Piping Fabrication STDS

*THIS PRINT IS NON-CONTROLLED *
Bechtel France S.A.S.
Reliance Petroleum Limited

Jamnagar Export Refinery Project
Specification
25194-3PS-PL-006
Title
Piping Fabrication
This specification is based on 22960-3PS-PL-006 Rev.7

Confidential  Bechtel France S.A.S. 2005, 2006. This item contains confidential information
proprietary to Bechtel France S.A.S. that is not to be used, disclosed, or reproduced in any format
by any non-Bechtel party without Bechtel's prior written permission. Notwithstanding the above,
Reliance Petroleum Limited has the right to use the information contained in this document
pursuant to Agreements between Bechtel France S.A.S. and Reliance Petroleum Limited. All rights
reserved.
2 3-Jan-07 Issued for Construction PC SJH DH PKS
1 22-Mar-06 Re-issued for Design PC SJH DH PKS
0 23-Jan-2006 Issued for Design PC SJH DH PKS
Rev Date Revision By Chkd Appr Client
25194-3PS-PL-006 Page 1 of 15
Reliance Industries Limited *THIS PRINT IS NON-CONTROLLED*
Contents
1. Purpose......................................................................................................................................
2. Scope.........................................................................................................................................
3. Codes and Associated Specifications........................................................................................
4. Information Sources..................................................................................................................
5. Materials and Fabrication Requirements..................................................................................
6. Examination and Inspection......................................................................................................
7. Shop Detail Drawings and Spool Identification.......................................................................
8. Records and Reports.................................................................................................................
9. Shipping Preparation.................................................................................................................
APPENDIX A - Fabrication requirements for Steam and Feed Water Piping Subject to
Indian Boiler Regulations
APPENDIX B - Piping Alignment and Fabrication Tolerances (Pipe Fabrication Institute

ES - 3)
25194-3PS-PL-006 Page 2 of 15
Confidential  Bechtel France S.A.S. 2005, 2006. All rights reserved.
1. Purpose
This specification is issued to establish a uniform procedure for the fabrication of
above and below ground process and utility piping, fabricated at both shop and site
locations.
2. Scope
2.1. Process and utility piping shall be fabricated in accordance with codes, drawings,
and other requirements specified herein. Where conflict exists, this specification governs,
except where code requirements legally apply.
2.2. This specification applies to all piping contained within modules, packages or sub-
assemblies. Instrumentation, pipework and tubing downstream of the last block valve on a
pipe header is not included.
2.3. Piping subject to requirements of the Indian Boiler Regulations is covered by

Appendix A of this specification.
3. Codes and Associated Specifications

3.1. Codes
3.1.1. Local Codes or Regulations
Where local regulations, ordinances, statutes or codes take precedence

over ASME codes, such regulations, ordinances, statutes or codes shall
govern.
3.1.2. Refinery Code Piping
Except where specified otherwise, the Process Piping Code ASME

B31.3-2004 governs fabrication of all piping.
3.1.3. Boiler Code Piping
The Power Piping code ASME B31.1-2004 and the Indian Boiler
Regulations 1950 governs fabrication of steam and boiler feed water
piping within the battery limits of the boiler as defined in the code. For
steam and condensate lines outside the battery limit of the boiler the
applicable codes are IBR and ASME B31.3-2004.
Refer to Appendix A.
3.1.4. Other Requirements
GRE piping systems shall be in accordance with AWWA M45 Manual

of Water Supply Practises or ASME B31.3-2004 as applicable.
25194-3PS-PL-006 Page 3 of 15
Other codes, such as refrigeration, plumbing or national regulations may
govern some parts of the piping. Drawings shall indicate the applicable
codes in such cases.
3.2. Associated Specifications
25194-3PS-PL-001 Piping Material Classes (Includes Assemblies for

vents, drains, instrument connections etc.)
25194-3PS-PL-002 Piping Material Stock Code Index
25194-3PS-PL-004 Technical Supply Conditions for Piping Materials
25194-3PS-PL-005 Colour Coding of Piping Materials
25194-3PS-PL-007 Piping Erection and Testing
25194-3PS-PL-013 Chemical Cleaning of Pipework
25194-3PS-PL-019 Pipe Support Standards
25194-3PS-PL-102 Guidelines for supporting small bore connections
25194-3PS-PL-104 Induction & Cold Bending of Pipe
25194-3PS-GAW- Vendor Welding Procedure Approval and Welding

001 Quality Requirements for Pressure Retaining
Equipment and Piping
25194-3PS-GAW- Welding, PWHT and NDE of fabricated piping

