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PT Tenaga Listrik Cilegon

170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

17

Page 165

PIPING SYSTEM

17.1

General Requirements
The piping shall be engineered, procured and constructed considering the full range of
design pressures and temperatures, the full range of site ambient conditions and the
service medium characteristics. This requirement is also applicable for all temporary
pipework to be installed to assist plant cleaning and commissioning.

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The piping systems shall conform to the codes and standards specified in the various
sections of this specification. ASME B 31.1 shall be the standard applied for the main
power island process piping, including the boiler integral pipework. The codes and
standards shall be of the latest edition including all revisions, supplements, and
addenda which are in effect as of the date of issuance of the specification and shall be
considered to be part of this specification. The use of other internationally recognized
codes and standards are subject to the Employers approval. If the agreed codes and
standards are published in any language other than English translations into English
shall be provided for all documents required by the Employer for design review.
All parts and works necessary for the safe and efficient operation of the piping shall be
provided down to the smallest detail even if they were not particularly mentioned in
the specification.
17.1.1

Codes and Standards

All works, equipment, materials and systems shall be designed, manufactured and/or
constructed in accordance with the latest issue of the relevant international codes and
standards.
17.2

Design Requirements

17.2.1

General

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The Bidder shall design all piping systems in accordance with applicable system
performance and operating data and shall be responsible for all dimensions, wall
thickness, pressure losses, stress calculations, and reliability of the systems. The
piping systems shall be designed to meet the requirements of trouble-free and safe
operation under maximum load, part load, transient and fault conditions. All parts and
works necessary for the safe and efficient operation of the piping shall be provided
down to the smallest detail even if they were not particularly mentioned in the
specification.
The Bidder shall confirm in his proposal that the applicable design code for the
following systems is ASME B31.1:

Pyry Energy Ltd.

Steam Pipework (main steam, cold reheat, hot reheat and process steam)
including vents and drains.

Steam Turbine bypass system.

Steam turbine integral pipework, extraction steam lines, gland steam


line, vents and drains.

Feed water pipework including vents and drains.


Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 166

Feed water ancilliary pipework (e.g feed pump minimum flow lines,
attemporator spray pipework).

Condensate system including vents and drains.

Feed heating system integral pipework.

Turbine control oil pipework.

Fuel oil pipework.

Turbine lubricating oil pipework.

Compressed air pipework.

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Piping materials for the above systems shall be selected from seamless material listed
in the chosen international design standards. Equivalent materials shall not be used.
Piping systems which are exposed to creep shall be fitted with creep pips or other
means to allow periodic measurement of diametral creep distension.
Double isolation shall be provided for all piping systems with a design pressure of 40
bar(g) or above. This requirement is applicable for any equipment that requires
isolation for on-line maintenance and for all drains, vents and instrument root valves.
Drain and vent lines after the second isolating valve for the boiler, feedwater
pipework, steam pipework and the steam turbine shall have a wall thickness equal to
schedule 80.
All pipe fittings shall be proprietary fittings. All small bore connections to pipe
systems shall be by weldolets, sockolets or threadolets or similar proprietary fittings.
During the design phase the Contractor shall submit General Arrangement drawings
for all piping systems, including drains and warming lines, covered in this Section of
the specification for approval. General Arrangement drawings shall indicate all lines
DN80 and above in full detail. Lines below DN 80 shall be indicated by centre line
only. From the general arrangement drawings the Contractor shall develop detail
drawings, piping isometric drawings and pipe spool drawings for pipework erection.

PD

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Pipework below DN 50 may be installed as site run pipework for cold water systems,
compressed air distribution system, and system drains and vents. However the site
running of steam line drains is not permitted.

17.2.2

Pipework shall not be run across floors or walkways or anywhere that would
constitute a safety hazard, trip hazard or an obstruction for plant maintenance.
Design Pressure
The design pressure of a piping system subject to internal pressure is defined as the
highest of the following:

Pyry Energy Ltd.

The requirements of the selected design code

Design pressure of the equipment to which the piping is connected

Set pressure of a relief valve of the piping or equipment system

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 167

Pressure not lower than the shut-off pressure resulting from the sum of the
maximum suction pressure plus 1.5 times the design differential pressure, for
discharge lines of centrifugal pumps not protected by a relief valve

Pressure corresponding to absolute vacuum for piping systems under vacuum


pressure. All steam lines shall be designed for full vacuum or properly
safeguarded.

Lines for liquids, which may have vacuum, shall be designed for vacuum or
properly safeguarded

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The design pressure as defined above shall be assumed in the design of the whole
piping beginning from the operating machine (or equipment) upstream up to the last
valve (included) located before the inlet into the equipment with a lower design
pressure.
In the systems including control valve by-pass sets, the isolating valves and the bypass valve shall always be provided for the design pressure upstream.
17.2.3

Design Temperature

The design temperature of a fluid in a piping system is the maximum temperature


expected for the fluid from the equipment, machine or fluid supply. The design
temperature shall consider limitations of control systems (e.g. the control range for
boiler steam temperature), radiant heat gain and thermal conduction.
If exact data on maximum fluid temperature cannot be established the normal
operating temperature plus 20-30 deg. C shall be used.
The design temperature of the piping material is the same as that of the fluid.
The operating temperature, thus defined, can be used for the purpose of determining
the insulation thickness and the design temperature for thermal stress analysis and
flexibility of the piping.
The use of carbon steel shall be restricted to pipe systems with a design temperature
below 425C.
Pipe System Velocities

17.2.4

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Unless stated elsewhere within this specification fluid velocities shall not exceed the
values stated between

Pyry Energy Ltd.

Fluid

Velocity m/sec

Saturated steam

20 - 30

Superheated steam

30 - 45

Superheated steam (300 mm and larger pipe size)

50 60

Steam exhaust to atmosphere

25 - 50

Reheat steam

30 40

Turbine LP Bypass after PRV

50 - 75

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 168

1.0 1.5

Main cooling water pump discharge lines

2.0 2.5

Pump inlet for water

2.0 2.5

Pump outlet for water less than 10 bar

2.5 3.0

Pump outlet for water 10 bar or more

3.0 3.5

Drains

1.0 2.0

Low pressure air (less than 10 bar)

20 30

High pressure air (10 bar or more)

10 15

Fluid

Velocity m/sec

Air compressor inlet

10 20

Fuel oil and lubrication oil

0.5 2.0

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Main cooling water pump suction

17.2.5

Piping Arrangement Design General Requirements

The piping layout and arrangement shall be clearly shown on flow diagrams, pipe
routing, isometric and erection drawings. Pipe dimensions, materials, operating
conditions, insulation thickness, and piping and equipment identification numbers
shall be shown on the relevant drawings.
The Bidder shall design all piping systems with the piping arranged in orderly pipe
runs giving due consideration to pipe expansion, valve locations, practical pipe
supporting, and access to all piping accessories for maintenance purposes.
No nozzle or branch weld shall encroach over the heat affected zone of main pipe butt
welds.

Piping arrangements shall provide for the removal and/or maintenance of equipment
and equipment internals without removing the piping. A minimum of 2.1 metre
headroom shall be maintained to the bottom of all piping components or insulation in
walking areas.

PD

Fd

A minimum passageway of 1 metre shall be provided for access between and around
all equipment, and a 50 mm minimum clearance shall be provided between piping,
including insulation, and any point of adjacent equipment of piping. Additional
clearance shall be provided, where required, for pipe movement due to thermal
expansion.

Pyry Energy Ltd.

In developing the general arrangement drawings, particular attention shall be given to


access and egress throughout the plant:

Pipes shall be routed so that clearances around the pipe are adequate to meet
installation and field welding requirements, and furthermore valve, instrument,
and support maintenance requirements

Pipes shall be routed to reserve space for cable trays between the bottom of the
floor steel and the top of the pipe (or the top of the pipe insulation) taking into
account the worst condition, either hot or cold

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 169

Interference with pipe supports shall be prevented.

