Document No.

: Rev No: 00
NSC/DP/FEP FABRICATION & ERECTION OF PIPING Section : 1

NEO STRUCTO CONSTRUCTION LTD. Page 1 of 7

CONTENTS

I. BASIS OF WORK

II. FABRICATION

1 Piping Material
2 Dimensional Tolerances
3 Pipe Joints
4 Butt Welded & Socket Welded Piping
5 Screwed Piping
6 Flange Connections
7 Branch Connections
8 Bending
9 Forging & Forming
10. Miter Bends & Fabricated Reducers.
11. Cutting & Trimming of Standard fittings.
12 Galvanised Piping.
13 Shop Fabrication.
14 Miscellaneous
III. ERECTION
1 Cleaning of Piping before erection.
2 Piping routing
3 Cold pull
4 Slopes
5 Flange connections
6 Line Mounted equipments / items.
7 Pipe Supports
8 Static Protection in System.
Document No.: Rev No: 00
NSC/DP/FEP FABRICATION & ERECTION OF PIPING Section : 1

NEO STRUCTO CONSTRUCTION LTD. Page 2 of 7

I. BASIS OF WORK

The complete piping work shall be carried out in accordance

with following -

1) “Issued for construction” drawings & sketches issued by

client to NSCL - Piping plans or isometric.

2) Drawings, sketches & documents prepared by NSCL & duly

approved by client (such as isometrics of small bore piping /
offsite piping).

3) Approved construction job procedure prepared by NSCL

4) Client’s other specifications viz.

i. Process and instrument diagrams.
ii. Piping & material specification.
iii. Piping Support Standards..
iv. Line List.
v. Standard Specification for NDT
vi. Standard Specification for Welding
vii.Standard Specification for Inspection, flushing &
Testing of Piping System.
viii. Standard Specification for Steam tracing.
ix. Any other specifications attached by client.
x. Procedure for storage, preservation and positive
identification of materials at work site.
5) Applicable codes, standards and regulations. (All codes
referred shall be latest revisions at the time of contract)

6) Deviations:-In case any item of work is not covered by

drawings, specifications, standards or codes referred to above or
where a deviation from provision of such drawings or standards
is deemed advantageous or essential then, the matter shall be
brought to the notice of client and the work carried out after
obtaining written approval in each case.
Document No.: Rev No: 00
NSC/DP/FEP FABRICATION & ERECTION OF PIPING Section : 1

NEO STRUCTO CONSTRUCTION LTD. Page 3 of 7

II. FABRICATION

1) Piping Material:- Pipe, Pipe fittings, flanges, valves, gaskets,

studs, etc used in piping system shall be strictly as per the
“Piping Material Specification” (PMS) for the “Pipe Class”
specified for that system. To ensure the above requirement, all
piping materials supplied shall have proper identification
marks. Also these marks shall be provided by NSCL on left over
items for further usage.

2) Dimensional Tolerances:- NSCL shall be responsible for

working to the dimensions shown on the approval drawings.

3) Pipe Joints:- The piping class of each line specifies the type
of pipe joints to be adopted. In general joining of 2” NB & above
in process & utility piping shall be accomplished by butt welds.
Joining of lines 1½” NB & below shall be by socket welding /
butt welding/threaded joints, Flange joints shall be used at
connections to vessels, equipments & tanks, valves & where
required for case of erection & maintenance as indicated in
drawings.

4) Pipe Fittings:- Butt welded & socket welded piping End

preparation, alignment & fit up of pipe pieces to be welded,
welding, pre-heating, post - heating & heat treatment shall be
as specified in WPS.

5) Screwed Piping:- Galvanised piping shall have threads as

per IS 554 or ANSI - B2.1 NPT as required to match threads on
fittings, valves etc. all other piping shall have threads as per
ANSI B 2.1 tapered unless otherwise stated. Threads shall be
clean cut without any burrs or stripping and the ends shall be
reamed. Threading of pipes shall be done preferably after
Bending, Forging or Heat treatment. Threaded joints to be seal
welded shall be cleaned of all foreign matter, including scaling
and made up to full thread engagement before seal welding.

6) Flange Connections:- All flange facing shall be true and

perpendicular to the axis of pipe to which they are attached.
Flange bolt holes shall straddle the normal center line, unless
different orientation is given. Wherever a spectacle blind is to be
Document No.: Rev No: 00
NSC/DP/FEP FABRICATION & ERECTION OF PIPING Section : 1

NEO STRUCTO CONSTRUCTION LTD. Page 4 of 7

provided, drilling and tapping for the jack screw in the flange
shall be done before welding it to pipe.

7) Branch Connections:- Branch connections shall be as

indicated in PMS or approved Drawings. Reinforcement pads
shall be provided where ever required.