004 including Form 167A.
25194-3PS-GAW- Shop and field Painting

005
4. Information Sources
The following sources contain information affecting detailing and fabrication of
piping.
4.1. Piping Material Classes
The Piping Material Classes specify by Service Class, the material

requirements for pipe, fittings flanges, etc., and design details for branch
connections, vents, drains, pressure and temperature connections. Where
special or non standard material for a particular class is required, it will
be noted on the drawings.
4.2. Supplementary Table of Wall Thickness and Branch Reinforcement
25194-3PS-PL-006 Page 4 of 15
The Supplementary Table of Wall Thickness will specify by individual
pipeline number the requirements of wall thickness subject to calculation
as specified in the Piping Material Classes.
4.3. Piping Stock Code Index
The Piping Stock Code Index identifies and describes all piping material
item codes in documents related to piping material.
4.4. Schedule of Welding, Heat Treatment and Non-Destructive Examination of Piping

(Form 167A from specification 25194-P14-JG000-046).
Form 167A will specify, by individual service class, the requirements for
welding, heat treatment and non-destructive testing of piping.
5. Materials and Fabrication Requirements

5.1. Extent of Shop Fabrication
5.1.1. Carbon steel piping 2" nominal bore and larger is generally shop fabricated,
exceptions are long straight runs such as in piperacks which are field fabricated. Carbon
steel piping less than 2" bore will be field fabricated.
5.1.2. Alloy and stainless steel pipe, all sizes, including less than 2”, is generally shop
fabricated except for long straight runs.
This is to maximise the specialised welding in the shop. Alloy and SS pipe classes in
the PDS model will default to “shop” for all sizes
5.1.3 Where long straight runs of field piping require expansion loops, the
expansion loops shall be shop fabricated.
5.2. Materials
5.2.1. Materials Supply
All materials necessary for the fabrication and installation of the piping
systems shown on the isometrics & GA drawings shall be free issue. The
FABRICATOR shall supply all temporary materials, pipes, supports etc.
required for fabrication, testing, inspection and transportation.
5.2.2. Unless otherwise identified on piping drawings, all materials shall

conform to the Piping Materials Specification 25194-3PS-PL-001 for
the individual line service.
Individual line class materials and SP items will be identified on piping

drawings and P&IDs by conventional line work and graphic symbols.
Out-of-class materials will be identified by code numbers or
descriptions.
FABRICATOR shall inspect all piping materials on receipt to ensure

that the correct grade, quality, condition, end preparations, identification
25194-3PS-PL-006 Page 5 of 15
and dimensions have been supplied and are in accordance with the
applicable project standards and specifications.
5.2.3. Material Identification
All materials shall be new and identifiable and shall be supplied with
certification to meet project requirements.
Marking requirements and techniques, shall be in accordance with

project specification 25194-3PS-PL-004 “Technical Supply Conditions
for Piping Materials”.
As an aid to preliminary recognition, pipe materials shall be colour

coded in accordance with 25194-3PS-PL-005 “Colour Coding of Piping
Materials”.
5.2.4. Control of Materials
FABRICATOR shall submit a procedure to BUYER/CLIENT describing

the controls to be applied to the receipt, storage and issue of piping
materials.
The procedure shall describe as a minimum, the following:-
a) Method of controls on material receipt.
b) Handling, segregation and storage procedures.
c) Details of proposed file or stock card control system.
d) Issue of materials procedure.
e) Method of transfer of identification markings on piping materials.
f) Method of determining and reporting material shortages
5.2.5. Unidentified Piping Materials
Piping materials that cannot be identified by identification markings

shall be placed in a storage area separate from acceptable material with
sufficient safeguards to preclude them being used.
5.2.6 Material and Weld Identification
Weld identification symbols shall be recorded onto fabrication drawings

with a cross reference to any Non Destructive Examination (NDE) report
numbers.
If at any time during installation or fabrication, any piece of material is

not readily identifiable, it shall be rejected, including other components
welded thereto.
25194-3PS-PL-006 Page 6 of 15
5.2.7 Damaged Materials
Materials which have been damaged, gouged or found to have defects

shall not be used except that minor surface marks may be dressed,
provided that the mill tolerance minimum wall thickness is not
encroached upon. Dressing will require BUYER/CLIENT approval.
BUYER/CLIENT shall be informed immediately if received materials

are damaged and unfit for fabrication.
Particular care must be taken with flange faces. Radial grooves or

scratches are not allowed. Refacing will require BUYER/CLIENT
approval. Edge thickness of flanges shall be checked after refacing.
Damaged material shall be placed in a separate storage area from

accepted material, with sufficient safeguards to prevent its use.
5.2.8. Different piping materials shall be stored in segregated areas.