Contractor shall co-ordinate the design of all piping systems with other power
plant services (e.g. cabling) to ensure that there is no interference.

Adequate clearance shall be provided around all pipes to permit the installation
of insulation material. Local reduction of insulation thickness due to
interference with other pipework equipment or structures will not be permitted.

The general clearances for crossings and passageways defined in Chapter 3.7.1
shall also apply.

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In general, the branches shall be located at the bottom or at the side of lines conveying
liquids, and at the top of lines conveying gases or vapours. Branches shall be
furnished with an isolating valve close to the branching point.
Pipes shall be arranged in such a manner that thermal expansion does not cause any
undue stresses on the piping. The same requirement applies to vent and drain pipes.
Piping shall be supported so as to minimise the loads on pump and equipment nozzles.
Piping for connection to equipment shall be installed so as to leave a sufficient
clearance for access and maintenance operations.
All condensate and water lines shall be run with a minimum gradient of 1:500 sloping
downwards in direction of flow.
Pump suction pipes shall be routed in such a manner that no air can be trapped in the
suction piping. The top of the suction branch lines shall be in no place lower than the
top of the manifold at the point of their interconnection.
17.2.6

Valve Arrangements

All manual isolating valves shall be manoeuvrable, in order of precedence, in the


following manners:
from grade

from walkway or from a special platform

by extension

by chain

PD

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The height of hand wheel axis from the operating floor shall preferably be 1,200 or
1,400 mm; in any case, it shall not exceed 1,800 mm.
Normally, the valves shall not be installed with the stem below the horizontal position.

All valves with one end non-connected shall be equipped with blind flanges or plug.
17.2.6.1

Safety and/or Relief Valve Arrangements


These shall be located as close as possible to the equipment they are to protect, and be
accessible for inspection and maintenance purposes.
Relief or safety valve venting to atmosphere shall be arranged as follows:

Pyry Energy Ltd.

steam vent pipes shall be routed to free atmosphere outside the building.
Preferably the vent pipes shall be separate for each valve.
Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 170

condensate and water vent pipes shall be routed to the nearest trench on ground
floor. Special attention shall be paid to flashing fluids. Vent pipes shall be
arranged and dimensioned also for the flashing.

Preferably each valve shall be oriented to discharge parallel to the axial centre-line of
the pipe it is protecting.
Each pipe discharging to atmosphere shall have a 1/2" (min.) diameter drain pipe at
the lowest point.

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Relief valves shall always be installed on those lines which may be closed off at both
ends, if the line internal fluid, at maximum ambient temperature, may reach a pressure
higher than the rating of the line itself.
17.2.6.2

Vents and Drains

All pipelines shall be provided with vent and drain connections at all high and low
points respectively, and also as otherwise required for suitable operation.
Where practicable, all steam lines shall be sloped in the direction of steam flow and
shall be adequately trapped at low points and vented at high points in the pipe runs.
Drip legs shall be provided on steam lines at the drainage points to avoid blockage of
drain pipes. Each trap and strainer arrangement shall have suitable block valves,
bypass valve, strainer, and blow-off valve.
High pressure and high temperature drain lines shall have a slope of 2.5% for drainage
to ensure that a slope is maintained during the life of the plant when allowance is
made for possible pipe creep, pipe settlement and spring hysteresis.
The position of isolating valves and orifices shall be taken into account, when locating
drip legs. Condensate pots, drip legs and drain lines shall be adequately sized to
remove all condensate during plant start-up. Each drainage pipe shall be separately
run to blow-down vessels, drain tanks or flash vessels as may be appropriate.
Piping for drains and vents from vessels shall be protected from erosion/corrosion by
the same material as the vessel lining unless otherwise approved by the Employer.

All system piping shall be arranged to permit complete drainage when the plant is
shutdown.

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All vent lines shall be terminated 3 m or higher above the highest service platform.

Pyry Energy Ltd.

All drain lines, which run to waste, shall be routed to a suitable drain trench, floor
drain, or sewer.
The sizes of vent and drain valves shall be selected as a function of the characteristics
of the fluid to be vented or drained however they shall not be smaller than the
following:

Lines DN 50 and smaller:

size of vent DN 15 and drain size DN 25

Lines DN 65 ... DN 250:

size of vent DN 20 and size of drain DN 40

Lines DN 300 and larger:

size of vent DN 25 and size of drain DN 50

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

17.2.7

Stress Analysis

17.2.7.1

General

Page 171

Stresses due to thermal expansion and mechanical loads in the piping systems and in
the selection of the type of supports shall be checked. The stress and flexibility
analysis shall be calculated using proprietary computer software specifically that is
compatible with the piping design code.

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As a minimum requirement the following pipe systems shall be checked and stress
analysed:

all high pressure steam systems including drains and safety valves

all high pressure feed water excluding small sized lines ( DN 50)

all steam lines connected to the turbines including heater connections

Generally, high pressure is considered to be a design pressure of 40 bar(g) or above.


The specified requirements represent the minimum requirements, and the Contractor
shall perform stress analysis of other systems that may potentially be subject to
significant thermal stresses and/or expansion based on the Contractors design
considerations and practices.
In general it is recommended to avoid, as far as possible, the use of expansion joints
and cold pull.
Each piping system shall be considered as a structure properly supported, which works
at the operating conditions stated in the specifications for the respective equipment. If
the flexibility of the pipe is insufficient, the expansion shall be absorbed adopting the
procedures below in the listed order of precedence:
spring or constant supports

guides or restraints

change in piping routing

insertion of loops built from pipe and bends

installation of expansion joints

Fd

PD

17.2.7.2

17.2.7.3

Accuracy of Calculations
The calculation methods applied shall have an accuracy degree proportioned to the
importance of the piping and the operating conditions. The Contractor shall submit
calculation sheets for all required piping systems for the Employer's approval.

Adjusting Temperature for Stress Analysis Calculations


The following requirements shall apply:

Pyry Energy Ltd.

the turbine exhaust piping shall be checked also at full speed no load
temperature

the steam turbine bleed-off piping shall be checked also at the highest possible
temperature

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 172

the exhaust pipes after attemperator stations shall be checked also in a case in
which the supply of spray water is lost.

For circuits with one normal operating temperature and a second different temperature
for transitory periods, both conditions shall be analysed.
17.2.7.4

Lines Temporarily Closed

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For lines connected to two or more items of equipment, of which one is operating and
the remaining ones are still-standing, the temperature established in the dead sections
shall be analysed and considered in the flexibility analysis.
17.2.7.5

Stresses on Equipment

The stresses produced by piping (due to weight, expansion forces, etc.) on pumps,
vessel shells and heads of vessels, shall be checked for being limited within the
allowable values accepted by the equipment manufacturer. The Contractor shall
submit a schedule of permissible nozzle loadings for the boiler connections, turbine
connections, condenser connections, feed heater connections and boiler feed pump
connections. The data for the schedule shall be provided by the equipment
manufacturers.
17.2.8

Pipe Supports and Hangers

High pressure pipe supports shall be designed and spaced in accordance with the
requirements of the pipework design code and the results of the pipework stress
analysis report.
All hangers and supports for high pressure piping systems shall be proprietary items
capable of meeting the requirements specified by the pipework stress and flexibility
report. The Bidder shall nominate a short list of proposed suppliers of pipe supports
and hangers in his Proposal.

PD

17.2.9

Fd

During the Design Phase the Contractor shall submit details of all proposed pipe
supports and hangers to the Employer for approval. Each pipe hanger or support shall
have its own unique number and shall be identified on the relevant isometric drawings
and shall be cross referenced with pipe hanger design documents.

17.2.9.1

Miscellaneous Design Requirement


Fire Water System
The fire water pipework shall be installed above ground on either pipe racks or pipe
sleepers. The pipework shall be protected from accidental damage in all areas where
there is a risk of damage (e.g. roads).

