Beruflich Dokumente
Kultur Dokumente
Specification
25194-3PS-PL-006
Title
Piping Fabrication
This specification is based on 22960-3PS-PL-006 Rev.7
1
0
Rev
22-Mar-06
25194-3PS-PL-006
Revision
PC
SJH
DH
PKS
PC
SJH
DH
PKS
By
Chkd
Appr
Client
Page 1 of 15
Contents
1. Purpose....................................................................................................................................3
2. Scope.......................................................................................................................................3
3. Codes and Associated Specifications......................................................................................3
4. Information Sources................................................................................................................4
5. Materials and Fabrication Requirements.................................................................................5
6. Examination and Inspection..................................................................................................11
7. Shop Detail Drawings and Spool Identification....................................................................12
8. Records and Reports.............................................................................................................12
9. Shipping Preparation.............................................................................................................14
APPENDIX A -
APPENDIX B -
25194-3PS-PL-006
Page 2 of 15
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 subassemblies. Instrumentation, pipework and tubing downstream of the last block valve on a
pipe header is not included.
2.3.
3.
3.1.
Codes
3.1.1.
3.1.2.
3.1.3.
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
3.2.
Associated Specifications
4.
25194-3PS-PL-001
25194-3PS-PL-002
25194-3PS-PL-004
25194-3PS-PL-005
25194-3PS-PL-007
25194-3PS-PL-013
25194-3PS-PL-019
25194-3PS-PL-102
25194-3PS-PL-104
25194-3PS-GAW001
25194-3PS-GAW004
25194-3PS-GAW005
Information Sources
The following sources contain information affecting detailing and fabrication of
piping.
4.1.
4.2.
25194-3PS-PL-006
Page 4 of 15
4.4.
5.
5.1.
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 is generally shop fabricated except for long straight runs
and small bore items which are field 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.
5.2.3.
Material Identification
All materials shall be new and identifiable and shall be supplied with
certification to meet project requirements.
25194-3PS-PL-006
Page 5 of 15
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)
5.2.5.
5.2.6
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.
25194-3PS-PL-006
Page 6 of 15
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).
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.
25194-3PS-PL-006
Page 7 of 15
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.
5.3.8.
Piping components shall be in accordance with Project Specification 25194-3PS-PL004 Technical Supply Conditions for Piping Materials.
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.
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.
Page 8 of 15
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.
5.5.
5.5.1.
Bends
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.
5.5.3.
5.6.
25194-3PS-PL-006
Page 9 of 15
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.
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.
5.8.
+ 3mm
+ 5mm
Page 10 of 15
within:
+ 1.5mm
+ 3mm
+ 0.25
6.
6.1.
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.
6.2.
Inspection
6.2.1.
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.
6.3.
6.3.1.
Procedures
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)
25194-3PS-PL-006
Paint procedures.
Page 11 of 15
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.
7.
7.1.
7.1.1.
The fabricator shall use SPOOLGEN to make shop detail spool drawings for piping
fabrication. Alternatively, BUYERs 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.
7.2.
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 CONTRACTORs
spool drawings or be marked on BUYER/CLIENTs piping isometric drawings.
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, 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.
8.1.
Page 12 of 15
j)
Paint procedures.
k) Fabrication drawings.
l)
8.3.
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.
FABRICATOR shall prepare schedules to show his forecast for:a) Material procurement (as needed)
b) Spool detailing.
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.
25194-3PS-PL-006
Page 13 of 15
9.
9.1.
Shipping Preparation
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)
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.
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.
25194-3PS-PL-006
Page 14 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.
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.
All welding configurations shall conform to Standard Drawing No. 25194-P14JG000-046 and the requirements of Form 167A from specification 25194-3PS-GAW004.
5.
Inspection
All fabrication activities will be subject to IBR inspection and approval prior to
installation.
6.
Hydrostatic Testing
FORM III-A
Certificate of Manufacture and Test
25194-3PS-PL-006
Appendix A Page 1 of 7
(Regulation 4(e))
Name of Part
:......................................................................................................
:......................................................................................................
Design Pressure
:......................................................................................................
Design Temperature
:......................................................................................................
MATERIAL
Process of Manufacture
:......................................................................................................
Fully killed/rimmed
:......................................................................................................
Chemical Composition
:......................................................................................................
PIPES
Main Dimensions
:......................................................................................................
Tolerances
:......................................................................................................
Mode of Manufacture
:......................................................................................................
Identification Marks
:......................................................................................................
Drawing Numbers
:......................................................................................................
:......................................................................................................
:......................................................................................................
Flattening Test
:......................................................................................................
Tensile Strength
:......................................................................................................
:......................................................................................................
Size of Branches
:......................................................................................................
:......................................................................................................
:......................................................................................................
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.
25194-3PS-PL-006
Appendix A Page 2 of 7
250
275
300
325
375
400
425
450
475
500
525
550
575
600
625
Et
Sc
Sr
.................................................................
Date. .......................................................
(Name and Signature of Inspecting Authority).
.................................................................
25194-3PS-PL-006
Appendix A Page 3 of 7
FORM III-B
Certificate of Manufacture and Test
(Regulation 4(f))
Makers Name
:......................................................................................................
Design Pressure
:......................................................................................................
Design Temperature
:......................................................................................................
MATERIAL
Process of Manufacture
:......................................................................................................
Fully killed/rimmed
:......................................................................................................
Chemical Composition
:......................................................................................................
TUBES
Process of Manufacture
:......................................................................................................
Main Dimensions
:......................................................................................................
Tolerances
:......................................................................................................
Bend Test
:......................................................................................................
Flattening Test
:......................................................................................................
Tensile Strength
:......................................................................................................
Elongation Percentage
:......................................................................................................
Crushing Test
:......................................................................................................
Flare Test
:......................................................................................................
:......................................................................................................
:......................................................................................................
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.
up to C
250
275
300
325
375
400
425
450
475
500
525
550
575
600
625
Et
Sc
Sr
25194-3PS-PL-006
Appendix A Page 4 of 7
......................................................................
Date .........................................................
(Name and Signature of Inspecting Authority)
.......................................................................
25194-3PS-PL-006
Appendix A Page 5 of 7
FORM III-C
(Certificate of Manufacture and Test of Boiler Mountings and Fittings)
(Regulation 269)
Name of Part
:......................................................................................................
:......................................................................................................
:......................................
:......................................
Main Dimensions
:......................................................................................................
Drawing Nos.
:......................................................................................................
Identification Marks
:......................................................................................................
Chemical Composition
:......................................................................................................
Tensile Strength
:...........................................................
ii)
iii)
Elongation
:...........................................................
25194-3PS-PL-006
Appendix A Page 6 of 7
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
the particulars entered herein are correct.
Place........................................................................ Name And Signature of the Inspecting Officer
who witnessed tests.
Date.........................................................................
25194-3PS-PL-006
Appendix A Page 7 of 7
APPENDIX B
PIPING ALIGNMENT AND FABRICATION TOLERANCES
(Pipe Fabrication Institute ES-3)
25194-3PS-PL-006
Appendix B