FABRICATOR shall ensure that separate batches of materials can be
related to the original manufacturers’ advice note and certification.
Carbon steel, low temperature carbon steel, alloys and stainless steel
shall be stored and transported such that any possibility of cross
contamination of materials is prevented. Materials destined for Indian
Boiler Regulation coded systems shall be separated from other materials
of a similar nature.
All materials, whether loose or prefabricated shall be stored above

ground on a flat surface, on platforms or pallets, in a manner that will
prevent any deterioration from debris, grease, paint spray or any other
foreign matter.
5.3. General Fabrication Requirements
5.3.1. General
In addition to the requirements of the governing code, the following

shall also apply unless otherwise noted on the piping drawings.
5.3.2. Fabrication Area
Fabrication of different materials e.g. Carbon Steel, L.T. Carbon Steel,

alloy steel and stainless steel etc. shall be carried out in segregated areas
to prevent any possibility of cross contamination during cutting and
welding.
5.3.3. Dimensions
Dimensional tolerances shall be in accordance with Appendix B

“Fabrication and Alignment Tolerances” (Based on PFI ES-3).
25194-3PS-PL-006 Page 7 of 15
5.3.4. Bolt Holes
Flange bolt holes are to straddle principal centrelines of equipment and

piping, unless otherwise shown on the drawings.
5.3.5. Threaded Connections
All threaded connections must be gauge checked or chased after welding

or heat treating. Openings for thermowells and other inserts are to be
drilled through the connections and be free from obstruction.
All intermediate threaded pipe joints shall be made using threaded

couplings. The use of unions is not permitted, threaded flanges shall be
used to facilitate easy removal of valves and in line instruments for
maintenance purposes. When 2”and 3” NPS pipes with ends threaded
BSP “T” are required to match fittings with NPT threads, the pipe shall
be cut and threaded NPT to match.
5.3.6. Socket Welding
Care shall be taken to ensure that a clearance of 1.5mm remains between

the male and female ends at the bottom of the socket. Pipe for socket
welding shall be square cut.
5.3.7. Piping components shall be in accordance with Project Specification 25194-3PS-PL-

004 “Technical Supply Conditions for Piping Materials”.
5.3.8. Orifice Runs
Welding neck orifice flanges are specified up to 18” NPS and shall have
the same bore as the pipe. Orifice runs shall not contain welds except at
the flanges. Pipe ends and bevels at orifice flanges shall be machine cut
and shall be perpendicular to the axis of the pipe. Welds at the orifice
flanges shall be ground smooth and flush inside. Pipe tap connections
on orifice flanges or directly on the pipe where so specified, shall be
drilled through the pipe wall and shall be finished smooth and flush
inside. Pipe nipples to orifice flanges are threaded and require seal
welding. All orifice tap pipe connections and valves to be adequately
supported/braced as per spec 25194-3PS-PL-102 to minimise vibration
and the potential of seal weld failure leading to leakage.
Taps shall be oriented as shown on the piping drawings.
5.3.9. Branch Connections
Branch connections are by Olets or Stub-ins with reinforcement if

required - refer to Specification 25194-3PS-PL-001 Branch Tables. 12"
and larger pipe stubs and branches shall extend to the first flange or to
the field weld point as indicated on the piping drawings or as required
for reasonable spool piece size.
25194-3PS-PL-006 Page 8 of 15
Where reinforcement pads are required at branch connections which are
to be field welded they must be fabricated by the Shop Fabricator and
tack welded to the 'stub in' spool for shipment.
A vent/tell tale hole is to be drilled in each reinforcement pad or

reinforcement pad section.
5.3.10. Loose Piping Components
Any piping components specified on piping drawings to be shipped

loose for welding on site, are to be separately packed for shipment, with
the package clearly tagged (see para. 9.2) and labelled "Components for
Site Welding to Prefabricated Pipework".
5.3.11. Welded Pipe Support Attachments
Pipe supports shall be in accordance with piping drawings and with

requirements of 25194-3PS-PL-019 “Pipe Support Standards”.
5.4. Welding
5.4.1. General
In addition to the governing code, welding shall conform to project

specifications 25194-3PS-GAW-004 “Welding, PWHT and NDE of
Fabricated Piping”.
Field Welds
Field Welds (F.W.) may be used at any pipe spool interface, where
piping dimensions to weld locations can be accurately determined and
where no cutting or trimming of pipework is necessary. Field welds shall
be closed without any tension in the lines, especially at strain sensitive
equipment.
Field Fit Welds
Wherever Field Fit Welds (F.F.W.) are indicated on piping drawings,

