of NPS 14 inch (DN 350) and greater the NPS size is the actual diameter in inches and the DN
size is equal to NPS times 25 (not 25.4) rounded to a convenient multiple of 50. For example, NPS 14 has an
OD of 14 inches or 355.60 millimetres, and is equivalent to DN 350.

Since the outside diameter is fixed for a given pipe size, the inside diameter will vary depending on the wall
thickness of the pipe. For example, 2" Schedule 80 pipe has thicker walls and therefore a smaller inside diameter
than 2" Schedule 40 pipe.

Pipe + Pipe Schedule Table-

Double
Nominal Extra Schedule Schedule Schedule Schedule Schedule
Standard Extra Schedule 20 Schedule 30 Schedule 40 Schedule 60 Schedule 80
Pipe Size O/d (mm) Strong 10 100 120 140 160
Strong
(Inches)
Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m Wall Kg/m
1/2 21.3 2.77 1.27 3.73 1.62 7.47 2.55 2.77 1.27 3.73 1.62 4.78 1.95
3/4 26.7 2.87 1.69 3.91 2.20 7.82 3.64 2.87 1.69 3.91 2.20 5.56 2.90
1 33.4 3.38 2.50 4.55 3.24 9.09 5.45 2.77 2.12 3.38 2.50 4.55 3.24 6.35 4.24
1 1/4 42.2 3.56 3.39 4.85 4.47 9.70 7.77 3.56 3.39 4.85 4.47 6.35 5.61
1 1/2 48.3 3.68 4.05 5.08 5.41 10.15 9.56 3.68 4.05 5.08 5.41 7.14 7.25
2 60.3 3.91 5.44 5.54 7.48 11.07 13.44 2.77 3.99 3.91 5.44 5.54 7.48 8.74 11.11
2 1/2 73 5.16 8.63 7.01 11.41 14.02 20.39 3.05 5.34 5.16 8.63 7.01 11.41 9.53 14.92
3 88.9 5.49 11.29 7.62 15.27 15.24 27.68 3.05 6.56 5.49 11.29 7.62 15.27 11.13 21.35
3 1/2 101.6 5.74 13.57 8.08 18.63 3.05 7.43 5.74 13.57 8.08 18.63
4 114.3 6.02 16.07 8.56 22.32 17.12 41.03 3.05 8.50 6.02 16.07 8.56 22.32 11.13 28.32 13.49 33.54
5 141.3 6.55 21.77 9.53 30.97 19.05 57.43 3.40 11.74 6.55 21.77 9.53 30.97 12.70 40.28 15.88 49.11
6 168.3 7.11 28.26 10.97 42.56 21.95 79.22 3.40 14.04 7.11 28.26 10.97 42.56 14.27 54.20 18.28 67.56
8 219.1 8.18 42.55 12.70 64.64 22.23 107.92 3.76 20.27 6.35 33.31 7.04 36.81 8.18 42.55 10.31 53.08 12.70 64.64 15.09 75.92 18.26 90.44 20.62 100.92 23.01 111.27
10 273.1 9.27 60.31 12.70 81.55 25.40 155.15 4.19 28.21 6.35 41.77 7.80 51.03 9.27 60.31 12.70 81.55 15.09 96.01 18.26 114.75 21.44 133.06 25.40 155.15 28.58 172.33
12 323.9 9.53 73.88 12.70 97.46 25.40 186.97 4.57 36.54 6.35 49.73 8.38 65.20 10.31 79.73 14.27 108.96 17.48 132.08 21.44 159.91 25.40 186.97 28.56 208.14 33.32 238.76
14 355.6 9.53 81.33 12.70 107.39 6.35 54.69 7.92 67.90 9.53 81.33 11.13 94.55 15.09 126.71 19.05 158.10 23.83 194.96 27.79 224.65 31.75 253.56 35.71 281.70
16 406.4 9.53 93.27 12.70 123.30 6.35 62.64 7.92 77.83 9.53 93.27 12.70 123.30 16.66 160.12 21.44 203.53 26.19 245.56 30.95 286.64 36.53 333.19 40.49 365.35
18 457 9.53 105.16 12.70 139.15 6.35 70.57 7.92 87.71 11.13 122.38 14.27 155.80 19.05 205.74 23.83 254.55 29.36 309.62 34.93 363.56 39.57 408.26 45.24 459.37
20 508 9.53 117.50 12.70 155.12 6.35 78.55 9.53 117.15 12.70 156.12 15.09 183.42 20.62 247.83 26.19 311.17 32.54 381.53 38.10 441.49 44.45 508.11 50.01 564.81
24 610 9.53 141.12 12.70 187.06 6.35 94.53 9.53 141.12 14.27 209.64 17.48 255.41 24.61 355.26 30.96 442.08 36.89 547.71 48.02 640.03 52.37 720.15 59.54 808.22

10

NPS table
NPS to NPS 3

Wall thickness
DN OD [in (mm)]
NPS
[in (mm)]
SCH 40s/40 SCH 80s/80
SCH 5 SCH 10s/10 SCH 30 SCH 120 SCH 160 XXS
/STD /XS

6 0.405 (10.29) 0.035 (0.889) 0.049 (1.245) 0.057 (1.448) 0.068 (1.727) 0.095 (2.413)

8 0.540 (13.72) 0.049 (1.245) 0.065 (1.651) 0.073 (1.854) 0.088 (2.235) 0.119 (3.023)

10 0.675 (17.15) 0.049 (1.245) 0.065 (1.651) 0.073 (1.854) 0.091 (2.311) 0.126 (3.200)

15 0.840 (21.34) 0.065 (1.651) 0.083 (2.108) 0.095 (2.413) 0.109 (2.769) 0.147 (3.734) 0.188 (4.775) 0.294 (7.468)

20 1.050 (26.67) 0.065 (1.651) 0.083 (2.108) 0.095 (2.413) 0.113 (2.870) 0.154 (3.912) 0.219 (5.563) 0.308 (7.823)

1 25 1.315 (33.40) 0.065 (1.651) 0.109 (2.769) 0.114 (2.896) 0.133 (3.378) 0.179 (4.547) 0.250 (6.350) 0.358 (9.093)

1 32 1.660 (42.16) 0.065 (1.651) 0.109 (2.769) 0.117 (2.972) 0.140 (3.556) 0.191 (4.851) 0.250 (6.350) 0.382 (9.703)

1 40 1.900 (48.26) 0.065 (1.651) 0.109 (2.769) 0.125 (3.175) 0.145 (3.683) 0.200 (5.080) 0.281 (7.137) 0.400 (10.160)

2 50 2.375 (60.33) 0.065 (1.651) 0.109 (2.769) 0.125 (3.175) 0.154 (3.912) 0.218 (5.537) 0.250 (6.350) 0.343 (8.712) 0.436 (11.074)

2 65 2.875 (73.03) 0.083 (2.108) 0.120 (3.048) 0.188 (4.775) 0.203 (5.156) 0.276 (7.010) 0.300 (7.620) 0.375 (9.525) 0.552 (14.021)

3 80 3.500 (88.90) 0.083 (2.108) 0.120 (3.048) 0.188 (4.775) 0.216 (5.486) 0.300 (7.620) 0.350 (8.890) 0.438 (11.125) 0.600 (15.240)

3 90 4.000 (101.60) 0.083 (2.108) 0.120 (3.048) 0.188 (4.775) 0.226 (5.740) 0.318 (8.077) 0.636 (16.154)