Where underground pipework is unavoidable for example road crossings the pipework
shall be installed in a pipe trench with adequate access for maintenance inspections.
The trench shall be sealed so it is weather-proof, have a drainage slope, drain sump,
level alarm to detect water ingress and facilities to install a submersible pump to
remove accumulated water. The Contractor shall provide a local power point for the

Pyry Energy Ltd.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 173

submersible pump and shall provide a suitable submersible pump as part of the scope
of supply of this Contract.
17.2.9.2

Air, Water Service Stations


For maintenance and cleaning purposes service stations consisting of hose connections
for compressed air and water shall be provided.

17.2.9.3

Compressed Air Lines (instrument and service air)

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Compressed air lines shall be fully drainable and wherever possible, run with a
minimum slope 1:500 away from compressors.
Drip legs with drain valves shall be provided at junction points, low points in the pipe
route, and if necessary, at approximately 50 to 100 m intervals along the main line.
17.2.9.4

Service Piping

Service piping headers shall be provided with an isolating valve from the supply main.
17.2.9.5

Underground Pipes

The Employer prefers pipework systems to be mounted above ground wherever


practicable.
All medium and small sized pipes that need to be below ground shall be run in open
concrete channels that are arranged to have effective drainage. These pipe channels
shall be fenced and traffic crossings and walkways shall be provided wherever
necessary. If in specific areas the pipes must be directly buried in the ground this shall
be subject to review and approval by the Employer.
Corrosion protection of underground pipework shall be approved by the Employer.
Pipelines shall be completely tested (hydrostatic, leak and porosity tests) and accepted
by the Employer and approving authority before any filling of trench.
Temporary Strainers

17.2.9.6

PD

Fd

The Contractor shall provide temporary strainers on the inlet side of all major plant
and equipment where permanent strainers are not provided. Strainers that slip between
flanges shall be provided. The strainers shall remain in place until the Employer
approves removal.

17.2.9.7

Wall Boxes and Collars


Wall boxes and collars shall be provided for all penetrations through walls and floors.
Pipes passing through roof collars shall be provided with an approved weatherproof
hood and cowl. Floor collars shall extend to 200 mm on concrete floors and 100 mm
on steel grating above the floor level and the pipes shall be fitted with hoods where
required. Weather flashings shall be fitted where required.
The boxes and collars shall not restrict any thermal expansion of piping.

Pyry Energy Ltd.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

17.3

Material

17.3.1

General

Page 174

All material used shall be new, of best quality, most suitable for working under the
specified conditions and it shall withstand the variations of temperature, pressure and
atmospheric conditions arising under working conditions. No welding, filling or
plugging of defective parts will be permitted without the permission in writing of the
Employer.

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Carbon steel pipes shall have a minimum corrosion allowance of 1.0 mm. Possible
higher allowances shall be adopted based on the process requirements. Due care shall
be taken to include thinning allowance for bends etc.
For a piping line handling two phase mixture a 5% chrome alloy steel piping material
shall be used. The pipe material for the systems specifically identified in Chapter
17.2.1 shall be manufactured using a seamless process.
17.3.2

Marking

All pipes and pipe fittings shall be marked with material identification markings so
that all material can also be identified after cutting. The Contractor is shall not erect
any material which cannot be identified. The Contractor shall submit to the Employer
a procedure detailing of how the transfer of material identification marks is controlled.
17.3.3

Storage and Protection

During transportation and storage the pipes and pipe fittings shall be protected against
corrosion and dirt.

Pipes in storage shall be dry and free from corrosion, shall be protected internally in
an approved manner and shall be stored off the ground. Prior to fabrication in the
shop or in the field, scale or any foreign material shall be blown or swabbed from the
interior of the pipe. After fabrication all open ends shall again be plugged, capped or
otherwise sealed. All loose fillings, slag, sand, dirt, oil, grease or other foreign
substances shall be removed from the interior and the exterior surfaces of all pipe
fabrication prior to installation and/or coating.

PD

Fd

Internal surfaces of valves shall be suitably protected and protectors shall be installed
on valve ends or other speciality ends at the factory. Protection shall not be removed
until the valves or specialities are installed. Valves and specialities shall be stored off
the ground and protected from foreign elements.

17.4

Fabrication and Erection

17.4.1

General
The following requirements are applicable for both shop fabrication of pipework, site
fabrication of pipework and site erection of pipework.
All pipework shall be fabricated to the requirements of the approved design code.
Prior to commencing erection the Contractor shall submit to the Employer for
approval an Inspection and Test Plan for the fabrication, erection and testing of the

Pyry Energy Ltd.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 175

pipework. Separate inspection and test plans shall be submitted for shop fabricated
pipework and for site fabrication, erection and testing of pipework. Separate
inspection and test plans shall be submitted for each fabrication shop and for each site
fabrication and/or erection subcontractor.
Sub-contractors selected for off-site fabrication shall be approved by the Employer.
For systems identified in Chapter 17.4.2 below the sub-contractor shall submit
supporting documents to demonstrate their fabrication capability, quality control
procedures, code approval certificates and provide a reference list of completed work.

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All welding procedures, welders and welding machine operators shall be qualified to
the applicable pipework design and fabrication code.
For both off-site fabrication and on-site fabrication and erection the Bidder shall
submit the following documents for the selected sub-contractors to the Employer:

Company financial report for the previous three years

Company brochure

Company quality manual

ASME certificates and ISO 9000 series certificates

Organisation chart for the project

CV of key personnel on the organisation chart

Reference list of similar projects

Details of available erection equipment

Welding consumable control procedures

9% Chrome Material ASME Grade 91 and Grade 92 Materials

17.4.2

PD
Fd

This section is applicable for ASME Grade 91 and Grade 92 modified 9% chrome
material and similar material manufactured to other internationally recognised codes.
Note that material manufactured to any code other than the ASME or ASTM codes
shall require Employer approval prior to purchase. These requirements in this Subsection are in addition to the requirements of the section for Piping and are applicable
for shop fabrication and for site erection work.
The Bidder shall include in his proposal a list of all pipe systems that he proposes to
fabricate from ASME Grade 91 and Grade 92 material.
Pipework material suppliers shall be selected from a list of material suppliers that has
been approved prior to award of Contract.
Pipework design, fabrication and testing shall comply with ASME B31.1.
Pipe material shall be supplied with mill certificates that confirm that the raw material
hardness shall be within the range 190 250 HBN.
Welding consumables shall comply with the requirements of ASME IX however the
Nickel content should not exceed 0.4% and the combined Nickel + Manganese should
not exceed 1.2%.

Pyry Energy Ltd.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 176

Flux core arc welding shall only be used with shielding gas. Flux core arc welding
shall not be used for root pass application without backing or back gouging and
welding. Shielded metal arc welding shall not be used for root pass application
without backing or back gouging and welding.

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Weld preheat shall be applied to the requirements of ASME B31.1. Pre-heat shall
preferably be applied by electric resistance or induction heating and the preheat
temperature shall be recorded by thermocouples. Gas heating shall only be used if it
is not possible to use electric resistance heating coils or induction heating, e.g. for
tubes and small bore pipework DN50. Heating by an oxygen rich (oxy-fuel) flame is
prohibited.
The maximum inter-pass temperature shall not exceed 316 deg. C.

All welds shall be adequately supported to ensure that no stresses can be applied to the
weld.
Welding shall be continuous, however if an interruption is unavoidable then the
following shall apply for welds where a minimum of 10mm thickness of weld is
deposited or at least 25% of the weld groove is filled:

For weld deposit thickness equal to or below 50mm the weld shall be held at
260 to 316 deg. C for one hour before cooling under insulation to a
temperature below 93 deg. C.

For weld deposit thickness above 50mm the weld shall be held at 260 to 316
deg. C for two hours before cooling under insulation to a temperature below 93
deg. C.

Prior to recommencing welding the weld shall be examined to ensure that there are no
cracks in the weld. Pre-heating shall be applied before welding resumes.
After welding is complete post weld heating shall take place as described above.
However if the weld and base material thickness is below 13mm and the weld has
been completed using only a GTAW process the weld can be cooled under insulation
to a temperature of 93 deg. C without post heating.