FABRICATOR shall detail and furnish the pipe spool such that Field
Construction can trim excess pipe and make final closing weld. The
amount of excess pipe furnished shall be 150mm, and the pipe end shall
be square cut.
5.4.2. Surface Defects
Surface defects caused by mishandling during fabrication shall be

considered injurious if the defect extends below the mill tolerance
minimum wall thickness or is more than 1.5mm in depth.
Fittings, flanges or pipe with injurious defects are deemed unacceptable

for spool fabrication and shall not be used.
25194-3PS-PL-006 Page 9 of 15
5.5. Bends
5.5.1. Unless otherwise specified on the approval drawings and specifications, bends in
pipes shall be effected using proprietary manufactured long radius elbows as listed in the
Piping Material Specification 25194-3PS –PL-001. Substitution of induction or cold bends
is only acceptable when the geometrical requirements of the piping specification are met.
5.5.2. Induction or cold bending shall be in accordance with Specification 25194-3PS-PL-

104.
5.5.3. If referenced in Piping Specification 25194-3PS-PL-001 for lines 8” NS and above,

mitred elbows as per STD Drg No P14-JG000-045 may be used.
5.6. Weld Seams
5.6.1. On welded pipe, longitudinal weld seams shall be out of phase at inline butt welds,
any welded attachments i.e. branch connections, instrument connections, pipe support
attachments etc. shall not bisect any seam weld.
5.6.2. The minimum rotation for welded seams shall be 10 times the pipe wall thickness or
90° out of phase, whichever is less.
The minimum distance between circumferential butt welds, shall be 6

times the pipe wall thickness or 50 mm, whichever is greater.
5.7. Cleaning
5.7.1. All shop fabricated piping assemblies/pipe spools shall be internally cleaned by
blowing air only and pipe ends shall be covered with plastic end caps for sizes up to 12”
NB. For sizes greater than 12” NB, the pipe ends will be left open and the shop fabricated
piping assemblies/ pipe spools shall be internally cleaned by blowing air to remove dust and
foreign matter prior to erection at site. In either case, wherever flanged pipe spools/ piping
assemblies are involved, the flanged ends shall be covered with plastic flange covers or
5mm thick ply boards cut to the size of the flanged ends so that the flange facings are fully
protected.
5.7.2. If water is used in cleaning austenitic stainless steel piping assemblies, it shall not
contain more than 30 ppm chlorides.
5.7.3. Any special requirements for cleaning of shop fabricated piping will be specified in
the Line Designation Tables.
5.7.4. Where specified on the piping drawings, chemical cleaning of pipework shall be in
accordance with project specification 25194-3PS-PL-013.
5.8. Alignment and Fabrication Tolerances
FABRICATOR shall be responsible for the dimensional accuracy of

fabricated pipe spools.
Line up clamps shall be used when necessary to ensure that fit-up is

within design tolerances.
25194-3PS-PL-006 Page 10 of 15
In addition to the alignment and fabrication tolerances specified in the
referenced codes and standards in para 3.0, the following shall apply:
Overall linear dimensions for line sizes 10 and

smaller: + 3mm
Overall linear dimensions for line sizes 12 and
larger: + 5mm
Linear dimensional tolerances shall be applicable to dimensions

measured from a common datum for the relative locations of branches,
flanged or butt-weld ends and shall not be cumulative.
Before bolting up, flange faces shall be aligned to
the design plane, measured across any diameter
within: + 1.5mm
Flange bolt holes shall be aligned within: + 3mm
Specified angles for bends or branches shall be
within: + 0.25°
For alignment and fabrication tolerances also refer to Appendix B.
6. Examination and Inspection

6.1. Examination
6.1.1. All piping components and workmanship for each installation shall be examined in
accordance with 25194-3PS-GAW-004, Form 167A. FABRICATOR shall be responsible
for non-destructive examination (radiography, liquid penetrant, ultrasonic, magnetic
particle, etc.) in accordance with the Code and to the extent specified in Form 167A.
6.1.2. Where examination reveals a failure to meet design or code requirements,

FABRICATOR shall make such repairs and carry out future examinations as are necessary
to meet the design or code requirements.
6.2. Inspection
6.2.1. All inspection shall be performed by FABRICATOR's inspector.