11

NPS 4 to NPS 9
Wall thickness
OD [in (mm)]
DN
NPS[5] [2] [in SCH SCH
(mm)] SCH
SCH 5 SCH 20 SCH 30 40s/40 SCH 60 80s/80 SCH 100 SCH 120 SCH 140 SCH 160 XXS[5]
10s/10
/STD /XS
4.500 0.083 0.120 0.188 0.237 0.281 0.337 0.437 0.531 0.674
4 100
(114.30) (2.108) (3.048) (4.775) (6.020) (7.137) (8.560) (11.100) (13.487) (17.120)
5.000 0.247 0.355 0.710
4 115
(127.00) (6.274) (9.017) (18.034)
5.563 0.109 0.134 0.258 0.375 0.500 0.625 0.750
5 125
(141.30) (2.769) (3.404) (6.553) (9.525) (12.700) (15.875) (19.050)
6.625 0.109 0.134 0.280 0.432 0.562 0.718 0.864
6 150
(168.28) (2.769) (3.404) (7.112) (10.973) (14.275) (18.237) (21.946)
7.625 0.301 0.500 0.875
7[5]
(193.68) (7.645) (12.700) (22.225)
8.625 0.109 0.148 0.250 0.277 0.322 0.406 0.500 0.593 0.718 0.812 0.906 0.875
8 200
(219.08) (2.769) (3.759) (6.350) (7.036) (8.179) (10.312) (12.700) (15.062) (18.237) (20.625) (23.012) (22.225)
9.625 0.342 0.500
9[5]
(244.48) (8.687) (12.700)

12

 NPS 10 to NPS 24
Wall thickness
[5] DN OD [in (mm)]
NPS [2]
[in (mm)]
SCH 5s SCH 5 SCH richs SCH 10 SCH 20 SCH 30 SCH 40s/STD
10 250 10.75 (273.05) 0.134 (3.404) 0.134 (3.404) 0.165 (4.191) 0.165 (4.191) 0.250 (6.350) 0.307 (7.798) 0.365 (9.271)
12 300 12.75 (323.85) 0.156 (3.962) 0.165 (4.191) 0.180 (4.572) 0.180 (4.572) 0.250 (6.350) 0.330 (8.382) 0.375 (9.525)
14 350 14.00 (355.60) 0.156 (3.962) 0.156 (3.962) 0.188 (4.775) 0.250 (6.350) 0.312 (7.925) 0.375 (9.525) 0.375 (9.525)
16 400 16.00 (406.40) 0.165 (4.191) 0.165 (4.191) 0.188 (4.775) 0.250 (6.350) 0.312 (7.925) 0.375 (9.525) 0.375 (9.525)
18 450 18.00 (457.20) 0.165 (4.191) 0.165 (4.191) 0.188 (4.775) 0.250 (6.350) 0.312 (7.925) 0.437 (11.100) 0.375 (9.525)
20 500 20.00 (508.00) 0.188 (4.775) 0.188 (4.775) 0.218 (5.537) 0.250 (6.350) 0.375 (9.525) 0.500 (12.700) 0.375 (9.525)
24 600 24.00 (609.60) 0.218 (5.537) 0.218 (5.537) 0.250 (6.350) 0.250 (6.350) 0.375 (9.525) 0.562 (14.275) 0.375 (9.525)

Wall thickness
NPS[5] [in (mm)]
SCH 40 SCH 60 SCH 80s/XS SCH 80 SCH 100 SCH 120 SCH 140 SCH 160
10 0.365 (9.271) 0.500 (12.700) 0.500 (12.700) 0.593 (15.062) 0.718 (18.237) 0.843 (21.412) 1.000 (25.400) 1.125 (28.575)
12 0.406 (10.312) 0.500 (12.700) 0.500 (12.700) 0.687 (17.450) 0.843 (21.412) 1.000 (25.400) 1.125 (28.575) 1.312 (33.325)
14 0.437 (11.100) 0.593 (15.062) 0.500 (12.700) 0.750 (19.050) 0.937 (23.800) 1.093 (27.762) 1.250 (31.750) 1.406 (35.712)
16 0.500 (12.700) 0.656 (16.662) 0.500 (12.700) 0.843 (21.412) 1.031 (26.187) 1.218 (30.937) 1.437 (36.500) 1.593 (40.462)
18 0.562 (14.275) 0.750 (19.050) 0.500 (12.700) 0.937 (23.800) 1.156 (29.362) 1.375 (34.925) 1.562 (39.675) 1.781 (45.237)
20 0.593 (15.062) 0.812 (20.625) 0.500 (12.700) 1.031 (26.187) 1.280 (32.512) 1.500 (38.100) 1.750 (44.450) 1.968 (49.987)
24 0.687 (17.450) 0.968 (24.587) 0.500 (12.700) 1.218 (30.937) 1.531 (38.887) 1.812 (46.025) 2.062 (52.375) 2.343 (59.512)

13

NPS 26 to NPS 36
Wall thickness
DN OD [in (mm)]
NPS[5] [2]
[in (mm)] SCH SCH
SCH 5s SCH 10s SCH 10 SCH 20 SCH 30 SCH 40
40s/STD 80s/XS
26.000 0.312 0.500 0.375 0.500
26 650
(660.400) (7.925) (12.700) (9.525) (12.700)
28.000 0.312 0.500 0.625 0.375
28 700
(711.200) (7.925) (12.700) (15.875) (9.525)
30.000 0.250 0.312 0.312 0.500 0.625 0.375 0.500
30 750
(762.000) (6.350) (7.925) (7.925) (12.700) (15.875) (9.525) (12.700)
32.000 0.312 0.500 0.625 0.375 0.688 0.500
32 800
(812.800) (7.925) (12.700) (15.875) (9.525) (17.475) (12.700)
34.000 0.312 0.500 0.625 0.375 0.688
34 850
(863.600) (7.925) (12.700) (15.875) (9.525) (17.475)
36.000 0.312 0.625 0.375 0.750 0.500
36 900
(914.400) (7.925) (15.875) (9.525) (19.050) (12.700)

14

Additional sizes (NPS)

OD
NPS DN Wall thickness [in (mm)]
[in (mm)]
22 550 22.000 (558.800) ?
40 1000 40.000 (1,016.000) ?
42 1050 42.000 (1,066.800) 42.000
44 1100 44.000 (1,117.600) ?
48 1200 48.000 (1,219.200) 48.000
52 1300 52.000 (1,320.800) ?
56 1400 56.000 (1,422.400) ?
60 1500 60.000 (1,524.000) ?
64 1600 64.000 (1,625.600) ?
68 1700 68.000 (1,727.200) ?
72 1800 72.000 (1,828.800) ?
76 1900 76.000 (1,930.400) ?
80 2000 80.000 (2,032.000) ?
88 2200 88.000 (2,235.200) ?

In North America and the UK, pressure piping is usually specified by Nominal Pipe Size (NPS) and schedule
(SCH). Pipe sizes are documented by a number of standards, including API 5L, ANSI/ASME B36.10M (Table 1)
in the US, and BS 1600 and BS 1387 in the United Kingdom. Typically the pipe wall thickness is the controlled
variable, and the Inside Diameter (I.D.) is allowed to vary. The pipe wall thickness has a variance of
approximately 12.5 percent.

