00200012F - G - Fabrication and Installation Oil Carbon Steel Pipework To ASME 831.3 Fuel Pipework

ENGINEERING SPECIFICATION
FOR
FABRICATION, INSTALLATION AND TESTING
OF FUEL FARM AND

FUEL HYDRANT PIPEWORK
APC Document No.:
HIA-J029-APC-ME-SPEC-0114
0 30/10/12 DESIGN VERIFICATION HS APC APC

G DEC 2011 PIPING CLASS UPDATE FM CM FM
F DEC 11 UPDATE FM CM FM
E 2011 FIRST ISSUE FM CM FM
REV. DATE DESCRIPTION
DOCUMENT REF NO. : PROJECT NO. : 0020
00200012F 3326
HIA-J029-APC-ME-SPEC-0012 Page 1 of 49
Fabrication and Installation of Carbon Steel Pipework
1. CODES, STANDARDS AND TERMINOLOGY

1.1. GENERAL
1.1.1 The selection of Fabricator shall be subject to the approval of the company, the basis of
the Fabricator s experience of similar work, shop facilities, production methods, quality
assurance procedures etc.
1.1.2 The Fabricator shall not sub-contract any part of the work without the Company s written
approval.
1.1.3 The Fabricator shall submit to the Company for review and approval the documentation
required by the Quality Assurance Data Sheets attached to the order. The allowable
timescale for submission of documentation and the required approval status prior to
release for fabrication shall be as specified in the QA Data Sheets.
1.2. TERMINOLOGY
1.2.1 The COMPANY shall be taken to mean -that client identified as such in the tender
enquiry.
1.2.2 The PURCHASE is the authority responsible for issuing the relevant enquiry or order,
and will be The Company of the Company s nominated Contractor.
1.2.3 The CONTRACTOR is the organisation appointed by the Company and responsible for
the overall mechanical design and procurement of process plant for a particular project.
1.2.4 The FABRICATOR is the organisation responsible for supplying materials, carrying out
the mechanical design where applicable, fabrication, preparation for shipment and
delivery of equipment in accordance with the Purchaser s order.
1.2.5 The INSPECTOR is the Company employee or duly authorised representative of the
Company, appointed to monitor material quality, workmanship and conformance to data
supplied, Standards and Codes during fabrication, testing etc.
1.2.6 The CERTIFYING AUTHORITY is the independent Inspection Agency or other body
authorised to inspect the equipment through the various stages of fabrication, examine
and approve all documentation including design calculations, and to certify that the
equipment and documentation meet all requirements.
1.2.7 Where matters have to be agreed or approved, this shall mean agreed or approved in
writing between the Purchaser and the Fabricator. Where the Purchaser is a Contractor,
he must first obtain Company agreement and approval concerning matters in this
document.
1.3. CODES AND STANDARDS
1.4. ALL PIPEWORK FABRICATION, TESTING, INSPECTION AND INSTALLATION

SHALL MEET, AS A MINIMUM STANDARD, THE REQUIREMENTS OF ANSI B31.3.
CHEMICAL PLANT AND PETROLEUM REFINERY PIPING.
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2. DESIGN
2.1. WELDING END AND BRANCH ATTACHMENT JOINT DESIGN
2.1.1 Each piping branch reinforcement pad or segment therefore shall be provided with one
hole (at the side and not at the crotch) drilled and tapped 1/4 NPT.
2.2. PROXIMITY OF WELDS
2.2.1 The minimum distance between toes of adjacent welds shall be the lesser of 40mm or
twice the wall thickness of the thickest pipe/fitting.
2.2.2 Dimensions less than those specified above are not permitted except where Company
agreement has been obtained and the following additional requirements met:
(a) Dependent on material, thickness and configuration, the Company may require
an intermediate stress relief to be carried out.
(b) Care shall be taken to minimise stress concentrations. Weld profiles shall be as
smooth as possible; at the discretion of the Inspector welds may be dressed.
(c) When branch welds cross or are located closer than the allowable to main
seams, such seams shall be radiographed or U/S tested for a distance on either
side of the hole of not less than the opening diameter.
(d) When attachments are located closer than the allowable to main seams they
shall cross the seam completely. The seam shall be radiographed to the extent
which will be covered by the attachment, plus on either side of the attachment, a
distance of twice the pipe wall thickness.
2.3. THERMAL RELIEF PROVISION
2.3.1 All protection sections of pipelines where locked in legs of product can exist shall be
protected with thermal relief. Thermal Relief assemblies should straddle the isolation
point closest to storage. it is likely that on one pipeline a series of thermal relief
assemblies will be required. It is essential that the set pressure on the relief valves are
properly selected to ensure the cascade effect valves limits the maximum line pressure
to below the design rating of the pipeline and/or any underated piece of equipment that
may be present on the particular system. Thermal relief assemblies cascade back
towards storage. Each thermal relief assembly shall consist of flanged thermal relief
valve. The contractor shall ensure all pipelines are adequately protected against
thermal expansion of product throughout the phase of the work.
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3. PIPE CUTTING AND WELDING EDGE PREPARATION

3.1. METHOD
3.1.1 Pipes shall be cut either by mechanical means or by thermal cutting.
3.1.2 End bevelling shall be done by machining, hand grinding or machine flame cutting.
3.1.3 Where thermal cutting is employed, all slag, oxides and traces of previously melted
metal shall be removed from welding edges by grinding or machining to sound metal.
3.1.4 The preheat level to be used for thermal cutting shall be as required by the relevant
welding procedure.
3.1.5 The bevel geometry shall be the same as and within the tolerances stated in the
approved welding procedure.
3.2. INSPECTION
3.2.1 After the material has been prepared for welding it shall be visually examined to confirm
the surface within 25mm of the bevel edge is smooth and uniform, free from cracks,
tears, laminations, gouges and any other discontinuities which may affect the integrity of
the weld. If there is any indication of defects the weld preparation area shall be
subjected to surface crack detection. Where any defects are found the weld bevel shall
be re-prepared and re-examined.
4. PIPE BENDING
4.1. GENERAL
4.1.1 Unless otherwise specified on drawings or Piping Class documents bends in piping shall
be achieved using standard elbows.
4.1.2 Where bending is required this may be performed either in the hot or cold condition and
shall be carried out in accordance with ANSI B31.3 except as modified below. The
bending and heat treatment procedures proposed by the Fabricator shall be subject to
the approval of the Company.
4.1.3 The bend centre line radius shall be 5 times the nominal pipe diameter unless otherwise
stated on the drawings.
4.1.4 Pipe bends shall be fabricated using seamless pipe and shall have no girth welds.
4.1.5 Bends shall not be wrinkled, cracked, scratched, gouged, die marked or buckled and
shall be in one plane.
4.1.6 Weld repair or pipe bends shall not be permitted.
4.1.7 Cut and shut , creased or corrugated bends are not permitted.
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4.2. HOT BENDING