BUYER/CLIENT’s inspector retains the right to visit FABRICATOR's place of work and
carry out random inspection. BUYER/CLIENT’s inspector may reject any material,
procedure or work, which, in his opinion alone, fails to meet the requirements of applicable
codes, specifications, procedures, drawings, purchase orders or contract.
6.2.2. Unless specified otherwise on drawings, shop hydrostatic testing of pipe spools is not
required. If required, all pressure testing shall be carried out in accordance with project
specification 25194-3PS-PL-007. However Pneumatic test for Reinforcement (RF) pad shall
be carried out at shop at 1.5 kg/sq.cm.
6.2.3. After installation, all fabricated assemblies will be hydrostatically tested in

accordance with the applicable Code. FABRICATOR shall guarantee his work to be
25194-3PS-PL-006 Page 11 of 15
capable of withstanding the hydrostatic test, and he shall repair or replace at his expense any
item which fails to pass such test.
6.3. Procedures
6.3.1. BUYER/CLIENT approval of the following Shop FABRICATOR's procedures and

activities is required prior to the use of such procedures.
a) Procedures and details of welding processes.

b) Weld repair procedures.
c) Heat treating operations.
d) Non-destructive examination procedures.
e) Quality control procedures.
f) Paint procedures.
6.3.2. All requests for relaxation of this specification, or, of the documents referenced in
this specification, shall be stated in writing for the consideration of BUYER.
6.3.3. Approval of FABRICATOR's procedures, drawings, etc. shall not relieve

FABRICATOR of responsibility for correctness, and compliance with all codes, legal
requirements and this specification.
7. Shop Detail Drawings and Spool Identification

7.1. Shop Detail Drawings
7.1.1. The fabricator shall use “SPOOLGEN” to make shop detail spool drawings for
piping fabrication. Alternatively, BUYER’s piping isometric drawings may be used.
Except for long straight runs of pipe, such as in pipeways, spool piece
mark number shall be assigned and shall follow in sequential order, the
fabricated spools in a line, ascending in direction of flow.
Lines covered by several sequential isometric sheets, shall have piece

mark numbers following the same sequence for the entire pipe line.
The same piece mark number may be used for two or more identical
pieces in the same line.
7.1.2. A number, consisting of the plant or unit number, commodity symbol, line number,
and spool piece number, shall identify each pipe spool. Piece mark numbers and location of
field welds between shop fabricated spool pieces shall be shown on the CONTRACTOR’s
spool drawings or be marked on BUYER/CLIENT’s piping isometric drawings.
7.2. Spool Identification
Spools shall be identified by a detail number comprising of their line

number and spool suffix which must be weather proof and painted or
marked in characters at least 50 mm high. Numbers must be located,
25194-3PS-PL-006 Page 12 of 15
and repeated as necessary, in such a manner that any spool may be easily
identified without turning or lifting it. Marking materials and technique
shall be in accordance with project specification 25194-3PS-PL-005
“Colour Coding of Piping Materials”.
8. Records and Reports

8.1. The following records, fully identified with the specific material or part of the piping
represented, must be available for reference or examination by BUYER/CLIENT Inspector.
On job completion, they must be collated, indexed and bound, and forwarded to
BUYER/CLIENT’s office addressed for the attention of Vendor Print Control/Expediting.
Certificates attesting that all the quality control requirements of the

applicable code and of the engineering design have been met.
a) Pyrometer charts and records of heat treatment.
b) Radiographic films.
c) Results of magnetic particle and dye penetrant examinations.
d) Charts or other records of Brinell hardness tests.
e) Results of any other supplemental types of examination, test or

analysis specified.
f) Welding procedure specifications (WPS) and their procedure

qualification records (PQR).
g) Repair procedures and approvals
h) Repair details.
i) Operators welding qualifications test results.
j) Paint procedures.
k) Fabrication drawings.
l) Weld maps/Form 167A
m) Approved deviations if any.
8.2. All records and reports stated in the purchase order shall be furnished upon or prior
to, the arrival of the piping at the job site. The record package shall be specifically
identified as to the shipment it represents.
8.3. FABRICATOR shall prepare schedules to show his forecast for:-
a) Material procurement (as needed)
b) Spool detailing.
25194-3PS-PL-006 Page 13 of 15
c) Spool fabrication.
d) Spool shipment.
These schedules must be updated at regular periods, as specified in the

purchase order, to reflect the actual situation against the original agreed
schedule.
8.3.1. FABRICATOR shall prepare and update every two weeks spool fabrication records
for each plant and the overall record.
8.3.2. FABRICATOR shall provide clear legible “as built” mark-ups of