15

In the rest of Europe pressure piping uses the same pipe IDs and wall thicknesses as Nominal Pipe Size, but labels
them with a metric Diameter Nominal (DN) instead of the imperial NPS. For NPS larger than 14, the DN is equal
to the NPS multiplied by 25. (Not 25.4) This is documented by EN 10255 (formerly DIN 2448 and BS 1387) and
ISO 65, and it is often called DIN or ISO pipe.

Standards
The manufacture and installation of pressure piping is tightly regulated by the ASME "B31" code series such as
B31.1 or B31.3 which have their basis in the ASME Boiler and Pressure Vessel Code. This code has the force of
law in Canada and the USA. Europe and the rest of the world has an equivalent system of codes. Pressure piping is
generally pipe that must carry pressures greater than 10 to 25 atmospheres, although definitions vary. To ensure
safe operation of the system, the manufacture, storage, welding, testing, etc. of pressure piping must meet
stringent quality standards.

Manufacturing standards for pipes commonly require a test of chemical composition and a series of mechanical
strength tests for each heat of pipe. A heat of pipe is all forged from the same cast ingot, and therefore had the
same chemical composition. Mechanical tests may be associated to a lot of pipe, which would be all from the
same heat and have been through the same heat treatment processes. The manufacturer performs these tests and
reports the composition in a mill traceability report and the mechanical tests in a material test report, both of
which are referred to by the acronym MTR. Material with these associated test reports is called traceable. For
critical applications, third party verification of these tests may be required; in this case an independent lab will
produce a certified material test report (CMTR), and the material will be called certified.

16

Some widely used pipe standards are:

The API range - now ISO 3183. E.g.: API 5L Grade B - now ISO L245 where the number indicates yield
strength in MPa
ASME SA106 Grade B (Seamless carbon steel pipe for high temperature service)
ASTM A312 (Seamless and welded austenitic stainless steel pipe)
ASTM C76 (Concrete Pipe)
ASTM D3033/3034 (PVC Pipe)
ASTM D2239 (Polyethylene Pipe)

API 5L was changed in the second half of 2008 to edition 44 from edition 43 to make it identical to ISO 3183. It is
important to note that the change has created the requirement that sour service, ERW pipe, pass a hydrogen
induced cracking (HIC) test per NACE TM0284 in order to be used for sour service.

ACPA [American Concrete Pipe Association]

AWWA [American Water Works Association]
AWWA M45

IS 2062, IS 2002 for general purpose pipe IS 2062 and IS 2002 for boiler quality pipe.

17

Traceability and Positive Material Identification (PMI)

Maintaining the traceability between the material and this paperwork is an important quality assurance issue. QA
often requires the heat number to be written on the pipe. Precautions must also be taken to prevent the introduction
of counterfeit materials. As a backup to etching/labeling of the material identification on the pipe, Positive
Material Identification (PMI) is performed using a handheld device; the device scans the pipe material using an
emitted electromagnetic wave (x-ray fluorescence/XRF) and receives a reply that is spectrographically analyzed.

Installation-
Pipe installation is often more expensive than the material and a variety of specialized tools, techniques, and parts
have been developed to assist this. Pipe is usually delivered to a customer or jobsite as either "sticks" or lengths of
pipe (typically 20 feet) or they are prefabricated with elbows, tees and valves into a prefabricated pipe spool [A
pipe spool is a piece of pre-assembled pipe and fittings, usually prepared in a shop so that installation on the
construction site can be more efficient. They are usually tagged with a bar code and the ends are capped for
protection. The Pipe and Pipe Spools are delivered to a warehouse on a large commercial job and they may be
held indoors or in a gridded laydown yard. The Pipe or pipe spool is retrieved, staged, rigged, and then lifted into
place. On large process jobs the lift is made using cranes and hoist and other material lifts. They are typically
temporarily supported in the steel structure using beam clamps, straps, and small hoists until the Pipe Supports are
attached or otherwise secured.

An example of a tool used for installation for a small plumbing pipe (threaded ends) is the pipe wrench. Small
pipe is typically not heavy and can be lifted into place by the installation craft laborer.

18

Joining-
Pipes are commonly joined by welding, using threaded pipe and fittings; sealing the connection with a pipe thread
compound, Polytetrafluoroethylene (PTFE) Thread seal tape, oakum, or PTFE string, or by using a mechanical
coupling. Process piping is usually joined by welding using a TIG or MIG process. The most common process
pipe joint is the butt weld. The ends of pipe to be welded must have a certain weld preparation called an End Weld
Prep (EWP) which is typically at an angle of 37.5 degrees to accommodate the filler weld metal. The most
common pipe thread in North America is the National Pipe Thread (NPT) or the Dryseal (NPTF) version. Other
pipe threads include the British standard pipe thread (BSPT), the garden hose thread (GHT), and the fire
hose coupling (NST).

19

Copper pipes are typically joined by soldering, brazing, compression fittings, flaring, or crimping. Plastic pipes
may be joined by solvent welding, heat fusion, or elastomeric sealing.

If frequent disconnection will be required, gasketed pipe flanges or union fittings provide better reliability than
threads. Some thin-walled pipes of ductile material, such as the smaller copper or flexible plastic water pipes
found in homes for ice makers and humidifiers, for example, may be joined with compression fittings.

Underground pipe typically uses a "push-on" gasket style of pipe that compresses a gasket into a space formed
between the two adjoining pieces. Push-on joints are available on most types of pipe. A pipe joint lubricant must
be used in the assembly of the pipe.

Under buried conditions, gasket-joint pipes allow for lateral movement due to soil shifting as well as
expansion/contraction due to temperature differentials.[6] Plastic MDPE and HDPE gas and water pipes are also
often joined with Electrofusion fittings.

Large above ground pipe typically uses a flanged joint, which is generally available in ductile iron pipe and some
others. It is a gasket style where the flanges of the adjoining pipes are bolted together, compressing the gasket into
a space between the pipe.

Mechanical grooved couplings or Victaulic joints are also frequently used for frequent disassembly & assembly.
Developed in the 1920s, these mechanical grooved couplings can operate up to 1,200psi working pressures and
available in materials to match the pipe grade. Another type of mechanical coupling is a Swagelok brand fitting;
this type of compression fitting is typically used on small tubing under 3/4 inch in diameter.

20

Fittings and valves

Fittings are also used to split or join a number of pipes together, and for other purposes. A broad variety of
standardized pipe fittings are available; they are generally broken down into either a tee, an elbow, a branch, a
reducer/enlarger, or a Y.

Valves control fluid flow and regulate pressure.

List of standards for Pipe and Pipe fittings

The ASME - American Society of Mechanical Engineers - ASME/ANSI B16 Standards covers pipes and
fittings in cast iron , cast bronze, wrought copper and steel.

ASME/ANSI B16.1 - 1998 - Cast Iron Pipe Flanges and Flanged Fittings
This Standard for Classes 150, 300, 600, 900, 1500, and 2500 Cast Iron Pipe Flanges and Flanged Fittings covers:
(a) pressure-temperature ratings,

(b) sizes and method of designating openings of reducing fittings,

(c) marking,
(d) minimum requirements for materials,
(e) dimensions and tolerances,
(f) bolt, nut, and gasket dimensions and
(g) tests.

21

ASME/ANSI B16.5 - 1996 - Pipe Flanges and Flanged Fittings

The ASME B16.5 - 1996 Pipe Flanges and Flange Fittings standard covers pressure-temperature ratings,
materials, dimensions, tolerances, marking, testing, and methods of designating openings for pipe flanges and
flanged fittings.