PD
Fd

Post weld heat treatment shall be conducted to the requirements described in ASME
B31.1 Clause 132 and Table 132. Sufficient thermocouples shall be attached to the
area subject to post weld heat treatment to ensure an accurate temperature record is
obtained. As a minimum there should be two thermocouples, one at top centre and one
at bottom centre for pipework up to and including DN 250. For pipework over
DN250 three equi-spaced thermocouples shall be used.
The control range for heating and cooling shall start and finish at 316 deg. C and the
rate of heating and cooling shall not exceed 150 deg. C per hour.

Hardness testing shall be conducted after post weld heat treatment. Each test line shall
consist of 5 readings in the sequence Base metal > Heat Affected Zone > Weld > Heat
Affected Zone > Base Metal. For pipe sizes below DN100 there shall be one test line.
For pipe sizes DN100 to DN250 there shall be two test lines diametrically opposite
and for pipe sizes in excess of DN250 there shall be four equi-spaced test lines. All
attachment welds to pipes shall have a minimum of one test line per weld.
The permissible harness range for the base metal is HBN 190 250. The permissible
hardness range for the weld metal is HBN 190 280.
Pyry Energy Ltd.

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170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 177

Positive material identification shall be carried out on all pressure retaining welds.
17.4.3

Site Erection
All piping shall be accurately installed according to the approved drawings. The joints
and connections shall be accurately aligned and parallel without stress. At the
assembly of the piping no stress shall be imposed on the equipment except the forces
necessary to pre-set any expansion devices.

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All piping shall be installed in a manner such that expansion will take place in the
direction desired and so that vibrations will be minimised. No piping shall be cold
pulled unless so indicated on the drawings that have been approved by the Employer.
Cold pull (pull up cold) shall be clearly indicated on drawings submitted for approval.
Standard "Factory Made" fittings shall be used for all piping systems. Shop or site
fabricated mitred fittings shall not be used.
No pipework shall be run in trenches carrying electrical cables.

All pipes, valves, fittings and specialities shall be properly protected. All damaged
coatings shall be rectified after installation.
In general, no valves shall be installed with their stem directed downward. Valves
with weld ends shall not be welded together. An intermediate pipe spool shall be used.
Welded connections shall be used as much as possible. The use of flanged or threaded
connections is allowed only in cases where erection, maintenance, cleaning of pipe so
demands. Threaded connections shall not be used in connection with high pressure
steam and feed water piping.
Welding or flame cutting of galvanised pipe or pipe support material is not permitted.
Prior to assembly of various piping components it shall be confirmed that every piping
component conforms to the specifications and the drawings.
Structure steel components shall not be cut, removed or damaged to make piping
installation work easier.

PD

Fd

During erection open ends of pipework shall be protected by temporary covers, which
shall be securely fixed. When welding valves to the piping the valve manufacturer's
recommendations shall be followed. During welding all valves shall be in the open
position.
During installation, flanged joints shall be fitted up, after checking the alignment of
the flange mating centres and confirming that the flange faces are parallel.
The bolt holes of the flanges to be welded to pipes shall be located symmetrically
from vertical centreline in horizontal pipeline, and from plant north in vertical piping
line, unless otherwise indicated on the drawings.
When declination exceeds any of the following limitations, flanged connection shall
not be allowed.

Pyry Energy Ltd.

3 angle difference between flange faces

5 mm declination of horizontal direction between flange centreline

5 mm distance between facing bolt hole, when a pair of bolt holes shall be
faced and rolled.
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Tender Documents
Section 3 Employers Requirements

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Threads of bolt-nuts and contact surfaces of gaskets shall be covered with


paste to prevent adhering, leakage, etc. These pastes shall be selected
according to service fluids and/or temperatures.

Openings, such as flanged joints for pumps, compressors etc., shall be covered with
thin plate or other blinds until final connection to prevent dust and other foreign
matters from entering into the machinery.
Pipe supporting elements for pipes DN 50 and larger shall comply with the indicated
location and equal to the shape shown on the drawings.

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If temporary supports are required during construction, except those indicated in the
drawings, they are subject to the approval by the Employer or the Engineer.
For cold pull gap the pipeline shall be supported and anchored according to the
drawings before the cold pull gap is recorded, and before the pipelines are drawn
together for the final connection.
For expansion joint space the pipeline shall be supported and anchored according to
the drawings before the measurement between the two flanges is taken and the
expansion joint installed.
17.5

Welding

17.5.1

General

The Contractor shall employ a qualified welding engineer to prepare all welding
procedures and weld repair procedures at fabrication shops and at the site prior to
submission of the procedures to the Employer for approval.
Welders employed on any work, either at workshop or on site, shall be tested and
formally approved to the requirements of the governing code or standard to be
competent to carry out the type and standard of welding required before starting the
work.
Each approved welder shall have an identification number.. All pipe welds shall
permanently marked to indicate the welder(s).

PD

Fd

All welding procedures and procedure qualification reports shall be submitted for the
approval of the Employer. All expenses in connection with welder tests and procedure
tests shall be covered by the Contractor.

Pyry Energy Ltd.

Prior to commencing fabrication shop welding activities and site welding activities the
Contractor shall submit the following documents and procedures for each pipework
fabrication and erection subcontractor:
-

Welding Procedures and Procedure Qualification Reports

Welder Qualification Procedures

General Welding Procedure

Welding Consumable Control Procedure

All Non-destructive Examination Procedures to be utilized

Pre-heat and Post Weld Heat Treatment Procedures

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PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

17.5.2

Page 179

Hardness Testing Procedure

Positive Material Identification Procedure

Specialist NDE company profile and NDE Inspectors qualifications.

Inspection of Welding

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The Contractor shall employ quality control inspectors to conduct welding


inspections. All inspectors shall be formally qualified to a recognised code standard
as required by the pipework design and fabrication code or qualified to American
Society for Non-destructive Testing (ANST) for the inspection technique applied.
All welds shall be visually examined after completion by the QC inspector.
In addition the systems detailed below shall be fabricated to the requirements of
Chapter 4.4 Boiler Pressure Parts and shall be subjected to the non-destructive
examination requirements listed in this clause.
-

Main Steam Pipework.

Hot and Cold Reheat Pipework

Process steam pipework

Steam Turbine bypass systems.

Steam turbine integral pipework, extraction steam and gland steam lines.

Feed water pipework including attemporator spray pipework.

Turbine control oil pipework.

RT

UT

MT/PT

100

100*
by exception

100

Branches with ND > 100

100

100

Nozzles, nipples etc 100

10

100

PD

Fd

Circumferential butt welds

Instrument tappings

100

Socket welded joints

100

Pipework attachments

100

Pipe bending (induction)

100

RT = Radiographic Testing, UT = Ultrasonic Testing, MT/PT = Magnetic Particle


Testing / Dye Penetration testing
Pyry Energy Ltd.

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PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 180

*UT shall only be used in lieu of RT where the joint configuration prevents RT for
being effective and only with the Employers approval
For other pipework systems listed above in Chapter 17.2.1, 10% sample radiography
shall be applied as detailed in Chapter 4.4.3 Boiler Pressure Parts Non-destructive
Testing.