BUYER/CLIENT’s piping isometric drawings.
“As builts” shall be issued to BUYER/CLIENT for record purposes

within 2 weeks of notification that piping is ready for shipment.
Drawings shall be clear of all revision markings, diamonds, clouds etc.,
and be issued on the next sequential revision as “Certified as Built”.
9. Shipping Preparation
9.1. Immediately after cleaning and inspection, fabricated piping spools shall be suitably
protected for shipment as follows:-
a) Flange faces, machined surfaces and threads shall be cleaned of all

mill scale, rust, etc.,, and coated with a corrosion preventative such
as Rust Ban 324.
b) Small branches and small header attachments shall be adequately

braced or otherwise protected to prevent damage during handling,
shipping and storage.
c) Threaded couplings and other internally threaded connections shall

be closed and protected by wrapping with plastic tape, or plastic
caps.
d) Threaded nipples and other externally threaded connections shall be

closed and protected by wrapping with plastic tape, or plastic caps.
e) Weld end preparations shall be protected with securely fastened

plastic or wooden covers and coated with a rust prohibitor.
f) Flange faces shall be protected with securely fastened plastic or

wooden covers.
g) Ring type joint flanges shall have the groove packed with grease
prior to attaching flange protective covers.
h) Socket weld ends shall be protected using plastic plugs.
25194-3PS-PL-006 Page 14 of 15
9.2. All small loose pieces shall be boxed for protection during shipment. Each box shall
be identified with a securely fastened stainless steel tag bearing the purchase order number
along with appropriate spool detail number (see paragraph 7.1.2) to indicate its place in the
final installed assembly.
9.3. Fabricated pipe spools shall be adequately blocked, strapped, or otherwise held in
position during shipment and shall be further separated by dunnage as may be necessary to
prevent damage. Spools shall be handled using nylon straps. Chains shall not be used.
25194-3PS-PL-006 Page 15 of 15
APPENDIX A
SUPPLEMENTARY REQUIREMENTS FOR STEAM AND FEED WATER PIPING
SUBJECT TO INDIAN BOILER REGULATIONS REQUIREMENTS
1. Purpose
Appendix A is a mandatory supplement to the fabrication requirements of this
specification to ensure all steam and boiler feed systems conform to or are superior
to the fabrication requirements of the Indian Boiler Regulations (IBR).
2. Piping Material Classes

Only materials specified by the relevant piping material classes shall be used to
fabricate the steam and boiler feed systems.
 3. Materials
All materials purchased for use on IBR systems are subject to specific purchase
orders and shall be segregated from all other materials of a similar grade. The
Fabricator shall inspect all materials on receipt to ensure the correct grade, quality,
condition, end preparation, identification and dimensions have been supplied and are
in accordance with the applicable purchase order and specification requirements. All
materials received shall be accompanied by a supplier completed IBR FORM IIIA,
B, or C (Examples attached).
 4. Welding and Non-Destructive Testing

All welding configurations shall conform to Standard Drawing No. 25194-P14-
JG000-046 and the requirements of Form 167A from specification 25194-3PS-
GAW-004.
 5. Inspection
All fabrication activities will be subject to IBR inspection and approval prior to
installation.
 6. Hydrostatic Testing
Hydrostatic Testing shall be performed following completion of installation with
prior approval of the IBR site Inspector.
FORM III-A
25194-3PS-PL-006 Appendix A Page 1 of 7

Certificate of Manufacture and Test
(Regulation 4(e))
Name of Part :......................................................................................................
Maker’s Name and address :......................................................................................................
Design Pressure :......................................................................................................

Design Temperature :......................................................................................................
MATERIAL
Process of Manufacture :......................................................................................................
Fully killed/rimmed :......................................................................................................
Chemical Composition :......................................................................................................
PIPES
Main Dimensions :......................................................................................................
Tolerances :......................................................................................................
Mode of Manufacture :......................................................................................................
Identification Marks :......................................................................................................
Drawing Numbers :......................................................................................................
Bend Test on Pipes :......................................................................................................
Bend Test on Weld :......................................................................................................
Flattening Test :......................................................................................................
Tensile Strength :......................................................................................................
Mode of attachment of Flanges :......................................................................................................
Flange Particulars :......................................................................................................
Size of Branches :......................................................................................................
Mode of attachment of Branches :......................................................................................................
Heat Treatment :......................................................................................................
Final Hydraulic Test :......................................................................................................
NOTE:-
In addition, the following information in respect of the material shall be furnished in a tabular form in
conformity with the requirements of Regulation 4(c)(vi) for the note thereto, as the case may be. The
information may be given from the established test data or if the material is of standard quality an
extract from the standard may be furnished instead.