4.2.1 Hot bending shall be carried out and completed at a metal temperature above the upper
critical point (AC3), within the range 900 degrees celsius.
4.2.2 Heat treatment after bending is not required unless the finished bend hardness exceeds
225 BHN (237 VPN), or otherwise specified on the drawings or Piping Class documents,
in which case a normalising operation shall be carried out at 900 -950 degrees celsius.
4.2.3 The temperature and furnace atmosphere shall be carefully controlled during the
bending and any subsequent heat treatment cycle to avoid excessive scaling,
carburisation or de-carburisation.
4.2.4 It is recommended that pipes 2 n.b and larger be packed with dry, sulphur free silica
sand before hot bending. The sand shall be completely removed after bending.
4.2.5 The bore of completed bends shall be visually examined to ensure freedom from
excessive scaling, which may be removed by pickling, blasting or mechanical means.
When pickling is used the procedure shall be subject to Company approval.
4.2.6 For pipework in sub-zero temperature service hot formed bends shall be normalised at
900 degrees celsius - 950 degrees celsius, unless it can be demonstrated that the
temperature control during hot forming results in the item having the same mechanical
properties as if is was normalised.
4.3. MITRE BENDS
4.3.1 Mitre bends shall only be used when specified by the drawings or piping Class
documents.
4.3.2 Mitre bends shall be produced by butt welding together segments cut from the same
length of pipe. The maximum change of direction between adjacent segments shall be
30 degrees.
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5. FLANGED JOINTS
5.1. GENERAL
5.1.5 Prior to welding on a slip-on flange the bore of the flange and the pipe end for a distance
equal to the flange thickness plus 25mm minimum shall be cleared free from any
protective coating, oil, grease, loose scale or rust. The difference between the diameter
of the flange bore and the outside of the pipe shall not exceed 5mm. Care shall be
taken when applying the inside fillet weld to avoid damaging the facing. The flange shall
be positioned such that the distance from the face to the pipe end is equal to the pipe
wall thickness plus 3mm.
5.1.2 Flange bolt holes shall straddle the vertical or NS centre line as applicable, except
where otherwise specified on the piping drawings, and shall match the orientation of the
mating flanges.
5.1.3 Loose flanges shall be bolted to an adjacent flanged piece for shipment or supplied in
hessian or canvas sacks securely attached to that part of the fabrication.
5.1.4 Flange facing shall be in accordance with the applicable Piping Class document. Should
warping take place during the fabrication the joint contact surfaces may be restored by
machining to their original accuracy provided the flange thickness dimensions are not
reduced below the minimum required by the relevant ANSI flange specification.
5.1.5 Pipe ends connected to threaded flanges shall not project through to form part of the
gasket surface.
6. WELDING
6.1. GENERAL
6.1.1 The Fabricator shall provide adequate and systematic supervision by competent
personnel to ensure that the required quality levels are maintained. At the discretion of
the Inspector, any welder who consistently fails to meet the standard shall be required to
undergo re-training, re-testing or shall be removed from the job completely.
6.1.2 All welding shall be carried out in accordance with qualified and approved weld
procedures by welders who have been qualified to the relevant testing code.
6.1.3 The Fabricator shall make maximum effort to ensure that arc strikes outside the welding
groove are avoided. When these occur outside of the finished weld the arc strike shall
be carefully removed by grinding, followed by a magnetic particle or dye penetrant
inspection of the ground area to confirm it is defect free. Care shall be taken to ensure
the ground area blends in smoothly with the surrounding material such that no sharp
notch results and the thickness is not reduced below the required minimum wall
thickness shall be carried out in accordance with an approved repair procedure. The
acceptance of arc strikes outside of the welding groove shall be at the sole discretion of
the Inspector who shall be requested to inspect the damage and approve the repair
procedure or reject the damage material as appropriate.
6.1.4 Weld stops and starts shall be staggered by 50mm minimum such that adjacent passes
or layers do not coincide. Weld stops and starts shall be ground or chipped prior to
laying subsequent passes.
6.1.5 The number of weld shall be minimised. Pipe lengths smaller than 1m shall not
normally be welded together.
6.1.6 Internals of inline valves and equipment which may be damaged due to heat transfer
from the welding process shall be removed prior to welding wherever possible.
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6.2. BUTT WELDS