The standard includes flanges with rating class designations 150, 300, 400, 600, 900, 1500, and 2500 in sizes NPS
1/2 through NPS 24, with requirements given in both metric and U.S units. The Standard is limited to flanges and
flanged fittings made from cast or forged materials, and blind flanges and certain reducing flanges made from cast,
forged, or plate materials. Also included in this Standard are requirements and recommendations regarding flange
bolting, flange gaskets, and flange joints.

ASME/ANSI B16.9 - 2001 - Factory-Made Wrought Steel Buttwelding Fittings

This Standard covers overall dimensions, tolerances, ratings, testing, and markings for wrought factory-made
buttwelding fittings in sizes NPS 1/2 through 48 (DN 15 through 1200)

22

 23

BUTT - WELDING PIPE FITTINGS ANSI B 16.9 / 16.28

24

DIMENSIONAL TOLERANCES AS PER ANSI B 16.9 / B 16.28 / MSS SP -43 BUTT WELD FITTING

25

 26

ASME/ANSI B16.10 - 2000 - Face-to-Face and End-to-End Dimensions of Valves

This Standard covers face-to-face and end-to-end dimensions of straightway valves, and center-to face and center-
to-end dimensions of angle valves. Its purpose is to assure installation interchangeability for valves of a given
material, type size, rating class, and end connection

ASME/ANSI B16.11 - 2001 - Forged Steel Fittings, Socket-Welding and Threaded

This Standard covers ratings, dimensions, tolerances, marking and material requirements for forged fittings, both
socket-welding and threaded.

ASME/ANSI B16.20 - 1998 - Metallic Gaskets for Pipe Flanges-Ring-Joint, Spiral-Would, and
Jacketed

This standard covers materials, dimensions, tolerances, and markings for metal ring-joint gaskets, spiral-wound
metal gaskets, and metal jacketed gaskets and filler material. These gaskets are dimensionally suitable for used
with flanges described in the reference flange standards ASME/ANSI B16.5, ASME B16.47, and API-6A. This
standard covers spiral-wound metal gaskets and metal jacketed gaskets for use with raised face and flat face
flanges. Replaces API-601 or API-601.

ASME/ANSI B16.21 - 1992 - Nonmetallic Flat Gaskets for Pipe Flanges

This Standard for nonmetallic flat gaskets for bolted flanged joints in piping includes:

(a) types and sizes;

(b) materials;
27

 (c) dimensions and allowable tolerances.

ASME/ANSI B16.25 - 1997 - Buttwelding Ends

The Standard covers the preparation of butt welding ends of piping components to be joined into a piping
system by welding. It includes requirements for welding bevels, for external and internal shaping of heavy-
wall components, and for preparation of internal ends (including dimensions and tolerances). Coverage
includes preparation for joints with the following.
(a) no backing rings;
(b) split or non continuous backing rings;
(c) solid or continuous backing rings;
(d) consumable insert rings;
(e) gas tungsten are welding (GTAW) of the root pass. Details of preparation for any backing ring must be
specified in ordering the component.

ASME/ANSI B16.34 - 1996 - Valves - Flanged, Threaded, and Welding End

This standard applies to new valve construction and covers pressure-temperature ratings, dimensions, tolerances,
materials, nondestructive examination requirements, testing, and marking for cast, forged, and fabricated flanged,
threaded, and welding end, and wafer or flangeless valves of steel, nickel-base alloys, and other alloys shown in
Table 1. Wafer or flangeless valves, bolted or through-bolt types, that are installed between flanges or against a
flange shall be treated as flanged end valves.

28

ASME/ANSI B16.38 - 1985 (R1994) - Large Metallic Valves for Gas Distribution

The standard covers only manually operated metallic valves in nominal pipe sizes 2 1/2 through 12 having the
inlet and outlet on a common center line, which are suitable for controlling the flow of gas from open to fully
closed, for use in distribution and service lines where the maximum gage pressure at which such distribution
piping systems may be operated in accordance with the code of federal regulations (cfr), title 49, part 192,
transportation of natural and other gas by pipeline; minimum safety standard, does not exceed 125 psi (8.6 bar).
Valve seats, seals and stem packing may be nonmetallic.

ASME/ANSI B16.39 - 1986 (R1998) - Malleable Iron Threaded Pipe Unions

This Standard for threaded malleable iron unions, classes 150, 250, and 300, provides requirements for the
following:

(a) design
(b) pressure-temperature ratings
(c) size
(d) marking
(e) materials
(f) joints and seats
(g) threads
(h) hydrostatic strength
(i) tensile strength
(j) air pressure test

29

Pipe Support
Pipes are either supported from below or hung from above. These devices are called pipe supports. Supports may
be as simple as a pipe "shoe" which is akin to a half of an I-beam welded to the bottom of the pipe; they may be
"hung" using a clevis or trapeze type of devices called pipe hangers. Pipe Supports of any kind may incorporate
springs, snubbers and/or dampers to compensate for thermal expansion, or to provide vibration isolation, shock
control, or vibration excitation of the pipe due to earthquake motion. Some dampers are simply fluid dashpots
whereas other dampers may be active hydraulic devices that have sophisticated systems that act to dampen peak
displacements due to forcing functions. The forcing functions may be process derived (such as in a fluidized bed
reactor) or from a natural phenomenon such as an earthquake (design basis event or DBE).

Cleaning
The inside of pipes can be cleaned with the tube cleaning process, if they are contaminated with debris or fouling.
This depends on the process that the pipe will be used for and the cleanliness needed for the process. In some
cases the pipes are cleaned using a displacement device formally known as a Pipeline Inspection Gauge or "pig";
alternately the pipes or tubes may be chemically flushed using specialized solutions that are pumped through. In
some cases, where care has been taken in the manufacture, storage, and installation of pipe and tubing, the lines
are blown clean with compressed air or nitrogen.

30

TECHNICAL SPECIFICATION FOR ERECTION OF PIPING

(INCLUDING FABRICATION, TESTING AND PAINTING)

1. SCOPE :
This document comprises the minimum requirements for fabrication, assembly, erection, inspection,
testing and acceptance of piping.

2. GENERAL:

2.1 Codes, Standards and Reference documents :

1 Fabrication, erection, inspection and testing of all piping shall be in accordance with following codes,
ASME B 31.3 , ASME SEC II , ASME SEC V , ASME SEC VIII , ASME SEC IX .

3. WELDING AND EXAMINATION :

3.1 Qualification :
3.1.1 The erection agency shall prepare welding procedure specification and submit for approval to ESTL.
31

3.1.2 Erection agency shall qualify the welders.

3.1.3 The Erection agency shall maintain a record of welding procedure specification (WPS), procedure
qualification record (PQR) and qualified welder log sheet. This record shall be submitted for ESTL
approval and made available to the ESTL upon demand.
3.1.4 The Erection agency shall prepare & test the required test specimen by an approved
testing laboratory to meet the requirement of ASME SEC IX. The test report shall be reviewed by ESTL
for compliance with code requirement.
3.1.5 ESTL in concurrence with the Erection agencys field representative shall have the right to stop any work
that is being done when in their operation, any welder does not maintain the required standards in his
works.