Metal
Temp. 250 275 300 325 375 400 425 450 475 500 525 550 575 600 625
up to C
Et
Sc
Sr
Tensile Strength at 20°C

where:
Et = Yield Point at temperature (0.2% proof stress)
Sc = Average Stress to produce an elongation of 1% (creep) in 100,000 hours at the various
working metal temperatures.
Sr = Average and lowest stress to produce rupture in 100,000 hours at the various working
metal temperatures.
Temperature range in the table may extend up to the limit of applicability of the material.
The value of Sc and Sr need be furnished only in respect of Pipes/Tubes intended to be used for
working metal temperatures above 454°C (850°F)
Certified that the particulars entered herein are correct.
The particulars of fabricated components are shown in drawing No :..................................................
The part has been designed and constructed to comply with the Indian Boiler Regulations for a
working pressure of ....................... and temperature ....................... and satisfactorily withstood a
water test of .......................... on the ...........................day of .........................19 ..... in the presence
of our responsible representative whose signature is appended hereunder.
Maker’s Representative........................................................
Maker....................................................................................
(Name and Signature)
We have satisfied ourselves that the pipes have been constructed in accordance with Chapter VIII.
The tests conducted on the samples taken from the finished pipes have been witnessed by us and
the particulars entered herein are correct.
Place. ...................................................... .................................................................
Date. ....................................................... .................................................................

(Name and Signature of Inspecting Authority).

FORM III-B
Certificate of Manufacture and Test
(Regulation 4(f))
Maker’s Name :......................................................................................................

Design Pressure :......................................................................................................
Design Temperature :......................................................................................................
MATERIAL
Fully killed/rimmed :......................................................................................................
TUBES
Main Dimensions :......................................................................................................
Tolerances :......................................................................................................
Bend Test :......................................................................................................
Flattening Test :......................................................................................................
Tensile Strength :......................................................................................................
Elongation Percentage :......................................................................................................
Crushing Test :......................................................................................................
Flare Test :......................................................................................................
Bend Test on Weld :......................................................................................................
Bulging Test and Drifting Test :......................................................................................................
(for copper and brass)
Heat Treatment :......................................................................................................
Hydraulic Test :......................................................................................................
NOTE:-
In addition, the following information in respect of the material shall be furnished in a tabular form in
conformity with the requirements of Regulation 4(c)(vi) for the note thereto, as the case may be. This
information may be given from the established test data or if the material is of standard quality an
extract from the standard may be furnished instead.
Metal
Temp. 250 275 300 325 375 400 425 450 475 500 525 550 575 600 625
up to C
Et
Sc
Sr
Tensile Strength at 20°C

where:
Et = Yield Point at temperature (0.2% proof stress)
Sc = Average Stress to produce an elongation of 1% (creep) in 100,000 hours at the various
working metal temperatures.
Sr = Average and lowest stress to produce rupture in 100,000 hours at the various working
metal temperatures.
Temperature range in the table may extend up to the limit of applicability of the material.
The value of Sc and Sr need be furnished only in respect of Pipes/Tubes intended to be used for
working metal temperatures above 454°C (850°F)
The particulars of fabricated components are shown in drawing No:...................................................
The tubes have been manufactured to comply with the Indian Boiler Regulations for a maximum
working pressure of ......................and temperature of ......................... at our works above named
and satisfactorily withstood a water test of ......................... on the ..................... day
of ..................... 19 ... in the presence of our responsible representative whose signature is
appended hereunder.
Maker’s Representative...........................................................
Maker......................................................................................
We have satisfied ourselves that the pipes have been constructed in accordance with Chapter II.
The tests conducted on the samples taken from the finished tubes have been witnessed by us and
Place ........................................................ ......................................................................

Date ......................................................... .......................................................................
(Name and Signature of Inspecting Authority)

FORM III-C
(Certificate of Manufacture and Test of Boiler Mountings and Fittings)
(Regulation 269)
Name of Part :......................................................................................................

Maker’s name and address :......................................................................................................
Intended Working Pressure :...................................... kg/cm² (lb./sq. inch)

Hydraulic Test Pressure :...................................... kg/cm² (lb./sq. inch)
Main Dimensions :......................................................................................................
Drawing Nos. :......................................................................................................
Identification Marks :......................................................................................................
Physical Test Results
i) Tensile Strength :...........................................................
ii) Transverse Bend Test :...........................................................
iii) Elongation :...........................................................
The part has been designed and constructed to comply with the Indian Boiler Regulations for a
maximum working pressure of ..................... and temperature of .................... and satisfactorily
withstood a hydraulic test using water and kerosene or with any suitable liquid in accordance with
the provisions of Clause (a) of Regulation 290 on the ........................ day of ...................... 19 .... in
the presence of our responsible representative whose signature is appended hereunder.
Signature of Makers Representative:..................................................................................................
Signature of Inspecting Officer who witnessed the test:......................................................................