8) Bending:- Bending shall be as per ANSI B 31.3. Cold bends

for lines 1½” & below, with a bend radius of 5 times the normal
diameter shall be used as required in place of elbows wherever
allowed by specifications. Bending of pipes 2” & above may be
required in some cases like that of headers around heaters,
reactors etc. The complete bend shall have a smooth out surface
free from Cracks, buckles, wrinkles, bugler, flat spots and other
serious defects. They shall be true to dimensions. The flattering
of bends as Measured by the difference between maximum and
minimum diameters at any cross section shall not exceed 8 %
and 3 % of the nominal out side diameter, for internal &
external pressure respectively.

9) Forging & Forming:- Forging and forming of small bore

fittings like reducing nipples for piping 1½” and below shall be
as per ANSI B 31.3.

10) Miter Bends & Fabricated reducers:- The specific

application of welded miter bends & fabricated reducers shall be
governed by the piping material specification. Generally all 90°
miters shall be 4 pieces 3 welds type and 45° miters of 3 pieces
2 welds type unless otherwise specified. Reducers shall be
fabricated as per client requirement. Also the radiography
requirement shall be as per material specification.

11) Cutting and trimming of standard fittings:- Fittings like

elbows, Couplings, half couplings, etc shall be cut or trimmed
wherever required to meet fabrication & erection requirements
either as per drawings or instructions from client.

12) Shop Fabrication:- Most of the piping work shall be

fabricated in work shop (spools). The intent of pre fabrication
shop is to accelerate progress of pipe work and to minimise field
work. Such pre-fabrication shall be based on approved
drawings, however these always a scope of variation at site
Document No.: Rev No: 00
NSC/DP/FEP FABRICATION & ERECTION OF PIPING Section : 1

NEO STRUCTO CONSTRUCTION LTD. Page 5 of 7

erection. Therefore adequate allowances at field joints are

provided permitting pre assembly to be installed without
modification.

13) Miscellaneous:- Elements like flash pots, seal pots, sample

cooler, extension of spindles and interlocking arrangements of
valves, operating platforms shall be fabricated to suit site
requirements.

III. ERECTION.

1) Cleaning of piping before erection:

Before erection all prefabricated spool pieces, pipes, fittings

etc. shall be cleared inside and out side by suitable means. The
cleaning process shall include removal of all foreign matter
such as scale, sand, weld spatter, cutting chips etc. by wire
brushes, cleaning tools etc.. and blowing out with compressed
air and flushing out with water. Special cleaning requirements
for some services, if any shall be as specified in clients spec.

2) Piping Routing:-

No deviation from the piping route as indicated in drawings

shall be done without the express consent of Engineer In-
Charge. Pipe to pipe, Pipe to structure/equipments
distances/clearances as shown in the drawing shall be strictly
followed as there clearances may be required for free expansion
of piping system.

In case of fouling of pipelines with other piping, structure or

equipment then re-routing shall be done with clients consent.

3) Cold Pull:-

Wherever cold pull is specified the necessary gap shall be

maintained as indicated in drawings. Stress relieving shall be
done before removing the gadgets for cold pulling.
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NEO STRUCTO CONSTRUCTION LTD. Page 6 of 7

4) Slopes.

Slopes specified for various lines in the drg/P&IO shall be

maintained corrective action shall be taken wherever such
slopes can not be maintained.

5) Flange connections:-

While fitting mating flanges, care shall be exercised to properly

align the pipes & to check the flange trueness; so that the
faces of flanges can be pulled together without inducing any
stresses in nozzles & other connected equipment.

Temporary protective covers shall be retained on all flanges of

equipment until the piping is finally connected; so as to avoid
any foreign material entering in these equipment. The
assembly of flange joints shall be in such a way that the gasket
between the flange faces is uniformly compressed, to achieve
this the bolt shall be tightened in proper sequence. All bolts or
studs shall extend from their nuts but not more than ¼”.
Steel to CI flange joints shall be made up with extreme care.

6) Line mounted equipment/items.

Installation of online & inline equipment like filters, strainers,

sample coolers, flame arrestors, sight & light glasses, safety
valves etc. including their supporting arrangements shall form
part of piping erection work.

7) Pipe Supports.

Pipe supports are designed and locked to effectively sustain the

weight and thermal effects of piping system and to prevent its
vibration. Location and design of pipe supports shall be as
shown in approved drawings. No pipe shoe/cradle shall be off-
set unless specifically shown in the drawings. Following points
shall be checked after installation.

i. All restraints have been installed correct.

ii. Clearances have been maintained as per drawings.
iii. Insulation does not restrict thermal expansion.
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NSC/DP/FEP FABRICATION & ERECTION OF PIPING Section : 1

NEO STRUCTO CONSTRUCTION LTD. Page 7 of 7

iv. All temporary tack welds provided during erection

have been removed.

8) Static protection system (Ear thing).

The complete piping work shall be provided with static

protection system. Pipes entering and leaving the units shall be
effectively earthen to these locations, in addition to other
locations as specified in the standard specs.