6.2.1 All pressure containing butt welds shall be full penetration. Where access permits
consideration shall be given to welding from both sides.
6.2.2 Permanent backing strips shall not be used. Temporary backing strips may be used only
when approved by the Company. The material for temporary steel backing strips shall
be of the same nominal composition as the parent material. After completion of welding
the backing strips shall be removed and the area dye-penetrant examined to confirm the
absence of significant defects. Alternative types of backing materials shall only be used
where approval has been obtained from the Company.
6.3. BRANCH WELDS
6.3.1 All welded branch connection shall be joined to the header with full penetration welds of
comparable quality to, and subject to the same limitations (fit-up, alignment, welding
process etc) as girth welds, unless otherwise specified.
6.3.2 Piping branch reinforcement pads shall preferably be one piece but when not practicable
pads may be split circumferentially or along the axial centreline and welded together by
full thickness/full penetration welds.
6.3.3 Reinforcing pads for branches and structural attachments shall be accurately shaped
and fitted to ensure that the gap between the periphery of the pad and the pipe outside
diameter is not greater than 1.5mm.
6.4. FILLET WELDS
6.4.1 A minimum of two runs shall be deposited for all permanent attachments to pressure
parts. Where strength requirements permit, one weld run shall be acceptable for weld to
non-pressure containing parts.
6.4.2 All fillet welds shall be continuous and their surfaces shall be free from marked
irregularities. All fillet welds shall be overlapped at the stop-start position by at least
10mm.
6.5. SOCKET WELDS
6.5.1 Care shall be taken during the assemble of socket weld joints to ensure there is a
1.5mm gap between the pipe end and root face of the fitting.
6.5.2 Welds shall be fillet welds deposited by the MMA or TIG process, with a minimum of two
runs. The weld surface shall be free from marked irregularities.
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6.6. ATTACHMENTS TO THIN WALL PIPES
6.6.1 Where attachments are to be made thin walled piping i.e. less than 5mm thick, care
shall be taken to avoid excessive oxidation or burn through. An inert gas purge shall be
applied to the bore necessary. Where access to the bore surface for cleaning and
inspection is not possible the inert gas purge is mandatory.
6.6.2 In order to demonstrate the suitability of the weld procedure the Company may require a
test weld to be made on pipe of the minimum contract thickness. Similarly the Company
may require Welders to be tested on their ability to weld attachments to the thin wall
pipes even if their qualification range apparently covers the thin wall situation.
6.7. ALIGNMENT
6.7.1 The ends of piping components to be butt welded shall be accurately aligned in
accordance with the requirements on ANSI B31.3. The maximum internal misalignment
shall be 1.5mm except that where the pipe wall thickness is less than 6mm the internal
misalignment shall not exceed 25% of the wall thickness.
6.7.2 Where mis-match of the bores results in misalignment greater than that permitted
above, this shall preferably be corrected by taper or counterboring in accordance with
ANSI B31.3. Permitted alternatives to machining are:
(a) Roller expanding for pipes up to 4 nb.
(b) Cold drifting with a slow taper drift provided the diameter is not increased more
than 3%.
6.7.3 Care shall be taken to ensure that the wall thickness after machining, expanding or
drifting is not reduced below 87.5% of the nominal thickness.
6.8. FIT-UP & TEMPORARY ATTACHMENTS
6.8.1 Parts to be welded shall be carefully aligned and held securely in position by clamps,
tack welds in the welding groove, bridge pieces or wedges.
6.8.2 All welding of fit-up tacks and temporary attachments shall be performed by qualified
welders using qualified procedures and the preheat level specified by the procedure.
6.8.3 Where tack welds are to be incorporated into the main welds they shall be of a length
such that they become part of the proposed root pass and their ends shall be ground.
Defective tack welds, and those which are not to be incorporated into the root pass, shall
be completely removed by grinding, following completion of welding.
6.8.4 Temporary attachments shall be of the same nominal composition as the parent
material. They shall be removed by cutting 3mm above the surface followed by grinding
flush. The area shall then be surface crack detected to confirm the absence of defects.
6.9. PROTECTION FROM WEATHER
6.9.1 The welder and welding area shall always be adequately protected from the weather so
that the weld integrity is not detrimentally affected by wind, rain or snow or from the
decline of the welder s ability when working at low temperatures or other adverse
conditions. The continuation of welding indoor weather conditions shall be at the
discretion of the inspector.
6.9.2 Weld areas shall be kept dry throughout the complete welding cycle until after the weld
has cooled. Metal surfaces which are damp or below 5 degrees the commencement for
a minimum of 100mm on either side of the weld, taking care to avoid hot spots.
6.9.3 Where gas shielded welding is employed, special care shall be taken to protect the
welding area from draughts.
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6.10. WELD CLEANING, BACK GOUGING AND REPAIR

6.10.1 After each welding pass the weld shall be thoroughly cleaned and all slag and foreign
matter removed before the next run is deposited.
6.10.2 Peening of weld runs or the finished welds shall not be permitted.
6.10.3 The removal of weld defects shall preferably be carried out by grinding, machining or
chipping. Arc or oxygen gouging may also be used, provided all slag and oxidation is
removed by grinding from the gouged surfaces.
6.10.4 Welds which have been repaired and remain defective shall be cut out completely and
re-welded in accordance with the original procedure, except where the Inspector
authorises one further repair attempt. In no case shall more than 2 repair attempts be
permitted.
6.10.5 All weld repairs shall be performed by qualified welders using an approved repair
procedure.
6.11. WELDED PROCESSES
6.11.1 Except where otherwise agreed, welds shall be made by the manual metal arc (MMA),
tungsten inert gas (TIG), metal inert gas (MIG) or submerged arc welding (SAW)
processes.
6.11.2 The oxy acetylene process is permitted only for joints in pipe sizes
6.11.3 Where root runs are made by the MMA process, the electrode shall not be larger than
2.5mm diameter.
6.11.4 If the TIG process is proposed, a high frequency arc initiation unit and crater eliminating
device shall be used. The electrode shall be 2% thoriated tungsten, 2.5 to 3.0mm
diameter.
6.11.5 The MIG process may be used where the Fabricator can demonstrate he is capable of
reliably producing full penetration, full fusion welds.
6.11.6 The SAW process may be used for circumferential joint filler runs onto root runs made
by some other acceptable process/method. Recycling of flux shall only be permitted
after Company approval of the Fabricators
7. WELDING CONSUMABLES
7.1. SPECIFICATION & SELECTION

7.1.1 All consumables such as coated electrodes, bare wire, fluxes and gases shall comply
with the applicable AWS of British Standard. Other consumables may also be used
provided full details of chemical and mechanical properties, and service experience are
submitted and approval obtained from the Company.
7.1.2 Shielding gases shall normally be one of the following, depending on the particular
application:
(a) Argon to BS 4365
(b) Argon/oxygen mixtures consisting of argon to BS 4365 with up to 5% oxygen to
BS 4365. Total impurities 0.07% maximum.
(c) Argon/carbon dioxide mixtures consisting of argon to BS 4365 with up to 25%
carbon dioxide to BS 4105 type 1 and up to 5% oxygen (if required) to BS 4363.
Other gases may also be considered where they have been proved satisfactory by the
weld procedure qualification tests and any other tests deemed necessary by the
Company.
7.1.3 Gases for back purging shall be argon as specified above or nitrogen to BS 4366 type 1.
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7.2. STORAGE, PROTECTION AND BAKING