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Radiography procedures shall in accordance with the applicable requirements of the


pipework design and fabrication code. Where there are no specific requirements
stated in the design code the radiography procedures and radiograph film
interpretation shall be in accordance with ASME Boiler and Pressure Vessel Code
Section V and ASME B31.1.
The results of all weld inspections shall be recorded on a weld history sheet. Each
weld history sheet shall include isometric drawings of the pipework identifying the
welds and the inspection reports for all inspections and NDE processes plus post weld
heat treatment charts hardness tests and positive material identification results if
applicable.
The material composition of both parent and weld metal shall be confirmed after
welding is complete for all pressure part components manufactured from microalloyed carbon manganese steels and all ferritic alloy materials. The inspection
method shall be approved by the Employer.
17.5.3

Weld Repairs

All weld repairs shall be carried out to a procedure approved by the Employer. If
repairs are to be carried out by welding, dimensioned sketches of the excavated areas
shall be prepared and the proposed repair procedure submitted for the approval of the
Employer before any repair is started. Under no circumstances shall the repair be
started until the approval of the Employer has been obtained. The areas shall be
subjected to a suitable non-destructive test and on completion of the weld they will
again be non-destructively tested. In the event that the repair requires all or any part
of the item to be stress relieved, the non-destructive tests shall be repeated on any part
deemed to have been affected by the stress relief.

Fd

PD

17.6.1

Pipe Supports

17.6

General Requirements
Standard supports shall be designed in accordance with material requirements.
Materials to be used:
galvanised carbon steel for parts directly attached to piping (non-insulated piping)
carbon steel (insulated)
All support parts, which shall remain outside insulation, shall be delivered painted in
accordance with good international engineering practice. The painting repairs after the
completed erection work are included in the Works.
Adjustment of supports (springs etc.) is included in the Works. In general pipe
supports and anchors shall be located at those points in the steel structure where
provision has been made for the loads imposed. The cutting of floor or roof beams or

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Section 3 Employers Requirements

Page 181

the reinforcement in slabs will not be permitted. Piping attached to equipment shall be
supported in such a way that the weight of the piping is not taken by the equipment.
All supports above DN50 shall be shop fabricated and positioned before erection.

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Supports, guides and anchors shall be designed so that excess heat will not be
transmitted to the structural steel. Designs generally accepted as exemplifying good
engineering practice, using stock or standardised prefabrication parts, shall be utilised
wherever possible. Accurate weight balance calculations shall be made to determine
the required supporting force at each hanger location and the pipe weight load at each
equipment connection.
17.6.2

Pipeline Support Locations

For the pipeline supports at least at the following locations shall be provided with such
supports:

at or near changes of direction on horizontal lines

at or near branch connections on horizontal lines

both sides of flanged joints on horizontal lines, unless otherwise specified

both sides of flanged valves or instruments on horizontal lines, unless


otherwise specified

on one side of welded valves DN 80 and larger on horizontal lines.

Structural connections for pipeline supports shall be preferably at the


following locations:

bayline beams (beams between steel columns)

building columns

underside of floor steel or top of curbed openings for vertical lines.

Pipeline supports shall not be attached to:

floor opening pipe-sleeves

concrete block walls

grating or checker plate

equipment support steel

an adjacent large diameter pipe line, except when approved by the Employer

fittings, welding point and branch point, except when approved by the
Employer

PD

Fd

Supports for overhead pipe shall not be located on the floor below unless there is no
possibility to otherwise support the pipe.
Pipe support attachments to existing beams, which would cause torsion stresses in
beams, shall be avoided.
Pipe support attachments to existing columns, which would cause bending about the
weak axis, shall be avoided.

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170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 182

All large pipes and all long pipes shall have at least two supports each arranged so that
any length of pipe or valve may be removed without any additional supports being
required.
Variable springs shall be furnished with travel stops. The travel stops shall be factory
installed at the "cold" position. Variable spring hangers shall have the cold set point
and the hot condition point clearly marked on the hanger body. These markings shall
be clearly visible from the adjacent walk-way.

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For low temperature, non-critical systems, where vertical movements up to 50 mm are


anticipated, pre-compressed variable springs design may be used. Where critical
movement is greater than 50 mm a variable spring hanger shall be used. Where
movements are of a small magnitude, spring hangers may be used.
Constant and variable support spring hangers shall have a minimum reserve
movement of 15 mm beyond the minimum and maximum settings representing the
calculated movement of the pipe from its cold position to its hot position.
All rigid hangers shall be provided with means for vertical adjustment after erection.
Where the piping system is subject to shock loads, such as thrust imposed by the
actuation of safety valves, etc., hanger design shall include provision for shock
absorbing devices of approved design.
Selection of vibration control devices shall be part of the Contractor's work. If
vibration is encountered after the piping system is in operation, appropriate vibration
control equipment shall be installed by the Contractor after Employer's approval.
17.7

Cleaning, Testing and Inspection

17.7.1

General

Local Codes and Authorities having jurisdiction over any part of the work covered in
the Contract shall apply.
Inspection
General

PD

Fd

17.7.2.1

17.7.2

On completion of the installation each pipeline or pipeline system shall be inspected


and tested as specified on the pipeline nomenclature drawing and flushed or blown
according to the procedures set out in the specifications.
All inspections shall be recorded on a "Pipeline Check-out Record", which shall be
approved by the Employer.
When the Contractor has completed the installation he shall initiate the "Pipeline
Check-out Record" sheet by filling in the pipeline number or system description;
indicate the completion of installation by signing the Record; setting out the testing
and cleaning required by the Specification; and if inspection or testing is required by
special authorities such as Government or Insurance Agencies, naming the authority
and stating the date that the testing is to take place ("independent agency").

After the Contractor has initiated the "Pipeline Check-out Record" sheet for a pipeline
or pipeline system, the Employer shall inspect the pipeline or system to ensure that it
Pyry Energy Ltd.

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170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 183

meets all the requirements of the specification. The inspection shall be recorded on
the "Pipeline Check-out Record".
In the case of inspection by a special authority the record sheet shall be submitted to
the Employer at least 2 weeks in advance of the date of testing, and if necessary in this
circumstance the sheet may be presented before the installation has been completed.
17.7.2.2

Independent Agencies (Government, Insurance, etc.)

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Where the specifications require the inspection, testing and/or cleaning to be


performed in the presence of any authority having jurisdiction over the work, the
Contractor shall identify the authorities having jurisdiction and shall notify them of
the inspection, testing and/or cleaning in advance according to the requirements of the
authority and shall obtain the signature of such authority on the sheet to indicate their
satisfaction and approval.
The Contractor shall bear all costs caused by any independent agency or authority.
17.7.3

Requirements for Testing and Cleaning

Before commencing the testing and cleaning of pipelines, the procedures to be used
shall be submitted to the Employer for approval.
Pipelines that are to be hydraulically leak tested shall have temporary air vents and
vacuum breakers located where necessary.
Pipelines, whose pressure limits exceed those of the equipment or vessel to which they
are attached, must be isolated from these items during the pressure test.
When the Employer is satisfied that the requirements for testing and cleaning of the
pipelines, as set out by the Contractor, are correct according to the specification this
shall be recorded on the "Pipeline Check-out Record" and after that the Contractor
may proceed with the testing and cleaning.
17.7.3.1

Testing

PD

Fd

All pipework shall be hydrostatically tested to 1.5 times the system design pressure.
For low pressure systems with a design pressure below 3.3 bar(g) the test pressure
shall be 5 bar(g).
For compressed air systems a pneumatic leak test to 1.1 times design pressure will be
accepted.
Prior to conducting hydrostatic tests a Hydrostatic Test Procedure shall be submitted
to the Employer for approval. The procedure shall include details of safety
requirements
Prior to conducting a hydrostatic test the Contractor shall submit a Test Package for
the system to be tested. This Test Package shall include the following:

Pyry Energy Ltd.

P&I Diagrams with the test boundaries clearly indicated, the location of all
vents and drains to be used during filling and draining of the system, the
location of the pressurising equipment, the location of the test gauge.

Details of any temporary blind flanges or blanks to be installed,

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Tender Documents
Section 3 Employers Requirements

Page 184

The status of all valves, i.e. open or closed,

The status of non-return valves.

The status of safety or relief valves.

Details of any permanent equipment excluded from the test e.g flow elements.

Factory test certificates for equipment excluded from the hydrostatic test.

The test medium and source shall be identified and test medium quality
specified.

The completed Weld History Sheet with supporting records as defined in


Chapter 17.5.2.