Date at ......................... the day of ................................ 19.....
Signature and seal of Inspecting Authority:.........................................................................................
Place..................................................................................
Date....................................................................................
Maker’s Representative........................................ Maker..................................................................


We have satisfied ourselves that the pipes have been constructed in accordance with Chapter II.
The tests conducted on the samples taken from the finished tubes have been witnessed by us and
Place........................................................................ Name And Signature of the Inspecting Officer

who witnessed tests.
Date......................................................................... Name and Signature of Inspecting Authority.

APPENDIX B
PIPING ALIGNMENT AND FABRICATION TOLERANCES

(Pipe Fabrication Institute ES-3)
25194-3PS-PL-006 Appendix B

Piping Fabrication STDS

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*THIS PRINT IS NON-CONTROLLED *

Bechtel France S.A.S.

Reliance Petroleum Limited

This specification is based on 22960-3PS-PL-006 Rev.7

2 3-Jan-07 Issued for Construction PC SJH DH PKS

1 22-Mar-06 Re-issued for Design PC SJH DH PKS

0 23-Jan-2006 Issued for Design PC SJH DH PKS

Rev Date Revision By Chkd Appr Client

3. Codes and Associated Specifications........................................................................................

5. Materials and Fabrication Requirements..................................................................................

6. Examination and Inspection......................................................................................................

7. Shop Detail Drawings and Spool Identification.......................................................................

8. Records and Reports.................................................................................................................

APPENDIX B - Piping Alignment and Fabrication Tolerances (Pipe Fabrication Institute

2.3. Piping subject to requirements of the Indian Boiler Regulations is covered by

3. Codes and Associated Specifications

3.1.1. Local Codes or Regulations

Where local regulations, ordinances, statutes or codes take precedence

3.1.2. Refinery Code Piping

Except where specified otherwise, the Process Piping Code ASME

3.1.3. Boiler Code Piping

3.1.4. Other Requirements

GRE piping systems shall be in accordance with AWWA M45 Manual

3.2. Associated Specifications

25194-3PS-PL-001 Piping Material Classes (Includes Assemblies for

25194-3PS-PL-002 Piping Material Stock Code Index

25194-3PS-PL-004 Technical Supply Conditions for Piping Materials

25194-3PS-PL-005 Colour Coding of Piping Materials

25194-3PS-PL-007 Piping Erection and Testing

25194-3PS-PL-013 Chemical Cleaning of Pipework

25194-3PS-PL-019 Pipe Support Standards

25194-3PS-PL-102 Guidelines for supporting small bore connections

25194-3PS-PL-104 Induction & Cold Bending of Pipe

25194-3PS-GAW- Vendor Welding Procedure Approval and Welding

25194-3PS-GAW- Welding, PWHT and NDE of fabricated piping

25194-3PS-GAW- Shop and field Painting

4.1. Piping Material Classes

The Piping Material Classes specify by Service Class, the material

4.2. Supplementary Table of Wall Thickness and Branch Reinforcement

4.3. Piping Stock Code Index

4.4. Schedule of Welding, Heat Treatment and Non-Destructive Examination of Piping

5. Materials and Fabrication Requirements

5.2.1. Materials Supply

5.2.2. Unless otherwise identified on piping drawings, all materials shall

Individual line class materials and SP items will be identified on piping

FABRICATOR shall inspect all piping materials on receipt to ensure

5.2.3. Material Identification

Marking requirements and techniques, shall be in accordance with

As an aid to preliminary recognition, pipe materials shall be colour

5.2.4. Control of Materials

FABRICATOR shall submit a procedure to BUYER/CLIENT describing

The procedure shall describe as a minimum, the following:-

a) Method of controls on material receipt.

b) Handling, segregation and storage procedures.

c) Details of proposed file or stock card control system.

d) Issue of materials procedure.

e) Method of transfer of identification markings on piping materials.

f) Method of determining and reporting material shortages

5.2.5. Unidentified Piping Materials

Piping materials that cannot be identified by identification markings

5.2.6 Material and Weld Identification

Weld identification symbols shall be recorded onto fabrication drawings

If at any time during installation or fabrication, any piece of material is

THIS PRINT IS NON-CONTROLLED