7.2.1 The Storage, protection and baking of all welding electrodes, filler wires and fluxes shall
be in accordance with the Manufacturer s recommendations.
8. WELDING PROCEDURE & WELDER QUALIFICATION
8.1. GENERAL
8.1.1 All pressure containing welds and welds made onto pressure parts shall be made in
accordance with a procedure written and qualified in accordance with the ASME Boiler &
Pressure Vessel Code Section IX. No welding shall be carried out until the procedure
have been approved and the test results accepted by the Company.
8.1.2 Each welding procedure shall be given a reference number and shall be cross
referenced to construction drawing and to the applicable qualification records.
8.1.3 All welders shall be qualified in accordance with the requirements of the ASME Boiler
and pressure Vessel Code Section IX.
8.1.4 Each Welder shall be assigned an identification number, letter or symbol, and a
complete circumference of 5% of above ground welds shall be radiographed. The
radiographs shall be retained for examination and approval by the Company.
8.2. REPAIR PROCEDURES
8.2.1 All weld repairs shall be carried out in accordance with written procedures which shall be
submitted to the Company for approval.
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9. FABRICATION TOLERANCES
9.1 Fabrication tolerances shall be in accordance with the specified codes and standards,
supplemented by the requirements given below.
9.2 Flattening of a bend, as measured by the difference between the maximum and
minimum outside diameter at any cross section shall not exceed 8% of the original
outside diameter of the pipe for internal pressure and 3% for external.
9.3 Flange alignment tolerances shall be as stated in Appendix A figure 1.
9.4 The tolerances on linear dimensions involved in the relative positions of branches,
bosses, flanged ends, flow instrument tappings and changes of direction shall be as
stated in Appendix A figure 2. Also given in this figure are tolerances on pipe bending
and across the land of prepared welding ends.
10. INSPECTION AND TESTING
10.1. GENERAL
10.1.1 The Inspector shall have free access to all parts of the Fabricator s Works engaged in
the manufacture of pipework and shall have the right to inspect any aspect of the work
during fabrication, installation, testing or an completion. The Fabricator shall afford the
Inspector all reasonable facilities to allow these inspection functions to be fulfilled. All
tests and inspections shall be conducted at the place of fabrication unless otherwise
stated.
10.1.2 The Fabricator is required to have an identification system such that each component
part can be identified against the Mill Test Certificates and that all weld seems can be
identified with the welder or welding operator and welding procedure specification.
10.2. INSPECTION CLASSES
10.2.1 Piping Systems are classified on the basis of service and material.
10.2.2 The extent of inspection to be carried out for each inspection class is shown in table
10.2.3.1.
10.2.3 Inspection Class stated in table 10.2.3.1 should be in accordance with the following
Class I All underground fuel pipework entire hydrant system

Class II Aboveground fuel pipework not applicable
Class III All above ground fuel pipework Resident engineer to nominate welds to be
examined
Class IV All above ground water pipework
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TABLE 10.2.3.1 EXTENT OF INSPECTION
11 PRESSURE TESTING
11.1 All flanged piping assemblies shall be hydrostatically tested in the Fabricator s works
prior to shipment. The test medium shall be potable water, unless otherwise specified.
The water temperature shall be maintained above 7 degrees celsius or the ductile/brittle
transition temperature, whichever is the higher, throughout the test.
11.2 Other piping assemblies, such as those with Welding ends, do not require to be
hydrostatically tested at the Fabricator s works. In this case however the Fabricator
remains responsible for any defects causing leakage or failure in his fabrication found
during the site test of the erected pipework.
11.3 Erected pipework shall be pressure tested in accordance with ANSI B31.3 Chemical
Plant and Petroleum Refinery Piping.
11.4 All pressure tests shall be carried out in the pressure of the Inspector and shall be to his
satisfaction. The test pressure shall be maintained for a sufficient time to enable a
thorough examination to be
made for leakage and
defects, with a minimum of 2
hours.
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CLASS METHOD BUTT NOZZLE ATTACHMENT SOCKET

WELDS WELDS WELDS WELDS
Visual 100% 100% 100% 100%
I Radiographic 100%
Ultrasonic 100%
Magnetic 100% 100% 100% 100%
Particle
Visual 100% 100% 100% 100%
100%
II Radiographic Exposure 20%
of Joints
Magnetic 20% 20%
Particle
Visual 100% 100% 100% 100%

100%
III Radiographic Exposure 10%
of Joints
Magnetic 10% 10%
Particle
Visual 100% 100% 100% 100%

IV Radiographic
Magnetic
Particle
11.5 Prior to pressure testing being carried out the inside of the pipework shall be clean and
free from loose millscale and foreign matter.
12. QUALITY CONTROL
12.1 GENERAL
12.1.1 The Fabricator shall afford the Company and/or the Certifying Authority adequate
opportunity and facility to verify that the design, material, construction and performance
of the equipment is in accordance with Company requirements.
12.1.2 Any verification of quality carried out by the Company and/or the Certifying Authority
shall not relieve the Fabricator of his obligations under the contract nor shall it preclude
any subsequent rejection of items.
13. TREATMENT AFTER FABRICATION
13.1 CLEANING AND PROTECTION