The Inspection and Test Plan with signatures to confirm that all inspections
have been completed.

Details of test equipment with calibration certificates.

Details of post hydrostatic test storage and preservation requirements.

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17.7.3.2

Cleaning

All pipelines shall be cleaned. Cleaning shall generally consist of flushing the pipe
hydraulically, or blowing the pipe with air or steam.
Care shall be taken to protect the Site and all facilities on the Site from damage
resulting from the cleaning operation.
Unless otherwise agreed during Design Review the following pieces of equipment
shall be left out during erection and replaced by temporary spool pieces before
cleaning:
Flow nozzles and lined magnetic flow meters

All control valves except butterfly valves DN 150 and larger and V-ball valves
DN 100 and larger.

The following pieces of equipment shall either be left out during erection or
removed from pipelines before cleaning:

PD

Fd

Orifice plates

Attemperator nozzles

Rupture discs

Spray nozzles

The following pieces of equipment shall be blanked-off or isolated before cleaning:

Pyry Energy Ltd.

Safety relief valves

Instrument connections

Equipment inlets and outlets

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PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

17.7.3.3

Page 185

Flushing
Flushing shall consist of running clean water or flushing oil as specified through the
pipeline either by gravity or by pump at a sufficient velocity to remove the dirt in the
pipe, such flow to continue until in the opinion of the Employer the pipeline is
discharging a clean fluid.

When pipelines are flushed into a vessel, the vessel shall be drained, cleaned and
inspected by the Contractor, witnessed by the Employer, on completion of the
flushing, and if such vessels are to be used as a source of supply for flushing another
pipeline, the cleaning and inspection of the vessel shall be completed before such use.

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Piping systems that require chemical cleaning and passivation shall have this done
immediately prior to start-up, and after the chemical cleaning and passivation shall be
flushed with a fluid that contains rust inhibitor.
The Contractor shall be responsible for the disposal of all flushing media in
accordance with local statutory requirements.
17.7.3.4

Air Blowing

Plant air supply lines and headers shall be blown with air from the plant air
compressors or a similar source approved by the Employer.
Instrument air supply lines and headers shall be blown with oil- and water-free air.
Lines that are to be air blown shall be blown at a sufficient velocity to loosen all dirt
and shall be blown until in the opinion of the Employer the discharge is entirely free
from dust.
17.7.3.5

Steam Purge

A steam purge of the boiler and the complete steam lines shall be carried out to
remove the mill scale, slag and other foreign materials from boiler and the steam lines
prior to initial operation of the steam turbine. The Contractor shall provide all
necessary temporary pipework, equipment and connections.

PD

Fd

Three months prior to conducting any steam purging the Contractor shall submit a
detailed purge procedure to the Employer for approval. The procedure shall identify
systems to be purged, how purging will be conducted, details of temporary pipework
including design NDE and testing requirements for the pipework, flow calculations,
disturbance factor, how cleanliness will be demonstrated, acceptance criteria, noise
mitigation measures and safety measures.
The steam purge shall include all steam lines between the boiler and the steam turbine,
the turbine bypass lines, the turbine seal steam system, and all other auxiliary lines
that return steam into the main steam and water system.
The temporary pipework shall be designed to the requirements of ASME B31.1. All
temporary pipework shall be hydrostatically tested to demonstrate system integrity.
The contractor shall supply all special valve inserts required to protect permanent
plant from damage during the purge process.
Adequate sirens and notices shall be provided and suitable barriers erected to warn
personnel of the steam blow. Noise during Steam blows shall not exceed the Noise

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Tender Documents
Section 3 Employers Requirements

Page 186

level requirements at the site boundary for day and night of 60 dBA and 55 dBA
respectively. The Contractors steam purge procedure which is subject to the
Employers approval shall be submitted six months prior to steam purge. The
procedure shall demonstrate that a mass velocity at least 1.25 times greater than which
occurs during the boiler operation at BMCR is generated during the steam purge. The
purge procedure shall include stress calculations to confirm the adequacy of the
temporary pipework and supports and all purge flow paths with the location and
setting of temporary and permanent plant valves indicated.

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The purge procedure shall detail the target plate material and demonstrate that the
material hardness is compatible with the turbine blade material.
The valve controlling the steam blow shall have an opening time suitable for creating
adequate disturbance. Calculations for the disturbance factor shall be based on boiler
conditions when the valve is fully open.
Disturbance factor shall be 1.25 for the main steam system using the following
formula:
Disturbance Factor =

Drag under Purge Flow

Drag under Max Steam Flow

Wp2 x Vp

W R2 x VR

Where W = flow rate in kg/h

V = specific volume in m3/kg

Suffix P is blow out condition

Suffix R is maximum steam flow condition

PD

Fd

Steam lines and other lines that are to be steam purge shall be blown in the following
manner and sequence:
1. Check that all spring hanger blocks are removed and that the cold load spring
setting is according to the drawings.
2. Install temporary atmospheric vents and drains, anchors, guides and if
required, target plates and have the installation approved by the Employer
before commencing a steam blow.
3. Close the shut-off valves to steam trap assemblies.
4. Heat the pipe or system slowly to operating temperature and while the pipe or
system is being heated, check that all expansion joints are working, that all
expansion shoes and roller saddles are of the proper length and that floor and
wall opening clearances are adequate.
5. As the pipe is being heated open all pipeline drains and slag pocket drains and
clean them if necessary.

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6. Steam blow the lines for sufficient times at a sufficient velocity to loosen and
remove dirt and scale.
7. Cool the pipe to the pre-agreed temperature listed during the Owners prior
review and agreement of the proposed purge procedure.
Repeat steps 4), 6) and 7) above at sufficient times until in the opinion of the
Employer the pipes are clean.

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The method for checking the completeness of the steam purge including the
acceptance criteria shall be described in the Bidders Proposal. The acceptance criteria
shall as a minimum satisfy the requirements of the supplier of the steam turbine.
17.7.3.6

Cleaning Records

When the Contractor has completed the cleaning operations, he shall record the
operation, and if the cleaning is to the satisfaction of the Employer, the Employer will
sign the Cleaning Records.
If any pipelines or vessels are flushed or blown into a pipeline or system that has been
previously cleaned the pipeline or system shall be re-cleaned as set out herein, and a
new Cleaning Record shall be filled out for the cleaning operation.
17.7.3.7

Employers Acceptance

When the testing and cleaning are completed and approved by the Employer and by
any special authority the Contractor shall remove all temporary piping and re-install
the parts removed, and shall close valves to isolate the pipeline or section.
When the Employer is satisfied that all of the requirements for testing and cleaning
have been properly completed, all of the parts re-installed, the Employer will indicate
his satisfaction and approval by signing the inspection Record, and will mark the pipe
to indicate that it has been completed and accepted.
17.7.4

Surface Treatment

All carbon steel pipes and equipment without insulation shall be painted in accordance
with good international engineering practice.

PD

Fd

All pipework to be insulated shall be coated with a heat resistant primer to prevent
corrosion prior to the initial start-up of the plant.

17.7.5

High temperature pipes shall be painted with heat resistant paint.


Identification of Erected Pipework
Final marking shall be done to meet the requirements of the Employer and in such a
way as the piping can be identified along the whole run. The pipe identification shall
comply with the approved plant identification system.
Nameplates, delivered and installed, on tanks, vessels and valves shall be included in
the Works.
The marking on pipes can be done by attaching tapes around the insulation cladding or
painted on pipes at suitable locations. The tape should mark the flow direction, the
flow media and the line code of the pipe.

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170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

17.8

Page 188

ocumentation and Drawings


Plan and section drawings shall be made in scale 1:50.
Pipes larger than DN 50 shall be fully detailed. Pipes DN 50 and below shall be
indicated by centre-line only.
Pipes shall be dimensioned to the nearest column centreline and elevation shall be
shown.