3.2 Welding Procedures:

3.2.1 The Erection agency shall Prepare and submit following welding procedure
specification for underground and above ground, for ESTL approval.
WPS for Carbon Steel
WPS for Austenitic Steel
WPS for Mixed welding (Carbon steel and Austenitic steel)
3.2.2 Copies of above approved WPS shall be available with Erection agency and ESTL.
3.2.3 WPS shall be revised whenever there is a change in any non essential variable. A new
WPS shall be prepared and qualified if an essential variable is changed or added.
3.2.4 The ESTL may ask for re qualification of a WPS at any time.
3.2.5 Erection agency shall submit the quality assurance plan to ESTL for approval.

32

3.3 Welding material :

3.3.1 Filler material shall be required to conform to the requirements of ASME SEC- IX. A
filler material not yet incorporated in ASME SEC- IX may be used with prior approval of
ESTL.
3.3.2 Low hydrogen coated electrodes shall be stored in sealed containers. Upon opening,
the electrodes shall be placed in heated oven maintained at temperature ranges as
recommended by ASME SEC- II Part C and as per electrode manufacturers recomm-
endation.
3.3.3 Welding electrodes for the SMAW process shall be selected as per AWS A 5.1, AWS
A 5.4 and AWS A 5.5 specifications.

3.4 Production welding:

3.4.1 Erection agency and ESTL shall verify that all the welders employed for production
welding are qualified and shall be responsible for instructing the welder to the correct
use of the WPS.
3.4.2 ESTL shall ensure that all weld joint fit ups are inspected for alignment and edge prepa-
ration prior to welding.
3.4.3 Tack welds used to secure alignment shall be removed completely after they have

served their purpose and shall be examined visually for defects, and if found to be defective the same
shall be rectified. Tack welds also shall be made only by qualified welders.

33

3.4.4 Peening is prohibited on the root pass and final pass of a weld.
3.4.5 Beveled pipe ends shall be used as far as possible. For pipe ends requiring beveling, ends may be
prepared by grinding or torch cutting & grinding.
3.4.6 Branch connections shall be made as indicated in approved drawings. Reinforcemen pad shall be
provided wherever required, as per code.
3.4.7 The specific application of welded miter bends & fabricated reducers shall be governed by the piping
material specification.
3.4.8 Flattening of a bend, the difference between maximum and minimum diameters at any cross section, shall
not exceed 8% of outside diameter for internally pressurized pipes.
The complete bend shall have a smooth outer surface free from cracks, flat spot and bulges and other
serious defects.For oxygen pipes, internal diameters of pipes of each joint shall match with each other.
Removal of metal shall not be used to achieve these requirements.

3.5 Preheating and Heat Treatment :

Preheating and heat treatment procedure shall be made in accordance with the requirements of the
Code and WPS. ESTL shall review and approve the same.

3.6 Identification of Welds :

3.6.1 The identification symbol of the welder shall be applied by marking with a coloured stamp & weather
proof colour for each weld containing pressure.
3.6.2 The identification symbol of the Radiograph agency shall be applied by marking with a coloured stamp &
weather proof colour for each pressure containing weld.
34

3.6.3 ESTL shall ensure the matching of welder & radiograph agencys identification on weld joint, while
assessment of radio graphed films.
3.6.4 Die stamping of the component shall not be permitted.

3.7 Examination :

3.7.1 The examination, repair of welds by the Erection agency shall be in accordance with the codes as
mentioned in Para 2.1of this specification.
3.7.2 Extent of Radiography shall be as per Table 1.

1 If any failure is found in the system based on 10 % Radiography further 30 % Radiography shall be
covered.

2 If any failure found in these 30 %, 100 % Radiography shall be adopted.

4. PREFABRICATION :

4.1 Erection agency shall mark the spool numbers on piping drawings and then prefabricate the
spools.
4.2 Each prefabricated spool piece shall bear the line number and the spool number.
4.3 Each spool piece shall be physically cleaned and ends appropriately closed to prevent dust & moisture
ingress into the spool piece.
4.4 Pipe, Spool piece, Elbows, Fittings, Supports and Structural steels shall be primer coated according to
painting specification if necessary, before assembly and erection leaving adequate margin for subsequent
welding with the matching element.
35

5 ASSEMBLY AND ERECTION :

5.1 General :

5.1.1 Proper care shall taken during pre fabrication to ensure that pipe ends are suitably closed to prevent
dust, debris and moisture ingress into the pipe / piping system.
5.1.2 Before erection of pipes all the necessary tools, tackles and equipment shall be kept ready at site.
5.1.3 Both prefabricated and site fabricated piping shall conform with the requirement of the code and
drawings.
5.1.4 Ferrite tools, alignment clamps and slings must not be used for processing of austenite stainless steel. Any
contact with ferrite material is to be avoided.

5.1.5 For Under ground piping

5.1.5.1 Spool interior shall be cleaned to remove dust / debris.
5.1.5.2 Spool pieces shall be made ready complete with all necessary testing and examination.
5.1.5.3 Spool pieces shall be drained / depressurized of the test medium and ends shall be suitably capped to
prevent dust/debris/moisture ingress into the spool interior.
5.1.5.4 Pipe trench shall be excavated and minimum 200mm sand bed shall be prepared in the pipe trench. Spool
pieces of pipe shall be erected in the pipe trench.
5.1.5.5 After erection of pipe in pipe trench, all the materials like stone, steel pieces, wooden pieces, etc., shall be
removed from the pipe trench.
5.1.5.6 Pipe shall be supported suitably with sand bag inside the pipe trench.
5.1.5.7 Erected line part ends shall be suitably capped to prevent dust / debris / moisture ingress till such time
that the upstream / downstream line part is erected.

36

5.1.6 For Above ground piping

5.1.6.1 Spool interior shall be cleaned to remove dust / debris.
5.1.6.2 Spool pieces shall be made ready complete with all necessary testing and examination.
5.1.6.3 Spool pieces shall be drained / depressurized of the test medium and ends shall be suitably capped to
prevent dust/debris/moisture ingress into the spool interior.
5.1.6.4 Pipe supports shall be erected as per the piping drawings before erection of the prefabricated spool
pieces.
5.1.6.5 Piping spools / elements shall then be erected on the pipe supports. Clamping wherever necessary
shall be done after piping erection.
5.1.6.6 Erected line part ends shall be suitably capped to prevent dust / debris /moisture ingress till such time
that the upstream / downstream line part is erected.

5.2 Flange joints :

5.2.1 Prior to fabrication and assembly the flange shall be examined for damages and cleaned. Flange face
scrapping and scratching with hard objects shall be avoided. Any damage to the gasket seating surface
would prevent proper gasket seating & hence would call for flange replacement.
5.2.2 All flanges shall be oriented so that the bolt holes straddle the pipe center lines, unless noted otherwise
on the drawings or unless necessary to match a companion flange on equipment which is oriented
otherwise.
5.2.3 All flanges facings shall be in perfect alignment (parallel, right angles to pipe) before bolting is
begun.
5.2.4 Bolts in flanged connections shall be uniformly tightened. Tightening to a predetermined torque is
recommended. Care shall be taken to secure uniform pressure n the gasket. All bolts shall extend
completely through their nuts.
5.2.5 For oxygen and hazardous gases service, care shall be taken to ensure the non application of grease,
oil etc. on raised face of flange.

37

5.2.6 All gaskets to be installed in water, nitrogen, air lines shall be applied with a thin film of grease, if
required.

