Beruflich Dokumente
Kultur Dokumente
This primarily applies to large bore fresh cooling water SectionTitlePage1.List of Project Specifications22.Storage and Preservation of
supply & return pipework. Piping Materials33.Colour Coding of Pipe Materials44.Colour Coding of Gasket
Materials55.Colour Coding of Bolting Materials56.Cold Bending67.High Frequency
During construction & installation special care is to be Induction Bending88.Piping Fabrication, Erection, Inspection &
taken with the cleanliness of this pipework. Further Testing11Intersecting Weld Seams11Welding Consumables11Welding Procedure
special requirements apply at the pre-commissioning Qualification12Welder Qualification13Welding Control16Post Weld & Post Bending
stage. Heat Treatment189.Positive Material Identification2010.Hardness
Testing2311.Radiography2412.Notes on Other NDT
Gauges for hydrostatic testing shall have a range of Methods2613.Tolerances2814.Bolting of Flanges3015.Threaded
between 1.5 and 2.2 times the test pressure; they shall Joints3216.Hydrostatic Testing (above ground piping)3317.Pneumatic
have been calibrated within the previous 1 month Testing3518.Hydrostatic Testing of Buried Pipework36
period. A pressure / temperature recorder is
mandatory.
36 1
For Your Notes
37
2 35
Test blinds shall be in accordance with sheet 41A of Storage & Preservation Of Piping Materials
drawing number QCS/50/00/MP/DR/TD/003. (QCS/50/00/PE/TS/NA/002)
Pressure gauges and chart recorders shall have been
Flange faces and threaded fittings must be protected at all
calibrated within the previous 30 period.
times by use of a suitable corrosion preventative oil.
Pressure gauges shall have a range of between 1.5 Flange faces shall further be protected by means of a
times and 4 times the test pressure. suitable flange face cover to prevent mechanical damage.
Flange faces must be inspected for corrosion & damage at
In general a minimum of 2 gauges shall be used. One
intervals not exceeding 3 months.
gauge shall be positioned at the high point and one at
Where uncoated stainless steel pipe spools stored for an
the low point of the system.
extended period they should be inspected periodically for
NOTE: EXCEPT AS SPECIFICALLY AGREED CHART pitting corrosion. Where uncoated carbon & low alloy steel
RECORDERS SHALL NOT BE USED pipe spools stored for an extended period they should be
inspected periodically for severe general or localised
The system shall be pressurised via a test manifold
corrosion.
incorporating a relief valve set at 110% of test
All pipe spools shall be stored on wooden skids to prevent
pressure.
soil contamination. This is particularly important in the
The ambient temperature of the pipework under test case of uncoated stainless steel spools.
and the test pressure shall be recorded at 5 minute The open ends of all pipe spools shall be suitably sealed
intervals throughout the duration of the test. during storage using suitable end covers. Where such
covers are found to be missing or damaged the affected
Prior to testing all pipework shall be thoroughly
spool shall be inspected & cleaned internally.
cleaned internally, by flushing, internal brushing or air
Spools should be stored in such a way that any water or
blowing as appropriate.
other liquid entering will quickly drain away.
Method: (1) raise pressure to 1 barg, hold for 10 Valve stems shall be coated with a suitable grease. Valves
minutes & check for leaks at flange joints, (2) raise stored in outdoor conditions shall be inspected at intervals
pressure at a controlled rate not exceeding 5 barg per not exceeding 3 months.
minute until the test pressure is achieved (on the high
point gauge), (3) wait for the test pressure to stabilise,
(4) once the pressure is stable the test starts, (5) the
minimum holding time shall be 30 minutes (longer
than this depending how long it takes to inspect all
welds for leaks), (6) if leaks are detected the system
must be depressurised, the leak fixed & the full test
repeated.
34 3
32 5
Colour Coding Of Pipe Materials Hydrostatic Testing (above ground piping)
(QCS/50/00/MP/TS/NA/003) (QCS/50/00/QA/PC/NA/754 & QCS/50/00/MP/TS/NA/001)
COLOURMATERIAL TYPECOMMON
SPECIFICATIONSNoneCarbon SteelA106 Grade B, A105, Pressure testing shall be generally in accordance with
A234 WPB, A216 WPBYellowNACE Carbon SteelA106 Grade the requirements of ASME B31.3.