13.1.2 On completion of the fabrication, prior to shipment, the Fabricator shall clean the inside
and outside of all fabricated assemblies of loose scale, dirt, sand, weld spatter and
swarf.
Using any suitable method. The assembly shall then be blown out with compressed air,
dried and the inside inspected for cleanliness.
13.1.2 Where the are any special requirements, such as wire brushing, spot or gritblasting, then
these shall be specified on the fabrication drawings and purchase orders.
13.1.3 Welding ends shall be clean and ready for welding. Unless otherwise specified, the
welding end shall be blanked off and protected from corrosion or mechanical damage.
Rigid plugs or discs of non-absorbent material securely held in position shall be provided
and the pipe ends, discs or plugs shall be sealed off using Denso paste and tape or an
approved alternative.
13.1.4 flanged ends shall be blanked off using 10mm thick plywood or 3mm thick steel covers
secured by a minimum of four bolts after the faces have been protected with a hard film
coating to BS 1133, Section 6, Type T.P.la or agreed alternative.
13.1.5 Threaded connections shall be sealed using distinctively colour-identified screwed
plastic plugs or caps.
13.1.6 Piping and components shall be stored under cover out of contact with the ground and
shall be regularly examined to ensure the materials do not deteriorate. Corrosion
protection shall be renewed as necessary. Pipe or piping components shall be protected
from exposure to salt water or salt spray.
13.1.7 The external surfaces of carbon steel pipework shall be coated with temporary corrosion
preventative or base primed when specific in the fabrication drawings or purchase
orders.
13.2 MARKING
13.2.1 All fabrication spool pieces shall be clearly marked and identified prior to shipment in
accordance with the following paragraphs or as otherwise specified in the purchase
order. All markings shall be applied after the application of any permanent protective
coatings which have been called for.
13.2.2 Fabricated spools requiring trial shop assembly shall be match marked with scribed lines
in white paint to facilitate erection.
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14. INSTALLATION
14.1 GENERAL
14.1.1 All pipework shall be inspected prior to erection to ensure it is free from dirt, scale, weld
spatter and other foreign matter.
14.1.2 Except where cold springing is specified on the piping drawings, all piping shall be
installed in place without springing or forcing.
14.1.3 Field run piping is restricted to line sizes below 50 ns. It shall be run generally in
accordance with the routing indicated on the piping drawings, in a neat and orderly
manner consistent with good operation, safety of personnel and economy of material,
with adequate provisions for expansion and flexibility.
14.2 FLANGED JOINTS
14.2.1 Flanged faces shall be cleaned of all dirt, grease and protective coating and shall be
inspected for defects such as scratches or dents prior to installation.
14.2.2 Flanges shall be properly aligned prior to the insertation of gaskets and bolts to avoid
stresses or uneven gasket loads. See Appendix A figure 1 for flange alignment
tolerance.
14.2.3 Where specified by the Company, bolts shall be tightened by means of suitable torque
wrenches or tensioning devices to ensure the correct bolt stress is obtained and the
gasket is properly compressed in accordance with the design principals applicable to the
gasket type.
14.2.4 All bolts shall extend completely though their nuts. The use of washers or spacers to
take up excess bolt length shall not be permitted.
14.2.5 Stud bolts cut from length of studding shall have the material grade stamped on the cut
ends.
14.2.6 Steel to cast iron flanged joints shall be assembled with care to prevent damage to the
cast iron flange.
14.2.7 Joint Rings shall be non-asbestos 1.6m thick in accordance with the general
specification.
14.3 EQUIPMENT FLANGE CONNECTIONS
14.3.1 Flange covers shall not be removed from equipment flange connections until ready to
connect the mating piping.
14.3.2 Connections to strain sensitive equipment shall not be made until the mating piping has
been fully erected complete with permanent supports. Prior to bolting up to the
equipment flange the connection shall be checked for correct alignment.
14.4 SCREWED PIPEWORK
14.4.1 Pipe ends cut shall be cut square, threaded, reamed and cleaned to remove cuttings
from internal and external surfaces. All threading shall be carried out after bending,
forging or heat treatment but where this is not possible suitable thread protection must
be provided. All screwed connections shall have taper threads in accordance with API
unless otherwise stated.
14.4.2 All joints shall be tightened using a suitable wrench; connection 50 ns and larger shall be
tightened using a RIGID compound leverage pipe wrench or equivalent. Excessive
wrench markings on pipe and fittings shall be cause for rejection of the fabrication at the
discretion of the Inspector.
14.4.3 The joints shall be assembled using a suitable Petroleum resistant pipe jointing
compound which shall be applied to the male thread only, taking care to ensure the
compound does not reach the inside of the pipe. PTFE tape shall not be used.
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14.5 PIPE SUPPORTS

14.5.1 Where pipe supports are required to be welded to the pipe, as specified in the drawings,
this shall be carried out during the fabrication of the pipe spool, with the exception of
pipe support shoes which are generally welded during installation.
14.5.2 The Fabricator shall ensure there is adequate field fit margin in the pipe supports to
allow the piping to be installed without forcing.
14.5.3 The burning of holes in structural steelwork or component parts shall not be permitted.
14.5.4 Adjacent structures or equipment shall not be used as temporary supporting or lifting
attachments without the permission of the Company.
14.5.5 Metallic surfaces of supports which will be inaccessible after erection shall receive a
protective coating before assembly in accordance with Company Standard Surface
Coatings.
14.5.6 Pipe reinforcement pads on supports, anchors, etc shall be provided with one hole (at
the side and not at the crotch) drilled and tapped 1/4 N.P.T.
1
5
15 ADDENDUM TO GENERAL PIPEWORK SPECIFICATION

15.1 CLEANING
All flanges of pipes, valves, fittings, filters, pumps etc are to be thoroughly cleaned of all
rust, protective coatings etc, before assembly.
At the completion of a days work and at any time when the end of a pipeline is left
unattached, the end of the pipe shall be closed by a suitable protector in the form of a
wooden blank. All piping after hydrostatic testing shall be thoroughly dried internally.
15.2 PIPE OFFCUTS

Wherever possible and economic the Contractor shall make use of short lengths of pipe.
15.3 BENDING
All bends shall be true to radius and the bore of the pipe at any point after bending shall
not vary be more than plus or minus 1/8 from the bore of the pipe before bending.
Lobster back or gusseted bends will not be accepted. The bend centreline radius shall
be 5 times the normal pipe diameter unless stated otherwise.
15.4 BOLTING
The contractor shall include in his supply for all studbolts, bolts, nuts etc. All bolts shall
be the correct length to ensure that all thread on nuts are engaged and that the end of
the bolt does not project more than 3mm from the upper face of the nut when tightened.
15.5 TESTING
Test pressures shall be held steady at the required pressure for a period of four hours,
without further use of the test pressurising pump.
Testing shall not be carried out when there is any likelihood of the water freezing in the
pipework, the Contractor shall be responsible for repairing and re-testing the damaged
pipework and fittings.
For all tests, vents shall be located at the high points in the system, or of the section to
be tested, in order to ensure compete displacement of air from the system.
All equipment likely to sustain damage during the test is to be removed from the
pipeline, control valves are to be left in the open position.
Records are to be kept of each test. The information to be recorded is to be as follows:
i) Pipeline or system tested
ii) Testing Medium
iii) Test Pressure
iv) Temperature of Testing Medium
v) Date of Test
vi) Signature of the Company s Engineer
vii) Signature of Agent or Contractors Supervisor
16
16. STAINLESS STEEL PIPING AND FITTINGS