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Following connections and details shall be shown with tag numbers:

Position numbers of pipelines and valves shall be marked.

measurement points

local measurement points

sampling points

dosing points

drain and vent points

Piping drawings should also indicate the following for reference:

cable routes

heating and ventilation ducts

During detail engineering piping design shall be finalised.


Following documents and tasks shall be done:

isometric drawings, DN 50

pipe support locations (piping drawings)

pipe support drawings

fabrication drawings for special fittings

"as built" drawings

PD

Fd

During the pipework erection the Contractor shall establish a Field Change
Notification system. The system shall be approved by the Employer prior to the start
of site activities. The Field Change Notification system shall ensure that all field
changes are correctly recorded and the changes are made to the as built drawings.
The Contractor shall deliver all the final documentation for the piping systems to the
Employer before the piping is taken over.

17.9

Instrument Connections

17.9.1

Arrangement
Process connections for instruments, chemical dosing and sampling shall be attached
to the piping at locations shown in the final P&I-diagrams. The location of
connections shall carefully be considered as to process demands, accessibility and
mechanical strength. Connections shall not be placed in piping bends or elbows.

Pyry Energy Ltd.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 189

High pressure connections (40 bar(g) and above) shall always be fitted with two shutoff valves at the connection point.
Local pressure gauges shall be provided with an isolation valve. Where determined by
the process, pulsation dampers and siphons will be provided.
For the following three requirements the extent of supply shall be reviewed and agreed
during design review. Adequate indications shall be provided to ensure safe local
operation and maintenance:
Local pressure gauges shall be installed at the suction and pressure sides of all
pumps and fans, pressure vessels, steam headers, heat exchangers, tanks and
vessels.

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Local temperature gauges shall be installed using thermo-wells at both sides of


all heat exchangers, pressure vessels, steam headers, tanks and vessels.

Local level indicators shall be installed on all tanks, vessels and tube heat
exchangers.

Local pressure gauges shall be installed at the suction and pressure sides of all
pumps and fans, pressure vessels, steam headers, heat exchangers, tanks and
vessels.

Differential pressure instruments shall be installed with five or three valve manifolds..
Single pressure measurement transmitters and switches shall have a two valve
manifold.
Chemical dosing connections shall be fitted with shut-off valve and check valve and
sampling points with a shut-off valve at the connection point.
Sample point for steam systems shall also include a flow restriction orifice. The
sample delay time shall not be sufficiently long that control of chemical dosing is
adversely affected and shall under no circumstances be longer than 30 minutes.
17.9.2

Materials

Materials of the process connections shall be of the same quality as the pipe.
Instrument manifolds will be stainless steel.

PD

Fd

All connections shall be designed according to the pressure and temperature specified
for the pipe to which they are connected. Strength calculations shall be performed.

17.10

Valves

17.10.1

General
All valves shall be manufactured and tested to a recognized international code.
ASTM, ASME, ANSI and MSS standards shall be considered to be the minimum
requirement. In addition fire protection valves shall meet the requirements of the
relevant NFPA code. Valve testing shall be conducted to the requirements of API 598
and the results of the tests shall be made available to the Owner.
The valves shall be suitable for the maximum design conditions of the system in
which they are installed and shall be capable of withstanding the hydrostatic test
pressure of the system.

Pyry Energy Ltd.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 190

Valves shall close against the full flow and design pressure and open against the full
design pressure of the system in which they are installed.
A Valve List shall be submitted with valve tag numbers, system operating and design
pressure temperature and flow details, valve size, valve materials and manufacturer.
The Contractor shall minimize the number of different valve suppliers to optimize the
spare parts requirements for valve maintenance.
For welded valves the valve end connections shall be compatible with the material of
the associated pipe.

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The selection of valve trim material shall be based upon tensile strength, chemical
stability and corrosion and erosion resistance at operating conditions, hardness and
toughness, coefficient of expansion relative to the valve body and sufficient difference
in properties of the seat and disc facing material to prevent seizing.
The seat material shall retain adequate compressive properties at operating
temperature and be immune to growth or chemical change due to temperature. The
seat shall also resist oxidation to retain a smooth surface essential for tightness.
All valves required for the regular operation and maintenance of the plant shall be
readily accessible from permanent platforms.
Suitable lifting points shall be provided on heavy valves or valve components to
facilitate lifting for maintenance.
All isolating valves shall be capable of being locked in both the open and closed
positions for the purposes of plant isolation. The Contractor shall provide the
necessary devices and locks, which shall not incorporate small loose components.
All valves shall be arranged so that the handwheel moves in a clockwise direction to
close the valve. The face of each handwheel shall be clearly marked with words
open and close and shall be provided with an arrow to indicate direction for
opening and closing. Valves shall not be fitted with the stems below the horizontal.
An indicator shall be fitted to each valve and each extended spindle to clearly show
the position of the valve.

PD

Fd

Hand wheels and gear reducers shall be sized to permit operation of valves without
using hand wheel spanners with the full pressure differential and with the force
applied to the handwheel not exceeding 250 N. All valves 300 mm and above shall be
provided with gear reducers.
All parts, particularly seats and discs, which are subject to wear, corrosion or other
deterioration which require adjustment, inspection or repair, shall be accessible and
capable of reasonably convenient removal when required. All valve internals shall
preferably be capable of being removed with the valve body in position.
Where desirable to protect valve rising spindles against ingress of dirt, or where the
position of the valve may create a hazard to operators when the spindle is extended,
suitable covers shall be provided. All valve stems for valves that are installed in an
outdoor location shall have a weatherproof protection cover.
High pressure isolating valves shall be arranged in tandem. Two valves in series shall
also be provided for drains, vents and sample lines. All test points and pressure gauge
connections shall be provided with double isolating valves.

Pyry Energy Ltd.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 191

All isolating shall be capable of being operated from floor level. Where valves are
located in pits or enclosures deemed to be confined spaces, extended operating
spindles or similar devices shall be provided. . All valves which are required to open
or close during normal operation of the plant, including start up and shut down shall
be equipped with an actuator.
All power operated valves shall have position indication in the DCS. The hand
operating and motor operating mechanism shall be interlocked in such a way that the
hand operating mechanism shall be disconnected before the motor can be started.

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Valves shall be fitted with permanent identification plates showing the valve function,
number and direction of closure. Each valve shall be permanently marked with the
code designation of valve, body material, manufacturers serial number, nominal bore
and the nominal pressure/test pressure and temperature. Where valve flow is only in
one direction the flow direction shall be clearly indicated on the valve body.
Flanged valve bolts shall be to the requirements of ASTM A 193 and 194 as a
minimum requirement.
17.10.2

Dimensioning

Minimum pressure class for steam and condensate valves is PN 16. Minimum pressure
class for stainless steel valves is PN 10. Valves shall be of full bore type.
Welding end dimensions shall be prepared for butt-welding. Welding end dimensions
shall be equal to the dimensions of the connecting pipe; neither use of transition piece
nor welding end preparation is accepted.
Steam and condensate

Valves equal or greater than DN 65 shall be gate


valves with butt-weld ends.
Small bore valves shall be globe valves with buttweld ends.

PD

Fd

Materials shall be according to pipe material

Steam and condensate

Large steam valves shall be furnished with by-pass


valves. Connections for by-pass valves shall be
welded to valve bodies.
Valves shall be furnished for drainage, with
minimum of DN 25
If required by construction of the valve, the valve
shall be furnished with body safety valve

Demineralised water

Pyry Energy Ltd.

Valves equal to DN 100 and greater shall be gate


valves with butt-weld ends or butterfly valves
between flanges.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 192

Valves below DN 100 shall be ball valves with


butt-weld ends.
Check valves shall be between flanges
Material requirement is AISI 316 or equal.
Valves equal or greater than DN 100 shall be
butterfly valves between flanges.