B, A105, A234 WPB, A216 WPBWhiteLow Temperature
Carbon SteelA333 Grade 6, A350 LF2, A420 WPL6, A352 Vents & open drains with a design pressure of 15 psig
LCCPurpleNACE or less are exempted from hydrostatic testing.
Low Temperature Carbon SteelA333 Grade 6, A350 LF2,
A420 WPL6, A352 LCCPink304L Stainless SteelA312 Relief or blowdown systems shall be tested in
TP304L, A358 304L, A182 F304L, A403 WP304L, A240 accordance with ASME B31.3. Relief valves & rupture
TP304LBrown304L Stainless Steel (valves only)A182 F304L, disks must be removed for testing. In no case shall the
A351 CF8MSky Blue316L Stainless SteelA312 TP316L, A358 test pressure be less than
316L, A182 F316L, A403 WP316LGreen1 Cr Mo Low 15 psig.
Alloy SteelA335 P11, A182 F11, A234 WP11Light
GreenNickel AlloysB622 N10276, The chloride content of water used for austenitic
B574 N08825Oxide RedIncoloyB705 N08825, stainless steel systems shall not exceed 50 ppm. After
B564 N08825Yellow GreyInconelB705 N06625, testing such systems shall be drained immediately
B564 N06625Note: This table is a simplified version of followed by air blowing to remove any remaining water.
QCS/50/00/MP/TS/NA/003 Table 2
Exemption from hydrostatic testing owing to reasons of
impracticality shall be subject to specific approval by
the Company.
A312 TP304L (or TP 316L) SCH 40S Thread lubricants must not contain lead. Thread
lubricants for use on stainless steel piping systems
Cold bending may be applicable if the line class is shall not contain chlorides, zinc, sulphur or low
1A1A, 1W3AX, 1W3AY, 1P1A, 1P1AR, 1S1A, 3P1A, melting point alloy constituents.
3S1A, 3S1AU, 1C0JL, 1Y0JL, 1C0KL, 3C0JL, 3C0KL,
6C0JL, 6C0KL or 9C0JL. Acceptable lubricants for various design temperatures
are listed in the table below:
Unless a larger bending radius is specified the bending
radius shall be 5 times the outside diameter of the Thread LubricantsLubricantBolting MaterialDesign
pipe. The maximum bending angle shall be 90. TemperatureGraphite and oilCarbon or low alloy steel-46C to
Compound bends shall be separated by a minimum 400CMolybdenum disulphide and graphite base Carbon or low alloy steel-
straight run of 150mm. At the end of the bent pipe the 46C to 400CCopper and graphite baseCarbon or low alloy steel-46C to
minimum length of straight run is 300mm. The 540CCopper baseStainless steel-196C to 870CNickel baseStainless
maximum allowable thinning ratio is 10%. The steel-196C to 870C
maximum allowable flattening ratio is 8% for internally
Torqued / tensioned flanges are to be marked by the
pressurised pipe & 3% for externally pressurised pipe.
attachment of a metal tag following torquing. This tag
shall be removed if the flange leaks during hydrostatic
Flattening ratio is defined as:
testing & the joint shall be re-torqued or re-tensioned
as appropriate.
30 7
(TM/T0) x100
TC = calculated thickness
(per ASME B31.3 paragraphs 304.1.2 & 304.2.1)
CA = corrosion allowance
TRT = retirement thickness
(per QCS/50/00/MP/DB/NA/001 paragraph 4.2.4)
High frequency induction bending is applicable to the Tolerance on dimension APipe DiameterTolerance (mm)10 &
materials and line classes list in the table below. In under312 to 245over 24 to 36648860107212
general high frequency induction bending is applicable In certain cases tighter tolerances apply:
to pipes in the nominal diameter range 2 to 12 but
the specific applicable diameter range varies For steam turbines and compressors other than those
dependent on line class. of the reciprocating type the tolerances applying to
flange alignment are 0.4 mm for vertical / horizontal
Materials & Line Classes For HF Induction BendingMaterialWall bolt offset, rotational offset, flange face parallelism
ThicknessNPSLine ClassesA106 and flange face separation
Grade BStandard
to Equipment nozzle and mating flange alignment
XXS2 121A1A, 1P1A, 1S1A, 3S1A4, 1C3AS, 1C3ASR, 1C4AS, 1C6AS, 1P3A, 1W3AX,
1W3AY, 3C3AS, 3C4AS, 3C6AS, 3P1A, 3P3A, 3S1A, 3S1AU, 6C3AS, 6C4AS, 6C6AS, 6P1A, tolerances for centrifugal pumps, reciprocating
6P3A, 6S1A, 6S1AU, 9C3AS, 9C4AS, 9S1A, 9S1AUA333 compressors and other rotating machinery are as
Grade 6SCH30 tabulated below.