16.1 Design
The design of piping systems shall comply the following:
All pipework fabrication, testing, inspection and installation shall meet as a minimum
standard the requirements of ANSI B31.4 Chemical Plant and Petroleum Refinery
Piping .
16.2 PIPES
Materials shall be in accordance with ANSI Type 316 Grade 18/8. Austenitic Stainless
Steel, clean smooth and free from scratches to ASTM A-269 or equivalent.
16.3 General
Field run piping shall be run generally in accordance with the routing indicated on the
piping drawings, in neat and orderly manner consistent with good operation safety of
personnel and economy of material.
16.4 Connections
All joints except where butt welded to change from tube, in nominal pipe size shall be
gauge cable double ferrule compression tube fittings in 316 stainless steel Swagelok or
approved equivalent, complete with gap inspection gauge. A thread sealant shall be
applied when assembling threaded fittings, Liquid PTFE or approved equivalent.
Flanges shall be drilled to ANSI class 150 to match existing. Flange bolts shall straddle
the vertical or NS centreline as applicable.
Joint rings shall be non asbestos 1.6mm thick in accordance with the General
Specification.
16.5 Supports
Pipework shall be adequately supported in trays. Pipework shall be fixed to horizontal
trays with Stauff polypropelene clamps or equivalent. Pipework shall be adequately
supported and securely fixed immediately before and after a bend or offset and at 0.5m
maximum pitch.
All carbon steel supports shall be isolated from pipe to prevent electrolytic corrosion.
16.6 Identification
Each pipe shall be clearly identified, labels shall be fitted during erection or pipework.
16.7 Snubbers or Pulsation Dampers

Where conditions for steady instrument readings are required due to pulsations a
snubber or pulsation damper shall be provided.
16.8 Testing - (HOLD)
A pressure and operating test shall be applied to the complete assembled system.
Testing shall be by pneumatic test to 20 PSI and a soap solution applied to all joints in
accordance with the General Pipework Specification.
All leaks shall be rectified and all connection proved fully leak proof before the system is
considered acceptable.
16.9 Flushing of the system
The injection system shall be final flushed using a suitable medium. During flushing, all
injector cubicles, control valves and flow meters shall be removed, where practical, or
by-passed using hoses.
1
7
16.10 Installation Stainless Steel Pipework

The use of elbows shall be kept to a minimum, bends and offsets shall be cold formed
wherever possible. Bends shall not be wrinkled, cracked, scratched, gouged or die-
marked or buckled and shall be in one plane.
Where connections are required in multi line pipework, pipe connections shall be
staggered to allow for maintenance.
Welding
The Fabricator shall provide adequate and systematic supervision by competent
personnel to ensure that the required quality levels are maintained. At the discretion of
the Engineer, any welder who consistently fails to meet the standard shall be required to
undergo re-training, re-testing of shall be removed from the job completely.
All welding shall be carried out in accordance with the qualified and approved weld
procedure by welders who have been qualified to the relevant testing code.
The Contractor shall make maximum effort to ensure that arc strikes outside the welding
groove are avoided. When these occur outside of the finished weld the arc strike shall
be carefully removed by grinding, followed by a dye penetrant inspection of the ground
area to confirm it is defect free. Care shall be taken to ensure the ground are blends in
smoothly with the surrounding material such that no sharp notch results and the
thickness is not reduced with an approved repair procedure. The acceptance of arc
strikes outside of the welding groove shall be at the sole discretion of the Engineer, who
shall be requested to inspect the damage and approved the repair procedure or reject
the damaged material as appropriate.
The number of welds shall be minimised. Pipe lengths smaller than 1m shall not
normally be welded together.
Butt Welds
All pressure containing butt welds shall be full penetration. Where access permits
consideration shall be given to welding both sides.
Fillet Welds
A minimum of two runs shall be deposited for all permanent attachments to pressure
parts.
All fillet welds shall be continuous and their surfaces free from marked irregularities.
Socket Welds
Care shall be taken during the assembly of socket weld joints to ensure there is a 1.5mm
gap between pipe end and the root face of the fitting.
Welds shall be fillet welds deposited by MMA or TIG process with a minimum of two
runs.
Attachments to Thin Wall Pipes
Where attachments are to be made to thin walled piping i.e. less than 5mm thick, care
shall be taken to avoid excessive oxidation or burn through. An inert gas purge shall be
applied to the bore surface.
In order to demonstrate the suitability of the weld procedure the Company may require a
test weld to be made on pipe of the minimum contract thickness. Similarly the Company
requires Welders to be tested on their ability to weld attachments to the thin wall pipes
even if their qualification range apparently covers the thin wall situation.
Alignment
The ends of piping components to be butt welded shall accurately aligned in accordance
with the requirements of ANSI B31.1. The maximum internal misalignment shall be
1.5mm except that where the pipe wall thickness is less than 6mm, the internal
misalignment shall not exceed 25% of the wall thickness.
1
8
Weld Cleaning, Back Gouging and Repair