5.3 Threaded joints :

5.3.1 All threaded pipe ends shall be reamed after threading.

5.3.2 Threaded joints shall be cleaned of metal chips and machining oil from the cut threads before
application of Teflon seal tape.
5.3.3 Teflon seal tape may be used for threaded joints for design temp. up to 120C. Jute, lead scraps, paint
or other fillers shall not be used.

5.4 Valves :

5.4.1 All welded ball valves shall be of three piece design. Middle piece of the three pieces ball valves shall be
removed before start of weld of ball valve faces in order to prevent damage to the valve PTFE seat.
5.4.2 Welded ball valves shall be first aligned with the piping and ends shall be tack welded.
5.4.3 The middle piece of the ball valve shall be removed prior to full welding of the valve ends.
5.4.4 The welded faces of the valves shall first be allowed to cool down naturally before rein- stallation of the
middle piece in position.
5.4.5 All other valves shall be first cleaned and then installed with valves in closed position.
5.4.6 Proper gasket seating shall be ensured before tightening of flange bolts.

5.5 Pipe supports :

5.5.1 To prevent sagging and damage to pipe & fittings, due to self weight and thermal effects, pipe

38

 supports shall be placed as per pipe specifications and drawings. The

location and design of piping supports shall be as shown in approved drawings.
5.5.2 Temporary tack welds provided during erection shall be removed. Note : If the distance between
consecutive pipe supports is not mentioned in drawing,
then same shall be kept as below : Below 2 = maximum 2 meters 2 to 6 = maximum 3 meters
8 and above = As per drawings

6. INSPECTION:

After completion of erection the system under the scope of work, shall be thoroughly inspected for compliance to
design requirement for layout, plans, elevations, connect- ions, details, material quality of welding and erection,
supporting, thermal expansion, safety, suitability for operation through valves, etc. approaches, maintenance, etc.
and quality records are maintained. Piping system shall be flushed until all pipe lines are thoroughly cleared of
loose scale, contaminants and debris. Pipes, fittings etc.,of each system shall be cleaned inside and out side by
suitable means. The cleaning process shall include removal of all foreign matter such as scale, sand, weld spatter,
erection clamps, cutting chips etc., by wire brushes, cleaning tools etc.

7. TESTING :

7.1 General :

7.1.1 Joints shall not be painted, insulated or coated prior to completion of testing.
7.1.2 All pressure test shall be performed by the Erection agency and shall be inspected and approved by
ESTL.
39

7.1.3 No test shall be performed until the prefabricated spool/system is examined physically. and cleared by
ESTL.
7.1.4 Valve shall be kept in open position during test.
7.1.5 Equipment and components not subjected to pressure test shall be disconnected or the erection agency
shall provide spools, blanks or blind flanges as required to adequately isolate the equipment during test.
If necessary, temporary pipe supports,

pipe anchors etc., shall be supplied.

7.1.6 All the instruments being used for testing shall be with necessary calibration certificate and same shall be
verified by ESTL prior to the test.
7.1.7 Hydro testing of spool pieces/piping system of above ground piping (particularly over pipe racks) shall
be carried out bearing in mind the load carrying capacity of the rack, only one line / piping system shall
be hydro tested at a time.

7.2 Hydrostatic Testing :

7.2.1 Hydrostatic testing shall be carried out only on those services mentioned in Table 1.
7.2.2 Each spool to be hydro tested shall be provided with suitable blinds at the ends.
7.2.3 The blinded ends shall be fitted with suitable valves for filling water, draining water and venting air. The
water filling and drain valves shall be installed at the lowest possible level and the vent valve at the highest
possible level.
7.2.4 Before start of water filling vent valve shall be kept open and water shall be filled into the line gradually
ensuring proper air venting.
7.2.5 Air vent valve shall be closed, once all the air is removed from the pipe line.
7.2.6 Suitable hydrostatic pressure pump shall then be connected to the pipe line and care shall be taken to
ensure gradual increase of pressure in the pipe line. Following pressurizing sequence shall be followed

40

 Pressurize to 50 % of the test pressure, hold pressure for one hour.

Drop pressure to static head + 1 bar at lowest point.
Pressurize to 75 % of the test pressure, hold pressure for one hour.
Drop pressure to static head + 1 bar at the lowest point.
Pressurize to the test pressure.

In case during the hold pressure periods indicated above a decrease in pressure is observed, the above operation
shall not be repeated more than twice, after which the line shall not be considered capable of test until the cause
for leak of water has been isolated and eliminated.

7.2.7 The gauge used for testing shall be installed as close as possible to the low point of the piping system.

7.2.8 The test pressure as per table-1 shall be maintained for a period of not less than 1 hour. Sweating, oozing
of drops shall be observed in the pipe being tested. Check for
pressure drop if any after the holding time is over. The test pressure shall be
maintain-
ned until the entire section under test has been examined. Defects revealed by the
tests shall be repaired, or defective parts replaced and the system retested. For
acceptance, no drop in pressure during the test period is allowed.

7.29 After completion of the hydrostatic test, the system shall be completely drained. Air
vents shall be kept open during system draining to avoid producing a vacuum.
7.2.1
For different service requirements min Percentage of Radiography, Hydrostatic test
pressure and Pneumatic test pressure are indicated in the table below.

41

 Protocol for completion of works before doing hydro/pneumatic test

Name of department : location: section of piping reference drawing

Check following documents:

1) Piping schematic Drawing ,P& ID & erection drawing

2) Pipe & pipe fitting materials as per specification
3) Supports as per drawing
4) Weld joints as per technical specification, radiography test results
5) Cleaning of pipe line
6) Flange joints , threaded joints as per technical specification

Signed by EPIL/CNTRACTOR Signed by ESTL ENGINEER

Signed by EESL Signed by safety engineer

42

 Protocol for hydro test / pneumatic test of pipe line

Name of department : location: section of piping reference drawing

1) test pressure as per specification kg/cm2

a) Hydraulic
b) Pneumatic
2) Duration of test as per specification hr/min
3) Leakage if any
4) Rectification of joints/ flange/threaded
5) Retest

Signed by EPIL/CNTRACTOR Signed by ESTL ENGINEER

Signed by EESL Signed by safety engineer

43

 Protocol for commissioning of pipe line : putting liquid/gas

Name of department location: section of piping reference drawing

1) Liquid : remove all water from pipe line by draining

Blow the air & remove all moisture from pipe line
2) Gas: after carrying out the pneumatic test blow the air and remove suspended
materials
3) If NG
BF Gas
Corex gas
Put the nitrogen purge it from the bleeding points , check no traces of O2 is
present
Seal the pipe line,
Slowly admit the NG/BF Gas/Corex gas/coke oven gas required pressure.