To
SCH1602 121R1B, 1R11BR, 1R3BS, 1R3BSR, 3R1B1, 3R1B3, 3R3BS, 6R1B, 6R3BS, Alignment CategoryMax. Permissible Misalignment
9R3BSA335 P11XS (mm)NPS 1214NPS22NPS 24Vertical bolt hole offset31.50.4Horizontal
to
SCH1602 121P3Y, 9S1Y, 9S1YUA312 TP304LSch20S
bolt hole offset31.50.4Rotational Offset31.50.4Flange face parallelism
To (across diameter)1.51.51.5Flange face separation
SCH80S2 61C0JL, 1Y0JL, 1C1JL, 1R0JL, 1R0JLR, 1R0JL5, 3C0JL, 3C1JL, 3R0JL, (+ space required for gasket)31.50.4
3R0JLT, 6COJL, 6C0JL6, 6R0JL, 9C0JLA358 304LSch20S
To
SCH80S8 10A312 TP316LSch20S
To
SCH80S2 61C0KL, 1Y0KL, 1C1KL, 3C0KL, 6C0KL A358 316LSch20S
To
SCH80S8 10
8 29
24 13
Austenitic Stainless Steel (Cryogenic Service) Radiographic Sensitivity
A test by the supplier for each lot of consumables is Source side IQIs are preferred. Where IQIs are placed
required as follows: film side they must be identified with the lead letters
FS.
The ferrite content of the deposited weld metal shall be in
the range 2-5% (ferrite number 2-5) for SMAW electrodes & ASME V Article 2 requirements apply.
3-10% (ferrite number 3-11) for GTAW filler wire.
For SMAW electrodes charpy impact testing shall be The table below gives wire diameters for ASTM type
performed at -196C. The minimum lateral expansion value IQIs:
shall be 0.38mm. This requirement does not apply to GTAW
filler wire. ASTM E747 Wire Type IQIs
wire diameter (mm) Set
Welding Procedure Qualification A0.080.10.130.160.20.25Set
B0.250.330.40.50.630.81Set C0.811.01.271.62.02.5
All welding procedure specifications shall be reviewed The table below gives essential wire diameter for
and approved by the Company. Work start is not single wall thickness up to 64mm:
permitted if the WPS is not approved.
ASME V Article 2 Sensitivity RequirementsThickness
When impact testing or hardness testing is required Range (mm)Source Side IQIFilm Side IQI 60.20.16< 6
(e.g. the process is wet H2S, amine, caustic etc) the 90.250.2< 9 130.330.25< 13 190.40.33< 19
brand name of the welding consumable becomes an 250.50.4< 25 380.630.5< 38 510.810.63< 51
essential variable. The WPQR must be performed 641.00.81Thickness is the nominal single wall thickness
using welding consumables which are identical in plus reinforcement in all cases.
terms of trade name with those to be used at the
construction site
12 25
14 23
Acceptable limits for PMI analysis are given in the Periodic Evaluation (method-2):
table below:
This method works on a 3 strikes & youre out basis.
AlloyMin
MaxELEMENTS (%)CrNiFeMoTiVCoCuMn 0304L Parent MaterialMin16.27.2xShould be The welders performance shall be monitored by
effectively zeroxx0Max2214.3xxx2.2308L random radiography. Where a weld is found not to
Weld Metal meet the specification 2 further similar welds welded
SMAWMin15.87.9x0.66xxx0.660.44Max23.612.4x0.85xxx0.852.8308L by the same welder shall be tested by radiography. If
Weld Metal both of these joints are acceptable the welders
GTAWMin17.17.9x0.66xxx0.660.88Max24.812.4x0.85xxx0.852.8316L Parent
performance shall be deemed acceptable; if either or
MaterialMin14.49.0x1.8xxxx0Max19.816.5x3.3xxxx2.2316L
both of these joints is / are rejected further penalty
Weld Metal
shots shall be taken on a 2 for 1 basis. If any of these
SMAWMin14.99.6x1.8xxx0.660.44Max22.515.8x3.4xxx0.852.8316L
Weld Metal joints fails to meet the required standard the welders
GTAWMin15.89.6x1.8xxx0.660.88Max22.515.8x3.4xxx0.852.8Incoloy qualification shall be revoked; if all of these joints are
B423 N08825Min17.634.219.82.30.54xx1.40Max25.950.6x3.91.3xx3.31.1Hasteloy* B622 acceptable the welders performance shall be deemed
N10276Min13.1x3.613.5x00x0Max18.2x7.718.7x0.392.8x1.11 Cr acceptable.