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Cooling water

Valves below DN 100 shall be ball valves with


butt-weld ends
Check valves shall be between flanges

Material requirement is AISI 316 or equal

Sampling and chemical dosing

Valves shall be globe or needle valves with buttweld ends


Check valves shall be with butt-weld ends.
Below DN 65 socket weld type is acceptable.
Material requirement is AISI 316L or equal

Steam traps

Low pressure steam traps shall be thermostatic


/thermodynamic or float traps with flanges

Fd

Body material of low pressure traps shall be carbon


steel

PD

17.10.3

Pyry Energy Ltd.

Motorised Actuators
All ball and butterfly valves shall be equipped with gear and hand wheel, if size is DN
150 or greater.
Actuators shall be equipped with:

3-phase 50 Hz motors

IP67 enclosure

travel limit microswitches (open/close)

torque limiting microswitches

local and remote (DCS) fault indication

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 193

remote (DCS) 4-20mA position transmitter however not for valves subject
only to on/off (open or closed) operation.

local position indicator

remote/off/local selection, with padlocking facility

open/stop/close local selection with local and remote (DCS) status indication

remote operation and monitoring from the plant DCS

The electrical actuators shall be equipped with integrated control and


power sections locally installed at the actuators.

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17.10.4

Binary actuators shall have short time ratings appropriate to duty cycle
type S2 10 min. to IEC 60034-1, and a maintenance free interval better
than 10,000 open/close cycles or better as required by the process.

Modulating actuators including inching shall have a rating appropriate to duty


cycle type S4 20% 1200 cycles/h to IEC 60034-1 and a maintenance free
interval better than 50,000 hours in normal operation or better as required by
the process.

Marking

The valves shall be permanently marked with:

equipment tag number

nominal size/pressure

name of manufacturer and type code of valve

serial number

construction material, or code by which the material can be identified

flow direction if needed for valve installation

permitted operating temperature zone

PD

17.11

Fd

valve number (Employers position number)

17.11.1

Thermal Insulation
General
Thermal insulation shall refer to the supply and application of all heat insulation
materials together with all necessary associated materials such as fastenings, vapor
barriers, jacketing cements, adhesives, etc., which are used as insulating materials for
piping, vessels, ductwork and equipment for the purpose of reducing heat loss,
prevention of condensation and for personnel protection.
All insulation materials for hot application shall be of non-flammable insulation
materials, compatible with the surface being covered and shall not cause corrosion of
the covered material. All insulation material shall be chemically inert and remain so in
the event of being saturated with water.

Pyry Energy Ltd.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 194

Asbestos insulation material or insulating material containing asbestos is not


acceptable.
Insulation for condensation prevention shall be applied to equipment, plant, piping,
etc. operating at temperatures below the maximum dew-point where condensation
could form to the determent of plant structures or equipment or cause discomfort to
operating personnel.

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The insulation shall generally be in accordance with ASTM C547 for pipework
DN200 and below and ASTM C592 for pipework above DN 200 or an equivalent
international standard. The Contractor shall submit a detailed insulation material
specification for approval during the design phase. If the Contractor nominates an
alternative material specification then the Contractor shall demonstrate that it is equal
to the ASTM standards.
The Contractors material specification shall list the materials he proposes to use, their
thermal conductivities calculated in accordance with the approved standard for the
operating temperatures of each application, the thickness and density of each material
used and where two layers of dissimilar materials are used, the actual interface
temperature.
The insulation material shall be durable and meet the service requirements of the plant
for the full life of the plant.
Thermal heat loss shall not exceed 200W/m2.

Thermal insulation shall be applied to all surfaces that operate at, or can intermittently
operate at a temperature in excess of 60C. Insulation shall be provided for heat
conservation and personnel protection.
The surface temperature of any insulated surface shall not exceed the ambient air
temperature by more than 25 degrees centigrade.
All equipment and piping with an operating temperature over 60C shall be insulated
by thermal insulation. This does not apply to places, which for functional reasons must
be left without insulation.

PD

Fd

For personnel protection, insulation shall be applied to lines that are normally 60C or
less, but may reach a higher temperature as a result of abnormal conditions or
intermittent operation.

17.11.2

Where lines are not insulated for operational reasons (e.g. steam vents and drains)
insulation for personnel protection shall be applied only to parts of the line that are
within 2.5 m above any floor, platform, or other normal access way, or within 1.2 m
horizontally and up to 2.5 m above the edge of any access way.
Insulation Design
The type and thickness of insulation materials used shall be entirely suitable for the
particular application and shall be subjected to approval by the Employer. Sprayed on
asbestos free insulation shall be provided on irregularly shaped items of equipment.
The type of jacketing to be used shall be capable of withstanding the site atmospheric
conditions without surface deterioration. All insulation shall be covered with at least
0.6 mm thickness aluminium sheet jacket for piping and vessels. However, at

Pyry Energy Ltd.

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

Page 195

locations where persons might cross over pipes or install temporary access for
maintenance the aluminium sheets shall be at least 1.2 mm thickness.
Spacers shall be provided for pipework with an insulation thickness greater than
60mm to secure the insulation evenly all around the surface to be insulated. Spacers
shall be installed every meter. The spacers shall be insulated to prevent heat migration
for the pipe to the aluminium sheeting. Clamp rings shall be secured with galvanised
bolts and nuts, minimum size M8.

Where aluminium sheeting is used, provisions must be made to avoid any electrolytic
action.

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Aluminium sheets shall be secured with a minimum of five stainless-steel pan head
self-tapping screws per meter run using UV resistant washers. Longitudinal seams
shall be installed to prevent water ingress. Sufficient overlap shall be allowed at all
seams for expansion.
All outdoor insulation shall be completely weather tight sealed. All joints in
aluminium sheeting shall have a rolled edge to prevent water ingress by capillary
action.
All valves and fittings shall be covered with insulating materials of the same kind and
thickness as that specified for the pipelines in which they are installed.. For reducer
fittings the material thickness shall be that for the larger diameter pipe.
Removable sections of insulation shall be provided over removable plates, lifting lugs,
access doors or areas where inspection data appears and in any other area specified.
Insulation shall be applied in a manner which will allow withdrawal of the removable
part without damage to such sections or to adjacent insulation. Equipment nameplates
mounted on brackets extending from the body shall be framed in with insulator so as
to leave the nameplates exposed ready for identification.
The insulation and cladding of the items requiring maintenance shall be designed to
permit quick and easy removal. The cladding shall have stainless steel adjustable
toggle catches to facilitate quick removal.

Insulation for vertical pipes shall be supported by rings at a maximum spacing of two
meters. Aluminium sheets shall be supported by S hooks and have sliding joints as
required for thermal expansion of the pipework.

PD

Fd

During the design phase the Contractor shall submit a detailed insulation design
document. The document shall detail the following:

Pyry Energy Ltd.

Design conditions

insulation materials to be used including material data

standard material thicknesses

standard installation material e.g. wire mesh, tie wire, jacketing sheets, screws

standard details for flanges, valves, instrument tapings, insulation support and
spacer materials

a matrix table giving insulation thickness for given pipe sizes and service
conditions

typical installation drawings

Sect3_ITB

PT Tenaga Listrik Cilegon


170MW (equiv) Combined Heat & Power Plant Project, Banten, Indonesia
Tender Documents
Section 3 Employers Requirements

17.11.3

Page 196

Installation
The following requirements are applicable for both factory and site installed
insulation.
The finished insulation shall be neat in appearance. Penetrations through the
aluminium sheets shall be neatly finished with an edge strip so the cut sheet is not
visible.

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Piping and equipment must be clean, dry and free from grease, dirt, loose rust or scale
before application of insulation materials. Surfaces shall be power brush cleaned to
remove loose materials prior to application of insulation. A stainless steel brush shall
be used for stainless steel materials.
Insulation shall be adequately protected again water and dirt during installation. Any
material that suffers rain damage during installation shall be replaced.
Aluminium sheets shall be protected against contact corrosion from tie wire or wire
mesh.

PD

Fd

A silicone based sealant shall be applied to all joints on outdoor installations and
indoor installations that could be exposed to water.

Pyry Energy Ltd.

Sect3_ITB