After each welding pass the weld shall be thoroughly cleaned and all slag and foreign
matter removed before the next run is deposited.
Peening of weld runs or the finished welds shall not be permitted.
The removal of weld defects shall be carried out by grinding, machining or chipping. Arc
or oxygen gouging shall not be used.
Welds which have been repaired and remain defective shall be cut out completely and
re-welded in accordance with the original procedure, except where the Inspector
authorises one further attempt. In no case shall more than 2 repair attempts be
permitted.
All weld repairs shall be performed by qualified welders using an approved repair
procedure.
Welding Processes
Except where otherwise agreed, welds shall be made by the manual metal arc (MMA),
tungsten inert gas (MIG) or submerged arc welding (SAW) processes.
Where root runs are made by the MMA process, the electrode shall not be larger than
2.5mm diameter.
if the TIG processes, a high frequency arc initiation unit and crater eliminating device
with a 10 second minimum delay sequence shall be used. The electrode shall be 2%
thoriated tungten, 1.5 to 3.0mm diameter.
16.10.1 Welding Consumables Specification and Selection
All consumables such as coated electrodes, bare wire, fluxes and gases shall comply
with the applicable AWS or British Standard. Other consumable may also be used
provided full details of chemical and mechanical properties, and service experience are
submitted, and approval obtained from the Company.
Welding electrodes and filler wires shall be selected to give a deposited weld metal
similar in composition to the parent metal. Unless otherwise specified austenitic welds
have a ferrite content of between 3% and 10%.
Filler metal for welds between authentic stainless steels and ferritic or ferritic alloy steels
shall be subject to agreement but shall normally be of the E309, Incoweld A or Inconel
182 type or equivalent. Where Post Weld Heat Treatment is required, the Incoweld A or
Inconel 182 type shall be used. Preheat and PWHT shall be required by the ferritic
material.
The shielding gas for the TIG process shall be argon to BS 4365. The purge gas shall
be argon to BS 4365 or dry nitrogen to BS 4366, type 1. No other gas or gas mixture
shall be used without prior approval of the Company.
16.10.2 Storage, protection and Baking
The storage, protection and baking of all welding electrodes, filler wires and fluxes shall
be in accordance with the Manufacturer s recommendations.
16.10.3 Protection From Weather
The welder and welding area shall always be adequately protected from the weather so
that the integrity is not detrimentally affected by wind, rain or snow or from the decline of
the welder s ability when working at low temperature or other adverse conditions.
19
17 BLANK
20
18 MATERIAL SPECIFICATION
Maximum Pressure 19.2 Bar for class 150 systems
Maximum Temperature 50C
Piping Design Code ASME B31.3
Line Pipe Seamless A.P.I. 5L Gr B (Carbon Content 0.23% Max)
Size Range (NPS) Description
15 40 Schedule 80 P.E.
50 150 Schedule 40 B.E.
200 350 Schedule 40 B.E.
Flanges Forged MATL ASTM A105 N (Carbon Content 0.23% Max)
DIMN ANSI B 16.55 CLASS 150
Finish
MSS SP 44
Incl
Welding Neck
Note: To Match Pipe Wall Thickness
Slip-on
Blind
L
Butt Weld Fittings
DIMN ANSI B16.9
Incl
Eccentric Weld Reducer
Concentric Weld Reducer
Equal Tee
90% Long Radius Weld Elbow
45% Long Radius Weld Elbow
NOTE All To Match Pipe Wall Thickness
Reinforced Branch Fittings MATL ASTM A105 N (Carbon Content 0.25% Max)
Spec Bonney Forge Or Equal
Incl
Weldolet
Sockolet
Elbolet
Thredolet
Latrolet
NOTE- Weight / Rating To Match Pipe Wall Thickness
Gaskets Non Asbestos Klingersil C4400 (OR EQUAL)

1.6 Mm Thk Flat Ring - Richard Klinger
Bolting Stud Bolts ASTM A193 Gr B7

Nuts ASTM A194 Gr 2H
NOTES:-
1 7
2
3 8
5
6
Minimum pipe size 15nps
All forgings shall be
normalised & tempered
Carbon content shall be
limited to 0.23% max for
pipe & 0.25% max for
other items (carbon
equivalent shall be
limited to 0.45% max)
Where flanges mate with
cast iron equipment the
mating flange face shall
be a smooth
finish
All unconnected
branches 40 nps and
below shall be class
6000 1b / schedule 160
For selection of
reinforced branch
connections see detail
drgs
Buried lines shall be
coated & wrapped in
accordance with
specification. All aviation
product pipes lines shall MAT ASTM A234 WPB (Carbon Content 0.23% Max)
be internally lined in
accordance with the
specification 3326-0025.
Material test certificates
to din 50049.3.1b
2
1
Branch Connection Chart
Header Size
350 300 250 200 150 100 80 65 50 40 25 20 15
15 RB RB RB RB RB RB RB RB RB RB RB RB T
B
20 RB RB RB RB RB RB RB RB RB RB RB T
R
25 RB RB RB RB RB RB RB RB RB RB T
A
40 RB RB RB RB RB RB RB RB W T
N
50 B B B B B B B W T
C
65 B B B B B B W T
H
80 B B B B B W T
S 100 B B B B W T
I 150 B B B W T
LEGEND
Z 200 B B W T
RB RE-INFORCED BRANCH
E 250 B W T B UN RE-INFORCED BRANCH
W - WELDOLET
300 W T T BUTT WELD EQUAL TEE
350 T
22
Appendix A Schedule of Rates
A1 DEFINITION OF TERMS USED IN THESE SCHEDULES OF RATES

A1.1 The terms erect , install and set-up shall mean taking delivery, off-loading, loading,
handling, storing, transporting to and from the fabrication area to the final position and
fixing to correct levels including lining up all pipework described including the taking of
all necessary measurements.
Pipework shall be measured nett and all specials, elbows, valves, flanges, jointing and
cutting etc have been measured separately.
A1.2 The term supply shall mean the cost of purchase, delivery and transporting to score on
site and storing.
A1.3 Where items have been described as extra over the Contractor is to include for making
such labours as described.
A1.4 The term cut pipe shall mean the unit of measurement per cut for the cutting of a
square end to both sides of the cut to receive bevelled ends, screwed ends or slip-on
flanges.
A1.5 The term bevel end shall mean the unit of measurement per end for preparing ends of
pipe for welding.
A1.6 The term make flanged joint shall mean to include for all fitting work and the supply and
fixing of all gaskets, studbolts, nuts and washers.
F
I
L
E
R
E
F
:
0
0
2
0
0
0
1
2
F
Schedule of bolts for flanged joints
A1.7 The term make screwed joint shall mean the unit of measurement per end of pipe or
fitting for making a screwed joint, including all fitting work and preparing ends with
specified jointing material.
A1.8 The term make 90 degrees branch shall mean to include for the cutting of holes in the
main pipe, shaping of branch ends, fitting, bevelling tacking and the finished welding of
the branch.
No distinction has been made in the description between main pipes of differing
diameter. Only the branch diameter has been stated. The Contractor should make any
allowance necessary in his prices for this lack of distinction.
A1.9 The term make weld joint shall mean the unit of measurement per end of pipe or fitting
for making a socket weld joint. To include all cutting of pipe end, preparing pipe end, all
fitting work and finished welding of the joint.
F
I
L
E
Pipe Diameter Number of Bolts Dia Stud Length Bolt Length
R
E (mm) (mm)
F
15mm 4 : 1/2 55 44
0
0
20mm 4 2 1/2 55 51
0
25mm 4 0 1/2 65 51
0
40mm 4 1 1/2 70 57
2
F
50mm 4 5/8 75 70
80mm 4 5/8 90 76
100mm 8 5/8 90 76
150mm 8 3/4 95 83
200mm 8 3/4 100 89
250mm 12 7/8 115 85
300mm 12 7/8 115 102
350mm 12 1 125 108
400mm 16 1 130 114
450mm 16 1 1/8 150 121
A2 SCHEDULE OF RATE FOR MECHANICAL WORKS