A335 P11Min0.9xx0.40xxxx0.27Max1.65xx0.72xxxx0.66
Note that in a case where the welders qualification is
*Note: For Hasteloy Tungsten (W) shall be 2.7% min, 5.0% revoked radiographic examination shall be performed
max. on all joints welded by that welder in the previous two
week period.
22 15
The following services are identified as critical: All tack welds, including bridge tacks shall be made by
qualified pipe welders.
Wet H2S (per NACE MR0175)
Hydrofluoric acid Bridge tacking outside the weld groove is not
Amine / ammonia permitted other than as specifically approved by the
Caustic Company. Material used for bridge tacks either inside
Hydrogen partial pressure over 100 psi or outside the groove shall have the same basic
Sulphuric acid chemical composition as the parent material.
Cryogenic service below -46C (except liquid nitrogen)
Welded type valves shall be positioned half open
Where PMI is required for shop and field welds in during welding and PWHT.
general the test shall include one sampling of the weld
cap & one sampling of the parent material each side Remote control of welding current is mandatory for
of the weld. field welding.
For piping systems only pressure containing welds are GTAW welding equipment shall be provided with a high
included within the scope of PMI. frequency start facility so as to reduce the occurrence
of tungsten inclusions.
20 17
Welding Control
The extent of PMI is a minimum of 10% for all alloy
Joint preparation, welding technique, root spacing and steel piping systems and 100% for those systems
alignment shall be in accordance with the approved identified as being in the critical service category (see
WPS. above). The table below specifies the extent of PMI for
various line classes.
Welding parameters such as travel speed and welding
current shall be in accordance with the approved WPS.
Preheating and maximum interpass temperature shall
be in accordance with the WPS, but, for austenitic
stainless steel, in no case shall the interpass MaterialLine ClassesPMI
temperature exceed 175C, similarly for carbon steel Extent304L1C0JL, 1C1JL, 1R0JL, 1R0JLR, 1R0JL5, 3C0JL,
and low alloy steel in no case shall it exceed 300C. 3C1JL, 3R0JL, 3R0JLT, 6C0JL, 6R0JL, 9C0JL100%1Y0JLNot
Reqd*316L1C0KL, 1C1KL, 3C0KL, 6C0KL100%1Y0KL, 3Y0KL,
For all full penetration welds, including branch welds
6Y0KL, 9Y0KL, XY0KLNot Reqd*Incoloy B423
the root pass shall be accomplished using GTAW. For
N088251C0N100%Hasteloy B622 N102761J0M100%1 Cr
small diameter pipe (2" and below) girth butt welds
A335 P111P3Y, 3S1Y, 9S1Y, 9S1YU10%316L Clad C.
and for all welds in Copper-Nickel (Cu-Ni) pipe only the
Steel6R0CM, 9C0CK, 9R0CM100%
GTAW process is permitted.
(on cladding)
The use of an inert gas back purge is required when *PMI is not required for lube oil, seal oil, seal gas, air
the GTAW process is used for girth butt or branch or water service
welds and the base material is stainless steel, copper-
nickel alloy, aluminium alloy or alloy steel (except as
described below).
An inert gas back purge is not required if the base
material is carbon steel or low alloy steel with a
chromium content not exceeding 1% by weight.
For socket welded pipe, carbon steel (1" NPS &
smaller) and stainless steel / non-ferrous alloys (all
pipe sizes) GTAW shall be used with a minimum of two
passes.
Where preheat is required only specifically designed
heating torches, gas rings or electric heaters shall be
used. Oxyacetylene welding and cutting torches shall
not be used.
16 21
18 19