Signed by EPIL/CNTRACTOR Signed by ESTL ENGINEER

Signed by EESL Signed by safety engineer

44

 TABLE - 1

Maximum
Radio allowable Design
Sr. Hydrostatic test Pneumatic test pressure
Media Graphy Working pressure
No pressure ( bar) ( bar )
( % ) Min. pressure ( bar )
( bar )
1 Natural gas, LPG 100 % 1.1 x M.A.W.P 1.1 x D. Pressure*
2 Corex gas, BF gas 10 % 1.1 x M.A.W.P 1.1 x D. Pressure*
3 Bleed off gas, Cooling 10 % 1.1 x M.A.W.P 1.1 x D. Pressure*
gas, Depressurizing gas,
Export gas, Pilot gas, Top
gas, Excess gas
4 Oxygen 100 % 1.1 x M.A.W.P 1.1 x D. Pressure
5 Nitrogen, Argon 10 % 1.1 x M.A.W.P 1.1 x D. Pressure
6 Compressed air, 10 % 1.1 x M.A.W.P 1.1 x D. Pressure
Instrument air.
7 Steam, Steam Condensate ** -- --
8 Air-conditioning cooling 10 % 1.1 x M.A.W.P 1.5 x D. Pressure ----
water, Firefighting water,
Make up water, Gland
water, process water, Slag
quench water, Secondary
cooling water,
Miscellaneous water,
Sludge water
9 Machine cooling water, 10 % 1.1 x M.A.W.P 1.5 x D. Pressure
----
Staves cooling water

45

 Fire fighting water, 10 % 1.1 x M.A.W.P 1.5 x D. Pressure

----Process water, Gland water, Miscellaneous water
M.A.W.P. --Maximum allowable working pressure
D. pressure -- Design pressure

* Minimum test pressure 2000 mmwc

** As per Indian Boiler Regulations

7.3 Pneumatic Testing :

Pneumatic testing shall be carried out for those services indicated in Table -1.

a)For Strength

7.3.1 The test shall be performed with compressed air, dry compressed air or nitrogen.

7.3.1 A Pressure relief device shall be installed between the piping system being tested and the pressure source
in order to protect the piping system from excess pressure.
Pressure relief device shall have a set pressure of not more than the test pressure plus the lesser of 3.5 kg/cm2 or
10 % of the test pressure.

7.3.2 Pressure in the equipment shall be gradually increased to not more than 50 % of the test pressure and then
thereafter by increments of 10 % of test pressure till it reaches to the final test pressure.

46

7.3.3 Pneumatic test pressure shall be maintained until the entire section under test has been examined for
leakage.

7.3.4 While holding the test pressure all welded, threaded and flanged Connections shall be inspected, by
soap solution test. Defects revealed by the tests shall be repaired, or defective parts replaced and the
system retested.

b) For Leakage
Pressure lowered to max. working pressure and leakage test will be conducted
over duration of 24 hour. Pressure and temperature recording shall be done
every 60 min. interval.

Following formulae for acceptance of leakages shall be adopted during testing

of pipeline with fluid.

100 x( 1 -Pf / Tf x Ti / Pi ) < 4 % for interplant piping

< 2 % for inside shop

Pi = Initial pressure Pf = Final pressure

Ti = Initial temperature Tt = Final temperature

8. RECORDS :

47

8.1 Record shall be made for each pipe line / system and shall be approved by ESTL. This record shall be
submitted to ESTL.

8.2 All test results of tested seams shall be recorded in the welding log book.

These records shall certify all the quality control requirements of the regulations and the engineering design. This
record shall include the following.

-- Inspection of Workmanship
-- Examination of Welds / Radiography test report
-- Test Pressure, Design pressure and Working pressure
-- Date of test
-- Pressure gauge calibration due date
-- Fluid media and test fluid media
-- holding time
-- Isometric line diagram
-- Comments during observation of testing.
-- Supplementary Test

9. COMMISSIONING :

9.1 Prior to commissioning

9.1.1 The tested pipeline kept plugged at both ends, shall be blown with dry compressed air / Nitrogen at a
velocity not less than 20m/sec.

9.1.2 During or prior to initial operation the pressure shall be gradually increased in steps until the operating

48

 pressure is reached, holding the pressure at each step long enough to equalize piping strains.
9.1.3 While holding the operating pressure, all welded, threaded and flanged connections shall be inspected.

10. SUPPLEMEANTARY REQUIREMENTS FOR OXYGEN PIPING :

10.1 General :

10.1.1 Oxygen service requires essentially complete removal of contaminants such as hydro carbon greases, oil,
thread lubricants, shop dirt, water, scale, weld spatter, chips, rust, fluxes, paints, crayon marks, packing
material or any other foreign materials. Many of these materials, especially hydrocarbon greases and oils,
can react violently in the presence of oxygen, causing fires or explosions. Others such as metal chips, can
be propelled by the oxygen stream with sufficient velocity to trigger an explosion on impact Still other, by
plugging small ports or seizing moving parts can cause dangerous mal-function of equipment.
All these material are considered contaminants and must be removed. It is especially important to avoid
trapping of contaminants in locations difficult or impossible to clean after assembly. Therefore, cleaning
and assembly procedure must be integrated to avoid this condition. Further more, once the system is
cleaned, it must be kept clean until it is put into service.

10.1.2 Personnel shall be aware of the proper cleaning techniques to be used and be fully aware of the serious
consequences that could result from inadequate cleaning. They shall be required to wear apparel which is
free of oil and grease and to work with clean hand gloves. (Note: A cleaned surface should never be
touched or handled by the bare hand as its in the natural skin are contaminants.)

10.1.3 Utilities directly involved in cleaning operations shall be compatible as follows. a) Gases like Nitrogen,
Compressed air Gases only dry, oil free, inert gases shall be used for cleaning, purging, drying and testing. b)
Water Water used for making up solutions or for flushing, rinsing or testing shall be potable. c) Steam
49

 Any steam used for direct contact heating or cleaning shall be free from oil and scale.

10.1.4 ESTL shall approve and/or inspect all materials, equipment procedures, etc., which is
necessary to produce the desired standards of cleanliness.

10.1.5 Welding

10.1.5.1 The TIG welding process shall be used for at least root pass. Subsequent passes shall be made with
welding processes according to WPS. An internal gas purge shall be maintained during the entire welding
process.
10.1.5.2 All roots shall be examined by Liquid Penetrant or Magnetic Particle examination for minimizing of
repairs and by it the risk of contamination.

10.1.6 Inspection
Wherever possible, equipment for oxygen services shall be inspected by using methods that apply to a
particular situation. This covers both, pre-cleaning and post cleaning inspections. If any of the tests reveal
contaminants, the item must be cleaned.

10.1.7 Static Protection System (Earthing)

The piping work shall be provided with static protection system wherever applicable. Pipes entering and
leaving the units or equipments shall be effectively earthed at the specified locations, in addition to other
locations as specified in the standard specs.

10.2 Cleaning procedure on site :

The cleaning shall be done in general conformance with this specification, and as outlined in the
contractors own cleaning specification which has been explicitly approved. Contractors specification

50

 shall contain a clear, accurate, step by step description of the cleaning procedure, a description of the
cleaning facilities cleaning agents and inspection methods.

10.2.1 Cleaning Process

The cleaning of pipes and other piping parts shall be done for each single part by the following steps.

10.2.1.1 Carbon steel:

a ) Degreasing
b ) Pickling for removal of scale, rust and other contaminants,
c ) Neutralization
d ) Passivation
e ) Drying with oil free air or oil free nitrogen

f ) Covering and sealing of both ends to prevent corrosion.

10.2.1.1a. DEGREASING, PICKLING AND PASSIVATION OF OXYGEN PIPELINES :

In view of the possible hazards due to violent reactions of oxygen with hydrocarbon materials like oil etc., the
oxygen pipelines need to be specially degreased, pickled, passivated and dried with oil free air or dry
nitrogen before being allowed to carry oxygen, after conducting satisfactory Radiographic and Pneumatic
test.

The following procedure may be adopted for the above.

1 The pipeline system to be commissioned shall be ready with respect to erection namely supporting, NDT,
51

leak test etc.