A2.1 The Contractor should enter a rate against all items. Items with no rate shall be deemed
to have been included in rates for other items.
A2.2 This schedule of rates is to be used in the costing of the works or variations to the works
deemed necessary by the Engineer, and in accordance with the General Conditions of
Contract.
A3 RATES TO INCLUDE
A3.1 For all handling and distribution costs, insurances, subsistence allowances, non
productive overtime in accordance with the working week which forms the basis of this
schedule, supervision, overheads, etc.
A3.2 Non-productive overtime charges will only be allowed if specific instructions have been
given to carry out extra work during overtime hours.
A3.3 Normal Working hours are as stated in Section 2, Form of Tender.
A3.4 Handling and distribution costs shall be deemed to be inclusive of taking from allocated
safe working area to erection site and all necessary double handling as a result of NO
hot work being allowed in erection areas.
A3.5 For all work up to a height of 2.00m and all depths in all locations on the site. Any safe
working platform required for any work over 2.00m will be reimbursed at cost. Any air
supplied breathing apparatus for work below 1.3m under ground level will be reimbursed
at cost.
A3.6 Provision of all consumables and sundry materials such as, but not limited to:-
i) Welding rods and electrodes.
ii) Cutting discs.
iii) Oxygen and Acetylene.
iv) Inert Gas.
v) Pipe jointing material other than gaskets.
vi) Nuts, bolts and studbolts.
vii) Fuel for generators and welding sets.
viii) Fuel for Contractor s plant and transport.
ix) Provision of all necessary plant and equipment such as, but not limited to:-
x) Temporary lighting and power.
xi) Temporary screens, fencing and guard rails.
xii) Welding plant and associated equipment.
xiii) Small hand tools, air operated or manual.
xiv) Lifting equipment. (See 9.3.11).
xv) Testing equipment. (See 9.3.12).
xvi) Temporary supports.
A3.7 Provision of all non structural steelwork supports (bottom of pipe to be supported less
than 1.5 meters above grade) including levelling and aligning before erection and final
bolting down on prepared foundations (foundations and bolts by others); for pipe-lines at
any level below 2 meters above ground level.
A3.8 For site checking of dimensions before fabrication for proper execution of work.
A3.9 All working platform above 2.00m will be provided by the contractor. he shall use the
terminals nominated specialist contractor, the cost of which shall be reimbursed on a
cost plus basis as nominated in the Form of Tender, Section 2.
A3.10 All powered lifting equipment shall be provided by the contractors as deemed necessary
to execute the works safely and efficiently. He shall use the terminals nominated
specialist contractor, the cost of which shall be reimbursed on a cost plus basis as
nominated in the Form of Tender.
A3.11 All water used on site for the purposes of wetting down during hazardous work and
hydrostatic testing shall be provided by the company unless otherwise stated.
FILE REF:00200012F

00200012F - G - Fabrication and Installation Oil Carbon Steel Pipework To ASME 831.3 Fuel Pipework

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ENGINEERING SPECIFICATION

FABRICATION, INSTALLATION AND TESTING

OF FUEL FARM AND

APC Document No.:

0 30/10/12 DESIGN VERIFICATION HS APC APC

1. CODES, STANDARDS AND TERMINOLOGY

1.4. ALL PIPEWORK FABRICATION, TESTING, INSPECTION AND INSTALLATION

3. PIPE CUTTING AND WELDING EDGE PREPARATION

4.2. HOT BENDING

6.2. BUTT WELDS

6.6. ATTACHMENTS TO THIN WALL PIPES

6.10. WELD CLEANING, BACK GOUGING AND REPAIR

7.1. SPECIFICATION & SELECTION

7.2. STORAGE, PROTECTION AND BAKING

Class I All underground fuel pipework entire hydrant system

TABLE 10.2.3.1 EXTENT OF INSPECTION

CLASS METHOD BUTT NOZZLE ATTACHMENT SOCKET

Visual 100% 100% 100% 100%

Visual 100% 100% 100% 100%

13. TREATMENT AFTER FABRICATION

13.1 CLEANING AND PROTECTION

14.5 PIPE SUPPORTS

15 ADDENDUM TO GENERAL PIPEWORK SPECIFICATION

15.2 PIPE OFFCUTS

16. STAINLESS STEEL PIPING AND FITTINGS

16.7 Snubbers or Pulsation Dampers

16.10 Installation Stainless Steel Pipework

Weld Cleaning, Back Gouging and Repair

NOTE- Weight / Rating To Match Pipe Wall Thickness

Gaskets Non Asbestos Klingersil C4400 (OR EQUAL)

Bolting Stud Bolts ASTM A193 Gr B7

Branch Connection Chart

350 300 250 200 150 100 80 65 50 40 25 20 15

Appendix A Schedule of Rates

A1 DEFINITION OF TERMS USED IN THESE SCHEDULES OF RATES

Schedule of bolts for flanged joints

A2 SCHEDULE OF RATE FOR MECHANICAL WORKS

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