2 Hydro testing of pipeline along with valves to be carried out before taking the pipe line for degreasing and
pickling.

3 All isolation valves and control valves provided in the pipeline are to be removed and appropriate spool
pieces to be provided to make the continuity in the pipe line.

4 Degreasing and acid pickling of valves shall be carried out separately by dipping valves in respective
solution bath.

5 The valves shall be flushed with fresh DM water/Potable water to remove acidtraces & cleaned with
Trichloro Ethylene (T.C.E.). The valve ends shall be covered & secured after cleaning with plastic sheets to
prevent entry of dust.

6 The system shall be circulated and flushed with oil free cold water.

7 The system shall be circulated and flushed with hot water at a temperature range of 50-60C.

8 The system shall be degreased with hot water containing 2-2.5%NaOH and 0.1% detergent (Surfactant) at a
temperature of 60-70C.
9
10 Oil content, alkalinity and pH shall be analyzed. Degreasing process shall be continued so as to obtain only
traces of oil content in the samples. DM water / potable water flushing shall be adopted.

11 Hot DM water/ potable water (60-70C) containing 3%inhibited ammoniated citric acid along with ABF
( Ammonium biflouride NH4HF2 ) shall be circulated and flushed for pickling the system. During the pickling
process, the pH value shall be 3-4, percentage of acid not less than 1.5 and Fe+3 shall not be more than 2500 ppm.
52

1 Drain the system with nitrogen under pressure.

2 The system shall be flushed with DM water/ potable water till the iron content is less than 100 ppm and the
pH is more or less constant.

3 The system shall be flushed with DM water/ potable water containing 0.3-0.5% citric acid.

4 The system shall be passivated with NaNO2.

5 The system shall be drained under pressurized nitrogen.

6 The system shall be dried with nitrogen at a velocity of 20m/s.

7 The open ends shall be duly plugged and maintained at positive pressure of about 1 kg/cm2 (g) with
nitrogen. The pressure shall be checked periodically till commissioning.

8 The system shall be blown with dry oil free nitrogen (min. purity 94%) at a velocity of 20m/s prior to
commissioning. During such blowing white cardboard shall be held in front of the outlet for assessing any
blackening. Blowing shall be continued for a minimum period of 8 hrs. till satisfactory results of maintenance of
clear white board.

9 The piping system shall be filled up with oxygen at a velocity of max. 10 m/sec.
The mixture of nitrogen and oxygen will be exhausted at a height of 2.5 meters from top most point. After
exhausting the pipes completely, the lines may be put into operation.

53

10.2.2 Flanges, Small fittings, Bolts and Nuts

Degreasing shall be done by immersion or wipe method. The cleaned components shall be sealed in proper
polyethylene bags.

10.3 Protection of Cleaned Materials :

10.3.1 Small parts, valves, gaskets, etc., shall be sealed in heavier polyethylene bags. The inspection tag may be
enclosed in the bag.
10.3.2 Seal under a slight positive pressure of high purity dry nitrogen.

10.4 Identification and Records:

After equipment has been cleaned for this class of service, it shall be identified as
such to avoid subsequent recontamination. The erection agency shall certify that the
lines are clean for oxygen service. ESTL shall confirm these records.
The method of marking will depend on the item cleaned, but it should at least conform
to the following requirements :

CLEANED FOR OXYGEN SERVICE

BY --------- DATE -----------

11. SAFETY PRECAUTIONS FOR FABRICATION AND ERECTION OF PIPING :

11.1 The applicable Indian government rules and regulation regarding storage of testing
equipment and execution of the tests are strictly to be followed.
54

11.2 A safety engineer/his representative to be appointed and have to be present at job /

site all the working time.
11.3 Work shall be started with safe work permit from concerned department, if necessary.
11.4 All tools and tackles, electrical equipment, etc., to be kept in safe conditions and to be
checked periodically.
11.5 Temporary platforms, ladders, stair scaffoldings, etc., to be kept in safe conditions
and to be checked periodically.
11.6 Marking and barricaded the hazardous areas, walkways etc., to be sufficient and
always in function.
11.7 Use all necessary PPEs while working at site.
11.8 Area to be covered / barricaded with danger tape while working at height as well as
underground, particularly during radiography and testing.
11.9 Gas warning system to be installed at the working area, if necessary.
Note: PPE = Personnel Protective Equipments
(Hand gloves, Safety helmet, Apron, face shield, Grinding goggles, Ear plug ,
Safety goggles, etc.)

12. STORAGE AND ERECTION INSTRUCTIONS :

12.1 General :

12.1.1 Erection agency shall be received material from store. Visual Inspection of Material shall be carried out
by Erection agency at store and shall be transported or shifted to site. Temporary storage area shall be
made by Erection agency.

55

12.1.2 Handling of material shall be done without damage due to sagging or wrong method of lifting, erection
agency shall be responsible for same.

12.1.3 All the drain and vent valve shall be provided as per drawing or additional requirement occur
during testing.

12.1.4 Radiographic testing of welding shall be carried out by ESTL.

12.1.5 Erection agency shall study the drawings carefully and according to bill of quantities, plan for
handling of the material. Erection agency shall submit the erection sequence with handling requirement,
prior to erection of materials / Equipments to his concern ESTL

12.1.6 Equipments/ Materials required for shot blasting and painting have to be carried out by Erection agency.

12.1.7 Materials / Equipments required for pressure testing, flushing etc. such as pumps, hoses, manometer,
pressure gauges tanks, etc. have to be supplied by the Erection agency.

12.1.8 Erection agency shall submit the total deployment of man, material and machinery report to ESTL on
demand. Report shall comprise, Man : Fabricator, fitter, welder with qualification, grinder, gas cutter,
foreman, rigger, etc. Material : Consumables items such as welding electrodes, grinding wheel, oxyge
cylinder, argon cylinder etc. Machinery : welding machine, grinding machine, cutting set, slings, winch
m/c etc.

13. PAINTING -

1.) Necessary line modifications (routing, bill of material) are subject to a written confirmation by ESTL.
2.)PAINTING SPECIFICATION - The complete paint system for any item shall include

56

 Surface preparation, Application of primer coat, intermediate coats and finish coats of specified
paints of approved quality.

13.1 Surface preparation

All surfaces shall be cleaned of loose substances and foreign materials, such as dirt, rust, scale, oil, grease,
welding flux, etc. in order that the prime coat is rigidly anchored to the virgin metal surface. The surface
preparation shall be as per Swedish Standard SIS 055900, German Standard DIN 55928 (Part 4), BS 4232
or IS 1477 Part I. Procedures for surface preparation shall cover solvent cleaning, hand tool cleaning, and
power tool cleaning or combination thereof in order to attain desired surface quality as required by the
specific primer paint.

13.2 Paint application

13.2.1 Paint shall not be applied in rain, wind, fog or at relative humidity of 80% and above or when the
surface temp. is below dew point resulting in condensation of moisture.
13.2.2 Paint shall not be applied when the ambient temperature is 5C and below.
13.2.3 Each coat of paint shall be even film thickness and shall be continuous, free of pores and spots.
13.2.4 Each coat of paint shall be allowed to dry sufficiently before application of the next coat to avoid
damage such as lifting or loss of adhesion.
13.2.5 The Surface Preparations required and painting Systems are indicated in Annexures1A. The colour
codes are indicated in Annexure 1B ,based on IS 2379.

57